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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/422,620, filed Jun. 7, 2006, the contents of which are incorporated herein in their entirety.
TRADEMARKS
[0002] IBM® is a registered trademark of International Business Machines Corporation, Armonk, N.Y., U.S.A. Other names used herein may be registered trademarks, trademarks or product names of International Business Machines Corporation or other companies.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to computer keyboards and particularly to the sounds emitted from a keyboard as keys of the keyboard are stroked.
[0005] 2. Description of Background
[0006] Technology now exists that makes it possible to determine which keys are stroked on a computer keyboard by recording the sound that emanates from the keyboard as the keys are stroked and processing the recorded sound in a personal computer (PC).
[0007] Using input from an unsophisticated PC microphone and processing the input using standard machine learning and speech recognition techniques it is possible to recreate typed input with up to 96% accuracy. Using a two-phase process of training followed by recognition, researchers were able to successfully recreate both English and random (password) input from multiple keyboards, across various (quiet and noisy) environments. While techniques such as the one described are still relatively new, one can envision several nefarious uses for the technology. For example, a person using a parabolic microphone could sit in a public setting, such as a coffee shop with Internet access, and eavesdrop on other patrons; recording sensitive information keyed into their computers, such as passwords and credit card numbers.
[0008] Accordingly, there is a need in the art for methods and apparatuses that inhibit the detection of keystrokes by the sounds emanating during stroking of the keys.
SUMMARY OF THE INVENTION
[0009] The shortcomings of the prior art are overcome and additional advantages are provided through the provision of a method of masking audible sounds emanating from a keyboard in response to a stroking of keys on the keyboard, the method comprising, selecting components from a plurality of components with various masses, building the keyboard with the selected components, moving a movable mass within the keyboard, and energizing a driving transducer within the keyboard.
[0010] Further shortcomings of the prior art are overcome and additional advantages are provided through the provision of a keyboard for a computer, comprising a plurality of keys, a cover with the keys protruding therethrough, a base supporting the cover and the keys, and at least one selectable mass wherein the mass is selected from a plurality of masses, a movable mass supported by the base and movable relative to the base, and a driving transducer supported by the base.
[0011] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.
TECHNICAL EFFECTS
[0012] The technical effect of the disclosed embodiments is improved security when using a computer keyboard in a public setting. Specifically, the technical effect is to inhibit the deciphering of which key of a keyboard is stroked based on the sound that emanates from the keyboard as the key is stroked. Computer algorithms for noise cancellation are known in the audiophile industry and are applied to listening to music, for example, in an environment with a noisy background such as on an airplane. Application of similar techniques to attenuate the sounds that are projected from a computer keyboard during the stroking of keys on the keyboard is disclosed.
[0013] As a result of the summarized invention, a solution has been devised that permits a computer user to key in private information, such as passwords and credit card numbers, in a public setting while preventing keystroke detection based on the sounds emanating from the keys as they are depressed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0015] FIG. 1 illustrates one example of a plan view of a keyboard disclosed herein;
[0016] FIG. 2 illustrates one example of an edge view of the keyboard of FIG. 1 ;
[0017] FIG. 3 illustrates one example of a cross sectional view of an embodiment of the keyboard in FIG. 2 taken at section line 3 - 3 ;
[0018] FIG. 4 illustrates one example of a cross sectional view of an embodiment of the keyboard of FIG. 1 taken at section line 4 - 4 ;
[0019] FIG. 5 illustrates one example of a cross sectional view of an embodiment of the keyboard in FIG. 2 taken at section line 5 - 5 ;
[0020] FIG. 6 illustrates one example of a cross sectional view of an embodiment of the keyboard of FIG. 1 taken at section line 6 - 6 ;
[0021] FIG. 7 illustrates one example of a plan view of a key of the keyboard of FIG. 1 ;
[0022] FIG. 8 illustrates one example of a cross sectional view of the key of FIG. 7 taken at section line 8 - 8 ;
[0023] FIG. 9 illustrates one example of a cross section view of an embodiment of the keyboard in FIG. 2 taken at section line 9 - 9 ; and
[0024] FIG. 10 illustrates one example of a cross sectional view of an embodiment of the keyboard of FIG. 1 taken at section line 10 - 10 .
[0025] The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Turning now to the drawings in greater detail, it will be seen that in FIGS. 1 and 2 there is a computer keyboard shown generally at 10 in accord with an embodiment of the invention. The keyboard 10 among other things includes; keys 14 that protrude through a cover 18 that is attached to and supported by a base 22 . Each of the keys 14 is spring loaded in a direction away from the base 22 and can move in a direction towards the base 22 in response to being depressed by an operator. Upon release, by the operator, the spring loading returns the keys 14 to their original position.
[0027] Each key 14 has a unique X-Y coordinate position relative to the cover 18 and the base 22 . Additionally, each key 14 also has a unique position relative to the other keys 14 on the keyboard 10 . This positional uniqueness results in a unique audible sound being emitted for every key 14 when it is stroked. This is partially due to the flat shape and uniform thickness of the base 22 , which forms a sounding board. Sound (pressure waves) generated from the depression of a key 14 impacts a specific location on the base 22 in accord with its coordinate position relative to the base 22 . This position on the base being a unique position creates a unique response from the base 22 . Disruption of the acoustic sounding board of the base 22 is easily achieved by the introduction of a mass to the keyboard 10 .
[0028] Referring to FIGS. 3 and 4 , cross sectional views of the keyboard 10 of FIGS. 2 and 1 , taken at arrows 3 - 3 and 4 - 4 respectively, are shown. A moveable mass 26 is able to move along slide 30 in the directions of plus X and minus X in a cavity 34 of the keyboard 10 between the keys 14 and the base 22 . The cavity 34 , by being located between the keys 14 and the base 22 may hide the mass 26 and its location from the operator as well as any other observer. The mass 26 may be formed of iron or other magnetic metal, for example, and may therefore be attracted to electromagnets 38 located near the four comers 42 of the keyboard 10 . Energization of the electromagnets 38 may cause movement of the mass 26 along the slide 30 . Movement of the mass 26 may result in a change to the acoustics of the keyboard 10 enough to alter the sound emitted by the keyboard 10 when any specific key 14 is stroked to prevent detection by analysis of the sound emitted.
[0029] Energization of the electromagnets 38 may be controlled by a variety of inputs. For example, a random number generator could be used in response to each keystroke resulting in a random direction and random distance of movement of the mass 26 . Alternately, a predefined movement of the mass 26 could occur regardless of which key is stroked. The electrical power that energizes the electromagnets 38 could be supplied from whatever source the PC is receiving power, for example, a battery or from an AC power source.
[0030] Alternatively, the mass 26 could be moved through a mechanical linkage to the keys 14 rather than using the electromagnets 38 . Such a system could use linkages (not shown) to move the mass 26 in a plus X or a minus X direction, for example, from its current location in response to the stroking of the keys 14 . Additionally, the mass 26 could be moved in a plus Y and minus Y direction with any applicable method while not deviating from embodiments of the present invention.
[0031] Referring now to FIGS. 5 and 6 , cross sectional views of the keyboard 10 of FIGS. 2 and 1 , taken at arrows 5 - 5 and 6 - 6 respectively, are shown. Similar to the embodiment of FIGS. 3 and 4 , FIGS. 5 and 6 use the redistribution of mass within cavity 34 , formed between the keys 14 and the base 22 , to disrupt the sound that emanates from the keyboard 10 when keys 14 are stroked. In embodiments disclosed in FIGS. 5 and 6 , the movement of mass 26 is carried out by locally deforming a bag 50 that is partially filled with a fluid 54 , herein depicted as a liquid. The deformation occurs when protrusions 58 , from the keys 14 , push on the surface of the bag 50 thereby forming a local depression in the bag 50 . Gas pockets 62 , within the bag 50 , redistribute themselves as the buoyancy force acting on the gas pockets 62 push the gas pockets 62 to higher elevations. Consequently, locations of the gas pockets 62 , within the bag 50 , changes with every keystroke causing a randomization of the location of the mass 26 , which is the fluid 54 , to occur. Additionally, the attitude and movement of the keyboard 10 itself will cause the fluid 54 to move within the bag 50 , thereby adding to the randomness of the mass 26 distribution.
[0032] Alternate embodiments may employ a cavity 34 that contains the fluid 54 in such a way that it is sealed without the use of a bag 50 . Such an embodiment may decrease the force required to depress the key 14 during a keystroke since no bag 50 would be undergoing deformation.
[0033] Referring to FIGS. 7 and 8 , the keys 14 include a protrusion 58 that extends from the underside of the keys 14 and engages the bag 50 , for example, in the cavity 34 , as described above. Many of the keys 14 have the same shape as one another and are made from the same plastic material and are therefore injection molded in the same mold. The character may be subsequently printed thereon. An embodiment of the invention shown in FIGS. 7 and 8 includes provisions for molding optional ribs 66 on the underside of the keys 14 . Molds can be inserted to facilitate easy changeover between various rib configurations. The optional ribs 66 can be of various lengths and widths to afford the keys 14 a wide variety of different masses. A short rib 65 , a longer rib 67 and even longer rib 68 are shown in phantom as possible variations. The keys 14 with various rib lengths and associated masses may be mixed together prior to character printing to increase the randomness of the mass that each character key 14 will have. Each different key mass may alter the sound that is emitted by the keyboard 10 when each key 14 is depressed, thereby creating a very large number of permutations of sounds that may emanate from any specific keyboard 10 . The larger the number of total sounds that may emanate from a keyboard 10 , the more the characteristics of the sounds from different keystrokes will overlap creating greater difficulty in determining which key 14 caused each sound. Such overlapping of keystroke sounds may render which key 14 was the source of which sound undeterminable. The foregoing embodiment discloses keyboards 10 made from selectable masses, disclosed herein as keys 14 , although, it should be noted that other components within the keyboard could be selectable as well with varying masses to create a variety of different possible keyboard mass combinations.
[0034] The foregoing embodiment, which relies on the different masses of keys 14 to thwart the determination of keystrokes, is a passive approach, while an embodiment of FIGS. 9 and 10 , relies on an active approach. Referring now to FIGS. 9 and 10 , cross sectional views of the keyboard 10 of FIGS. 2 and 1 , taken at arrows 9 - 9 and 10 - 10 respectively, are shown. Specifically, the keyboard 10 , among other things includes; a receiving transducer 70 , such as an accelerometer microphone or other device for converting vibrational or acoustical energy into electrical energy, located within the cavity 34 of the keyboard 10 that lays between the keys 14 and the base 22 . The receiving transducer 70 senses the vibrations of the keyboard 10 that result from each stroke of a key 14 . The signal from the receiving transducer 70 is then processed, by a processor (not shown) and a response signal is sent to a driving transducer 74 such as a piezoelectric transducer, an audio speaker or other device for converting electrical energy into mechanical energy, also located within the cavity 34 . The response signal may be 180 degrees out of phase with the signal sensed by the receiving transducer 70 such that the waves generated by the driving transducer 74 cancel waves from the stroking of keys 14 thereby attenuating the magnitude of the emanating sounds. Stated another way, the driving transducer 74 , by generating waves that are 180 degrees out of phase with the receiving waves, will create sound pressure waves that destructively interfere and, in effect, cancel the receiving sound pressure wave.
[0035] An alternate embodiment may utilize the input from the receiving transducer 70 to time the sending of a random noise signal to the driving transducer 74 . Such a system may transmit a random noise, or white noise, instead of an out of phase noise to cover the sounds made by the keystrokes, thereby making detection of a clean keystroke sound difficult. Still other embodiments may not utilize the receiving transducer 70 or a speaker to detect the sound emanating from a stroked key 14 at all, but instead rely on the electrical signal generated by the keystrokes themselves to determine the timing of when to energize the driving transducer 74 .
[0036] Embodiments of the invention may include some of the following advantages: attenuation of sound emanating from a keyboard, masking of sounds emanating from a keyboard, increased variations of sounds emanating from a keyboard, alteration of sounds emanating from a keyboard, continuously randomly modifying sounds emanating from a keyboard and changing, over time, the sound emanating from a keyboard in response to a given key being stroked.
[0037] The capabilities of the present invention can be implemented in software, firmware, hardware or some combination thereof.
[0038] As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media. The media has embodied therein, for instance, computer readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately.
[0039] Additionally, at least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform the capabilities of the present invention can be provided.
[0040] While preferred embodiments to the invention have been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described. | Disclosed herein is a method of masking audible sounds emanating from a keyboard in response to a stroking of keys on the keyboard, the method comprising, selecting components from a plurality of components with various masses, building the keyboard with the selected components, moving a movable mass within the keyboard, and energizing a driving transducer within the keyboard. Further disclosed herein is a keyboard for a computer, comprising a plurality of keys, a cover with the keys protruding therethrough, a base supporting the cover and the keys, and at least one selectable mass wherein the mass is selected from a plurality of masses, a movable mass supported by the base and movable relative to the base, and a driving transducer supported by the base. | 8 |
FIELD OF THE INVENTION
[0001] This invention refers to a system for selectively tuning multicavity filters of high frequency signals (HF), in particular microwave filters.
[0002] More particularly, the invention refers to a system for the selective tuning of simple or multiple microwave filters that include at least:—a body filter (CF);—a removable body filter lid (CO);—n resonant cavities (CA) made into (CF);—n resonators (R) placed in the center of each cavity CA;—n tuners (TU), each consisting of a rod passing from outside the filter lid and penetrating inside the cavity in correspondence to each resonator;—means (SL) to move the said tuners (TU).
[0003] The invention comprises also an advantageous and therefore preferred method for the embodying of the system.
TECHNOLOGICAL BACKGROUND
[0004] To have a microwave filter satisfying the electrical specifications in terms of insertion loss within the pass band filter and of rejection of undesired signals outside the pass band, it is necessary that each cavity be carefully tuned and that the intensity of the coupling between different cavity be sufficient but not exceeding a well defined limit.
[0005] Usually regulating means are introduced for each resonator and between any contiguous cavity: tuning properly these means, typically in the form of screws that pass through the lid and stick inside the body filter for a proper quote, makes the desired frequency response possible to be obtained.
[0006] It is known from experience that the manual tuning process is time consuming and quite expensive. It is also known that a filter could be tuned in different frequency bands by simply changing synchronously the resonant frequency of each cavity, maintaining the same coupling strength.
[0007] It follows that getting a selective filter tuned in translated bands with the same electric response is possible by simply changing synchronously each cavity's natural frequency.
[0008] From an industrial point of view, this technology is needed both for having a flexible design capable of being tuned on customer demand and for the cost reduction related to the manual tuning process.
[0009] Moreover, these devices can be remotely tuned even when already deployed on the field, by means of electronically controlled stepper motors.
STATE OF THE ART
[0010] Microwave multicavity filters are nowadays widely used thanks to the large spread of the mobile communication.
[0011] In general, multicavity combiners are made of TX filters for the transmission of signals and RX filters combined with amplifiers for the reception of signals, lightning protection circuit, etc. etc.
[0012] The Applicant (that is a leader supplier in this field) described multicavity filters in many patents, among them we would limit ourselves to mention the Italian patent no 1284538, no 1283662, no 1301857 and, in particular, no 1293622, dealing with the well-known TMA (Tower Mounted Amplifier).
[0013] In the International Patent Publication WO2004/084340, tuning systems with movable “tuners” combined with means for the longitudinal shift have been presented, but despite their many merits, it seems that they haven't reached the desired commercial success.
[0014] In fact these mechanisms present some drawbacks both from a mechanical and an electrical point of view, among them we mention that the movable tuner shifting device is seldom mechanically unstable during the movement, therefore the necessary synchrony of the natural frequency of each cavity is compromised and so is the tuning of the filter.
[0015] Moreover the reciprocal position of the single tuners assembled on the slide is fixed and not modifiable, that is the filter frequency response cannot be shifted, especially when the topology of the filter is complex because of cross-couplings and of transmission zeros. For these reasons and not for chance, a second international patent publication WO2005/122323 with improved capabilities has followed the aforesaid WO2004/084340.
SUMMARY OF THE INVENTION
[0016] The first purpose of the present invention is to provide a system of tuners associated to moving devices free from inconveniences, in particular from mechanical instability.
[0017] More specifically, the invention provides a system able to compensate the oscillations and the shakes to which are submitted the tuners during their sliding on the filter's lid, by means of suitable compensating devices and dynamic stabilizers.
[0018] Indeed the vibrations and the oscillations, even though small in a absolute sense, cause undesirable high frequency disturbs that adds pass-band insertion losses and worse out of band rejections.
[0019] The stabilizing system is designed to compensate both the vibrations produced during the slide movement and the mechanical tolerances inherent to the industrial production of the filter's lids and into the filter assembly process.
[0020] In accordance with an aspect of the invention, the system provides a mechanism for the mechanical stability that furthermore adds a degree of freedom for the positioning of the single elements mounted on a slide by means of a simple clamping device. In particular, the aforesaid system allows the regulation of the distance between single tuners while maintaining the stability of the whole tuning system.
[0021] This feature allows to adapt the frequency shift of each cavity independently, as requested in case of filters with transmission zeros.
[0022] Furthermore, it is important to carefully choose the right material to bring about said devices. From a mechanical point of view, it is important to choose light material with low friction and with a low thermal expansion coefficient in order to be able to slide fluently on the filter's lid and not to stick when the temperature rises.
[0023] From an electrical point of view, it is important to choose “transparent” RF material, that is isolating material characterized by dissipation coefficient which do not worsen the insertion losses.
[0024] From an industrial point of view, it is important to orient the solution towards materials which assure the best repeatable realization of every single device, the purchasing easiness, and the stability versus time consumption of the mechanical and electrical characteristics, even when the storage is not optimum.
[0025] The more important characteristics of the invention (system and method) are recited in the claims at the end of this specification, which are to be considered incorporated.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0026] The different aspects of the invention and its advantages will result more clearly from the description of the particular realization represented (to illustrative and not limitative title) in the accompanying drawings in which:
[0027] FIG. 1 represents a top view of a complex multicavity filter with three sections made of a filter body (CF) with cover (CO);
[0028] FIG. 2 represents a top view of the filter body (CF) without cover (CO);
[0029] FIG. 3 represents a perspective view of the filter as in FIG. 1 and FIG. 2 , with an exploded view of the filter's lid (CO) provided with n tuners (TU) (in that case n=14) and with relative shifting means, here named slides (SL);
[0030] FIGS. 4 and 5 represent partial views of the lid from outside ( FIG. 4 ) and inside ( FIG. 5 );
[0031] FIGS. 6 and 7 represent exploded frontal views of a single tuner (TU) with slide SL ( FIG. 6 ) and without slide ( FIG. 7 ), with enlarged central block (BLO 61 , BLO 62 , EL);
[0032] FIG. 8 represents a top section of the slide's blocking system placed on the external face of the filter's lid;
[0033] FIG. 9 represents a cross section view of the assembled system made of a slide SL and a tuner TU, blocked on it by means of blocking devices (BLO);
[0034] FIG. 10 represents an exploded view of the elastic system according to the invention;
[0035] FIG. 11 represents a frontal view of the filter's lid CO assembled with its slide SL, five tuners TU and their blocks (BO), said view being a cross-section having as a trace the line X-X of FIG. 3 ;
[0036] FIG. 12 is a lateral exploded cross sectioned view with a plane Y-Y of FIG. 11 ;
[0037] FIG. 13 is a cross-section of assembled elements of FIG. 12 ;
[0038] FIG. 14 represents a block diagram illustrating the preferred assembly method of the filter according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0039] FIG. 1 represents an exploded view of a multicavity filter F, made of a body filter CF in which resonant cavities CA and resonating rods R are drawn, and of a filter lid CO; tuner's moving means are assembled on the external face FE of the lid.
[0040] FIG. 1 shows a top view of a system made of three filters (TX-RX), F 1 , F 2 , F 3 , each full-filling the hereby exposed criteria: note the three slides SL 1 , SL 2 , SL 3 , associated to their respective filter F 1 , F 2 , F 3 , that are able to shift horizontally (arrow W) on the filter's lid CO. In this particular and preferred embodiment, the slides SL 1 , SL 2 , SL 3 , are electronically controlled by a high precision linear actuator ALP.
[0041] FIG. 1 and FIG. 2 represent respectively a top view of the above mentioned system without the lid and the exploded view that highlights the assembly process.
[0042] FIG. 4 shows a sampled filter lid CO ( 41 ) with an exploded view of the elastic tuner TU ( 42 ) and the slide SL 1 ( 43 ) by means of which the aforesaid tuner can slide in the W arrow direction ( FIG. 3 ).
[0043] Preferably the filter's lid CO is made of silver plated aluminum to enhance its conductivity property.
[0044] In relation to the vertical axis of any resonation rods, as many slots as the number of the cavities are drawn into the filter lid CO, and in each slot is placed one tuner TU able to absorb any vibration.
[0045] According to an aspect of the invention, the shape and the dimension of said slots are designed in order to obtain a tuner's shifting range wide enough to cover all the required frequency bands and at the same time to guarantee high spurious isolation outside the cavities CA.
[0046] In particular, the slot (AS) length in the filter's lid should not exceed the half of the cavity's side LA, and should be large enough to guarantee a high capacitance value when coupled with the tuner's face (PA) proximal to it. In this way a virtual grounding effect is carried out between the faces of the tuner and the filter's lid.
[0047] The virtual grounding assures the less energy dissipation and so the less insertion loss.
[0048] The double level groove SC ( 44 ) is useful as tuner guide and should be made in an accurate mode in order to eliminate the backlash of the sliding tuning device along the W arrow direction.
[0049] FIG. 5 shows a bottom view of the filter's lid CO with the slide assembled SL and a tuner TU. In order for the slide to run on the filter's lid accurately along a unique axis, it is necessary to guide its movement by means of fixing blocks (BLO in FIG. 8 ) that bind its movement in horizontal and vertical sense, because they partially overlay the slide by suitable grooves.
[0050] FIG. 13 shows the cross-section of a generic resonant cavity CA with its lid. A grooving SC is drawn in it so that tuners can pass through and the slide can run along. Fixing blocks BLO are assembled on the filter cover. The fixing blocks should not produce friction between the lid's surface and the slide.
[0051] FIG. 12 shows an exploded view of the preferred embodiment of the system according to the invention.
[0052] The shape and the material selection of the slide and of the fixing blocks is critical.
[0053] It has been found that “etherimmid” polymer based materials, such as ULTEM (trademark by General Electric), full-fill the following requirements:
Low friction on high porosity planes, such as silver plated aluminum plates; Good mechanical flexibility, that translates in manufacturing easiness and torsion strength; Good temperature behavior thanks to the same thermal expansion coefficient of the aluminum; this feature prevents from additional friction introduced by temperature changes; Low specific weight; High mechanical stability when subjected to strong mechanical stress.
[0059] The experience has shown that the best solution is to have the slide SL and the fixing blocks BLO made with ULTEM2300 (registered trademark), that is partially carbon charged.
[0060] Another suitable solution is to have the slide and the fixing blocks made of aluminum which have to be submitted to a surface coating treatment based on fluoride derivatives.
[0061] In this case, the fluoride surface prevents from high friction and the aluminum make the devices stable versus temperature.
[0062] The main drawbacks are the consumption of the surface treatment and the higher weight of the moving device.
[0063] According to the invention, the system aims to guarantee the fluid run of the tuners in their movement direction, avoiding any friction and any displacement orthogonal to their moving direction.
[0064] It is also important to assure the tuners mechanical stability respect to the vertical direction, that is to assure the tuners penetration quote (H in FIG. 9 ) inside of the cavity respect to the lid's surface.
[0065] According to an advantageous aspect of the invention, as pointed out in the introduction, we confirm the importance of having each tuner displaced independently on the slide, in order to have each cavity independently tuned.
[0066] The hereby invention aims to solve all these issues.
[0067] FIG. 6 shows a lateral view of the slide SL ( 63 ) and the tuner TU disassembled into its fundamental part.
[0068] The device (here called tuner TU) is made of five different elements, each equally important to achieve the aforesaid targets.
[0069] The “ensemble” blocks BLO 61 (head) and BLO 65 of FIG. 6 work together for fixing the tuner on the slide. When shifting, the slide makes all the tuners change their position synchronously.
[0070] The element BLO 61 is made of a threaded cylinder portion and a rectangular part below engaging in a correspondent hole (niche) NI obtained in the slide.
[0071] The element BLO 61 is a threaded nut that can block the cylindrical part.
[0072] In the proposed embodiment, the nut itself sinks in a slide's niche NI to reduce the vertical dimension.
[0073] The inferior portion BLO 62 is the tuner part (TU 66 ) that passes through the slots AS of the filter lid's (CO). The superior part is designed in order to fit perfectly into the filter lid's groove that act as a guidance. The inferior part pass through the cover and the tuning element TU 66 can be assembled on it.
[0074] As previously mentioned, the BLO 61 , BLO 62 , BLO 63 are made of an amorphous thermoplastic resin called ULTEM.
[0075] For the tuner TU 66 , the prior conventional technique suggested the use of dielectric materials or a combination of them.
[0076] The main problem is that high dielectric factor ceramics are needed in order to obtain the right frequency shift. High dielectric factor ceramics have also high dissipation factor, therefore high RF losses.
[0077] Moreover, suitable ceramics are usually expensive and hard to be found on the market. The solution proposed by the invention solves the aforesaid problems being made of a silver plated tuner TU 66 .
[0078] The appropriate frequency drift is determined by the penetration quote into the cavity and by the shape of the tuner itself, that need to be properly designed.
[0079] Furthermore, the current distribution on the tuner's surface has a low impact on the RF losses.
[0080] FIG. 9 shows in detail a cross-section of the tuning system.
[0081] As pointed out in the introduction, the distance between the surface of the cavity tuner (TU 66 ) and the lid surface (quote H in FIG. 9 ) must be steady, in order for the device to work properly during the shifting movements.
[0082] The elements suited to dynamically balance the tolerances due to the assembly process and the mechanical vibrations are shown in the exploded view in FIG. 10 .
[0083] In particular the element BLO 61 is bound to the slide by a blocking device.
[0084] The element BLO 62 , working as a support of the tuner, can shift into the filter lid's slots and can maintain its position thanks to an elastic constraint (EL). The vibrations caused by the movement are compensated by the aforesaid elastic device, in this case represented by a spring.
[0085] The mechanical features of the spring should be considered for the best elastic subsystem design (EL in FIG. 10 ).
[0086] In particular, the spring parameters to be considered are the material, the thread diameter, the number of coils per length unit, its steady length and its compression range.
[0087] According to the mechanical constraints, the design of the device associated to the spring ( FIG. 10 , BLO 61 , BLO 62 ) has to assure that the spring can work in its linear compression range during the slide movement, so that a constant pressure can be applied to the part BLO 62 of FIG. 10 .
[0088] The elastic pressure stands between the tuner's support BLO 62 and the filter's lid slots.
[0089] The compression strength depends on the thread diameter, on the number of coils and on the spring steady state length.
[0090] If the compression strength is too strong, the friction between tuners and cover increases and a block could happen.
[0091] On the contrary, if the compression strength is too weak, no vibration can be compensated and the tuner can vertically sway.
[0092] On the basis of the analyzed application the preferred material is the stainless steel because is stable in time, it's not subjected to the wear and tear of the time and it's stable versus temperature.
[0093] An advantageous and therefore preferred manufacturing method is represented in the block diagram of FIG. 14 .
[0094] The starting point is a filter body CF and a filter lid CO with slots AS provided therein.
[0095] As shown in FIG. 6 and FIG. 7 , the block BLO 62 and the elastic element EL are inserted into the filter cover slots CO+AS. The result is the component CO′=CO+BLO 62 +EL.
[0096] From block II the filter lid passes to block III, in which it is provided with the slide, previously assembled with BLO 61 , that is the tuner's heads, obtaining CO″=CO′+SL+BLO 61 .
[0097] CO″ goes to block IV where the slides SL are fixed to the filter lid by means of BLO ( FIG. 8 ), yielding CO′″=CO″+BLO.
[0098] CO′″ run to block V where is equipped with BLO 65 , that is the tuner's blocks, here represented by nuts and possibly flat washer ( FIG. 6 ).
[0099] The filter body passes in parallel from block VI to block VII, where a moving device ALP, that is a high precision linear actuator, is mounted, yielding CF′=CF+ALP.
[0100] In block VIII the body filter CF′ is assembled to its cover CO′″ coming from block V.
[0101] Block VIII yields the complex multicavity filter according to the invention.
[0102] For illustration clarity scruple the invention has been described with reference to the preferred embodiment shown in the accompanying drawings, which are however susceptible of all the modification and additions, which being obvious to the mean field expert, are to be considered as comprises and/or falling within the scope of the following claims. | The invention refers to a system and method to tune a multicavity filter of microwave signals, said filter comprising a filter body (CF), a removable lid (CO), n resonant cavities dug out in said filter body (CF) and n tuners (TU) susceptible of displacement under the action of movement means. Typically a sub-system to absorb the oscillations and vibrations generated in such displacements is associated to each tuner. | 7 |
REFERENCE TO RELATED APPLICATION
This application claims priority under 35 U.S.C. § 119(e) to U.S. patent application Ser. No. 60/526,304 filed on Dec. 2, 2003, the contents of which application are expressly incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The present invention relates generally to sliders for reclosable fasteners, and, more particularly, sliders that assist in opening and closing polymeric bags.
BACKGROUND OF THE INVENTION
Polymeric bags are popular household items that are used in a variety of applications including storage of food. The addition of reclosable fasteners or zippers to these bags has further enhanced their utility and the addition of a slider has made the fasteners easier to open and close. The fasteners include complementary first and second profiles that engage each other to close the bag.
One problem encountered in installing the slider to the fastener is distortion of the first and second profiles of the fastener. The profiles may be distorted when the slider is placed onto the fastener. More specifically, the profiles may be distorted from internal shoulders of the slider that partially form a cavity of the slider. To assist in preventing or inhibiting distortion to the profiles when inserting the slider onto the fastener, the slider may be constructed to have improved flexibility. These flexible sliders, however, do not generally have a desirable stiffness to remain on the fastener during normal use by a consumer.
A need therefore exists for an improved slider that can be inserted over the profiles of the fastener with little or no distortion, while providing a desirable stiffness to remain on the fastener during normal use.
SUMMARY OF THE INVENTION
According to one embodiment, a foldable plastic slider for straddling relation with a plastic fastener includes first and second profiles. The straddling slider is adapted to close or open the fastener by movement therealong. The slider comprises a transverse support member, first and second legs, first and second separating fingers, and first and second wings.
The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The first separating finger extends from the interior surface of the support member. The first separating finger is adapted to open the first and second profiles. The second separating finger extends from the interior surface of the support member. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener.
According to one aspect, at least one of the first and second separating fingers includes a rounded surface.
According to another aspect, at least one of the first and second separating fingers can include at least one of a generally half-moon shape, a circular shape, an elongated oval shape, and an elliptical shape.
According to another aspect, each of the first and second legs has gripper ribs formed by tactilely enhanced surfaces to assist in grasping the slider.
According to another aspect, the outer surface of the transverse support member is substantially free of coring.
According to another aspect, each of the latches is generally centered on the respective main body member.
According to another aspect, each of said legs has an edge with a shoulder for engaging the respective latch.
According to another embodiment, a foldable plastic slider for straddling relation with a plastic fastener includes first and second profiles. The straddling slider is adapted to close or open the fastener by movement therealong. The slider comprises a transverse support member, first and second legs, a separating finger, and first and second wings.
The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The separating finger extends from the interior surface of the support member. The separating finger is adapted to open the first and second profiles. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch. Each of the latches substantially extends across the full length of the respective legs. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener.
According to a further embodiment, a foldable plastic slider for straddling relation with a plastic fastener includes first and second profiles. The straddling slider is adapted to close or open the fastener by movement therealong. The slider comprises a transverse support member, first and second legs, a separating finger, and first and second wings.
The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The separating finger extends from the interior surface of the support member. The separating finger is adapted to open the first and second profiles. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a cored-out main body member and a latch. Each of the cored-out main body members has a plurality of cored-out regions on an interior of the respective cross piece such that the plurality of cored-out regions are at least partially hidden when the slider is installed on a fastener. The plurality of cored-out regions can form a plurality of triangular regions or a truss. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener.
According to yet another embodiment, a foldable plastic slider for straddling relation with a plastic fastener includes first and second profiles. The straddling slider is adapted to close or open the fastener by movement therealong. The slider comprises a transverse support member, first and second legs, a separating finger, and first and second wings.
The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The separating finger extends from the interior surface of the support member. The separating finger is adapted to open the first and second profiles. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener. The first and second legs form respective wing closing stops so as to prevent or inhibit the first and second wings from moving past a latched hinge rotational point formed after each of the latches engages one of the respective legs.
According to yet another embodiment, a foldable plastic slider for straddling relation with a plastic fastener includes first and second profiles. The straddling slider is adapted to close or open the fastener by movement therealong. The slider comprises a transverse support member, first and second legs, a separating finger, and first and second wings.
The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The separating finger extends from the interior surface of the support member. The separating finger is adapted to open the first and second profiles. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener. The support member further includes a molded rear window with an outer surface that is located adjacent to the first and second legs. The outer surface of the molded rear window is adapted to contact the first and second legs after the slider is installed on the fastener.
According to one embodiment, a reclosable plastic bag comprises opposing body panels attached to each other along a pair of opposing sides, a bottom bridging the sides, a mouth formed opposite the bottom, a reclosable fastener extending along the mouth, and a plastic slider. The fastener includes a first track with a first profile and a second track with a second profile. The first and second profiles are releasably engageable to each other.
The plastic slider is slidably mounted to the fastener. The slider comprises a transverse support member, first and second legs, first and second separating fingers, and first and second wings. The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The first separating finger extends from the interior surface of the support member. The first separating finger is adapted to open the first and second profiles. The second separating finger extends from the interior surface of the support member. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener.
According to another embodiment, a reclosable plastic bag comprises opposing body panels attached to each other along a pair of opposing sides, a bottom bridging the sides, a mouth formed opposite the bottom, a reclosable fastener extending along the mouth, and a plastic slider. The fastener includes a first track with a first profile and a second track with a second profile. The first and second profiles are releasably engageable to each other.
The plastic slider is slidably mounted to the fastener. The slider comprises a transverse support member, first and second legs, a separating finger, and first and second wings. The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The separating finger extends from the interior surface of the support member. The separating finger is adapted to open the first and second profiles. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch. Each of the latches substantially extends across the full length of the respective legs. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener.
According to a further embodiment, a reclosable plastic bag comprises opposing body panels attached to each other along a pair of opposing sides, a bottom bridging the sides, a mouth formed opposite the bottom, a reclosable fastener extending along the mouth, and a plastic slider. The fastener includes a first track with a first profile and a second track with a second profile. The first and second profiles are releasably engageable to each other.
The plastic slider is slidably mounted to the fastener. The slider comprises a transverse support member, first and second legs, a separating finger, and first and second wings. The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The separating finger extends from the interior surface of the support member. The separating finger is adapted to open the first and second profiles. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a cored-out main body member and a latch. Each of the cored-out main body members is in the form of a truss. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener.
According to yet another embodiment, a reclosable plastic bag comprises opposing body panels attached to each other along a pair of opposing sides, a bottom bridging the sides, a mouth formed opposite the bottom, a reclosable fastener extending along the mouth, and a plastic slider. The fastener includes a first track with a first profile and a second track with a second profile. The first and second profiles are releasably engageable to each other.
The plastic slider is slidably mounted to the fastener. The slider comprises a transverse support member, first and second legs, a separating finger, and first and second wings. The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The separating finger extends from the interior surface of the support member. The separating finger is adapted to open the first and second profiles. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener. The first and second legs form respective wing closing stops so as to prevent or inhibit the first and second wings from moving past a latched hinge rotational point formed after each of the latches engages one of the respective legs.
According to yet a further embodiment, a reclosable plastic bag comprises opposing body panels attached to each other along a pair of opposing sides, a bottom bridging the sides, a mouth formed opposite the bottom, a reclosable fastener extending along the mouth, and a plastic slider. The fastener includes a first track with a first profile and a second track with a second profile. The first and second profiles are releasably engageable to each other.
The plastic slider is slidably mounted to the fastener. The slider comprises a transverse support member, first and second legs, a separating finger, and first and second wings. The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member. The separating finger extends from the interior surface of the support member. The separating finger is adapted to open the first and second profiles. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch. The first and second wings are folded relative to the support member and each of the latches engages one of the respective legs to install the slider on the fastener. The support member further includes a molded rear window with an outer surface that is located adjacent to the first and second legs. The outer surface of the molded rear window is adapted to contact the first and second legs after the slider is installed on the fastener.
According to one method, a foldable plastic slider is installed onto a reclosable plastic bag including opposing body panels attached to each other along a pair of opposing sides, a bottom bridging the sides, a mouth formed opposite the bottom, and reclosable fastener extending along the mouth. The fastener includes a first track with a first profile and a second track with a second profile. The first and second profiles are releasably engageable to each other. The plastic slider is slidably mounted to the fastener. The slider comprises a transverse support member, first and second legs, first and second separating fingers, and first and second wings. The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member and having respective first and second shoulders. The first separating finger extends from the interior surface of the support member. The first separating finger is adapted to open the first and second profiles. The second separating finger extends from the interior surface of the support member. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch.
The transverse support member is placed on the plastic fastener with the first and second separating fingers between the first and second tracks and the first and second depending legs outside the respective first and second tracks such that the respective first and second tracks separate the first and second separating fingers from the respective first and second legs. The first and second wings are rotated downward toward a bottom of the reclosable bag until each of the latches engages one of the respective legs. The first and second wings are pressed until each of the latches snaps into engagement with one of the respective shoulders of the respective leg.
According to another method, a foldable plastic slider is installed onto a reclosable plastic bag including opposing body panels attached to each other along a pair of opposing sides, a bottom bridging the sides, a mouth formed opposite the bottom, and reclosable fastener extending along the mouth. The fastener includes a first track with a first profile and a second track with a second profile. The first and second profiles are releasably engageable to each other. The plastic slider are slidably mounted to the fastener. The slider comprises a transverse support member, first and second legs, a separating finger, and first and second wings. The transverse support member includes first and second opposing sides, an interior surface, and an outer surface. The first and second legs depend from the respective first and second opposing sides of the support member and having respective first and second shoulders. The first separating finger extends from the interior surface of the support member. The first separating finger is adapted to open the first and second profiles. The second separating finger extends from the interior surface of the support member. The first and second wings are hingedly attached to the respective first and second opposing sides. The first and second wings have respective first and second openings for receiving the respective first and second legs, and respective wing closing stops. The first and second wings have respective first and second cross pieces. Each of the cross pieces includes a main body member and a latch.
The transverse support member is placed on the plastic fastener with the separating finger between the first and second tracks and the first and second depending legs outside the respective first and second tracks such that the respective first and second tracks separate the separating finger from the respective first and second legs. The first and second wings are rotated downward toward a bottom of the reclosable bag until each of the latches engages one of the respective legs. The first and second wings are pressed until each of the latches snaps into engagement with one of the respective shoulders of the respective leg. The first and second legs form respective wing closing stops so as to prevent or inhibit the first and second wings from moving past a latched hinge rotational point formed after each of the latches engages one of the respective legs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged perspective view of a slider in the closed position according to one embodiment of the present invention;
FIG. 2 is a top plan view of the slider of FIG. 1 in the open position;
FIG. 3 is a bottom perspective view of the slider of FIG. 1 in the open position;
FIG. 4 is a bottom plan view of the slider of FIG. 1 in the open position;
FIG. 5 a is a first end view of the slider of FIG. 1 in the closed position;
FIG. 5 b is a second end view of the slider of FIG. 1 in the closed position;
FIG. 6 is a top view of an end termination according to one embodiment;
FIGS. 7-9 are a sequence of steps of inserting the slider of FIG. 1 on a fastener;
FIG. 10 is a polymeric bag with the slider of FIG. 1 ;
FIG. 11 is a cross-sectional view of the slider of FIG. 1 taken generally along the line 11 - 11 of FIG. 4 ;
FIG. 12 is a cross-sectional view of the slider of FIG. 11 just before being in the closed position; and
FIG. 13 is a cross-sectional view of the slider of FIG. 11 in the closed position.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention 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 invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1-5 , there is illustrated a foldable slider 10 according to one embodiment of the present invention. The slider 10 is an inverted generally U-shaped member. The sliders of the present invention may be combined with a fastener or zipper 12 in forming a reclosable polymeric bag 14 (see FIGS. 6-10 ). The foldable slider 10 in such an embodiment assists in opening the reclosable polymeric bag 14 between a closed position and an open position.
FIGS. 7-9 depict a mouth portion of the reclosable polymeric bag 14 . The polymeric bag 14 comprises first and second opposing body panels 16 and 18 fixedly connected to each other along a pair of sides (not shown) and a bottom (not shown) bridging the pair of sides. The entire bag 14 , however, is shown in FIG. 10 . The bag may be formed from a single flexible polymeric sheet folded upon itself. Alternatively, the bag may be formed from separate polymeric sheets. In this embodiment, the polymeric bag 14 is provided with the fastener 12 extending along a mouth formed opposite the bottom of the polymeric bag.
The body panels 16 and 18 typically comprise one or more polymeric resins. The body panels 16 and 18 may be comprised of polyolefins including, but not limited to, polyethylene, polypropylene, or combinations thereof.
The fastener 12 includes a first track 20 and a second track 22 . The first track 20 includes a first profile 24 and a first depending fin or flange 26 extending downward from the first profile 24 . Similarly, the second track 22 includes a second profile 28 and a second depending fin or flange 30 extending downward from the second profile 28 . It is not necessary for the tracks 20 , 22 to have fins depending therefrom. The first profile 24 includes a top portion 32 and the second profile 28 includes a top portion 34 . If the fastener 12 is formed separately from the body panels 16 , 18 of the polymeric bag 14 , the first and second fins 26 , 30 may be thermally fused to inner surfaces of the respective first and second body panels 16 , 18 . Alternatively, the fastener 12 may be integrally formed with the body panels 16 , 18 such that the first track 20 is integrally formed with the first body panel 16 and the second track 22 is integrally formed with the second body panel 18 .
The opposite ends of the fastener 12 are typically provided with opposing end termination clips, such as end termination clip 36 of FIG. 10 . End termination clips may have various purposes such as (a) preventing or inhibiting the slider for going past the ends of the fastener, (b) interacting with the slider to give a tactile indication of being closed, (c) assisting in inhibiting or preventing leakage from the bag, and (d) holding the fastener together and providing additional strength in resisting stresses to the bag.
Each end clip 36 of FIG. 10 comprises a strap member that wraps over the top of the fastener 12 . One end of the strap is provided with a rivet like member that is adapted to penetrate through the bag material and into a cooperating opening at the other end of the end clip 36 . The rivet is then deformed so as to create a head locked into the opening.
It is contemplated that other end terminations may be used instead of the above-described end terminations clip 36 . For example, an end weld may be formed by heated bars pressed against the end of the fastener, ultrasonic welding, or other ways known in the art.
One such example is shown in FIG. 6 where a top view of an end termination 38 is depicted. The end termination 38 can be initially formed from end portions 38 a , 38 b of the profiles 24 , 28 of the fastener 12 being pressed together by a process involving heat, such as ultrasonic welding. Before and/or during heating, the slider 10 can be disposed on the tracks 20 , 22 . During and/or after heating of the end portions 38 a , 38 b of the profiles 24 , 28 (e.g., during cooling of the end portions), separating finger 52 of the slider 10 can be pushed and/or otherwise disposed between the end portions 38 a , 38 b , so that the end portions 38 a , 38 b cool around the separating finger 52 and cooperatively form an end termination 38 having a shape similar to that of the separating finger 52 . After formation of the end termination 38 , the separating finger 52 can be positioned substantially within or entirely within the end termination 38 in the closed position of slider 10 . The end termination 38 desirably contracts behind the shape of the separating finger 52 , thus inhibiting and/or preventing leakage (e.g., of fluids or solid items) from bag 14 in the closed position of the slider 10 . The end termination 38 provides a tactile indication, or an audible indication, or both to the user that the slider 10 is in a closed position.
Referring back to FIG. 7 , the slider 10 is illustrated in an open position prior to being installed on the fastener 12 . FIG. 8 illustrates the slider 10 in the process of being installed on the fastener 12 , while FIG. 9 illustrates the slider 10 after being installed on the fastener 12 . The slider 10 in its assembled or closed position shown in FIG. 9 forces the first and second profiles 24 , 28 into engagement. FIGS. 7-9 illustrate one process of installing the slider on the fastener 12 . Although the tracks 22 , 24 behind the slider 10 in FIGS. 7 and 8 (e.g., to the right of reference numeral 50 ) are shown as being open, the spacing between the tracks 22 , 24 can be adjusted to facilitate installation of the slider 10 . For example, the tracks 22 , 24 behind the slider 10 can be adjusted to be partially closed.
Referring back to FIGS. 1-5 , the slider 10 has an opening end (located near separating finger 52 ) and a closing end (located near separating finger 54 ), the slider 10 is wider at the opening end to allow separation of the first and second profiles 24 , 28 . The slider 10 is sufficiently narrow at the closing end to press the first and second profiles 24 , 28 into an interlocking relationship as the slider 10 is moved in the closing direction.
To indicate the direction to move the slider 10 to close the bag, an optional arrow 40 may be formed in the slider 10 as shown in FIG. 1 . The arrow 40 may be formed on the top of the slider 10 by a molding process. If the arrow 40 is used, then it is desirable for the depth of the arrow 40 to be minimized. By minimizing the depth of the arrow 40 and any other potential coring of the slider top, the rigidity of the slider is increased, which results in improved slider-top retention. The term “slider-top retention” refers to the ability of the slider to prevent or inhibit being removed in a direction generally perpendicular with the movement of the slider between an open and closed position. The term “end retention” refers to the ability of the slider to prevent or inhibit being removed in a direction generally parallel with the movement of the slider between an open and closed position.
It is desirable to have the top of the slider that is substantially free of coring. As used herein, the term coring includes coring during molding as understood by those of ordinary skill in the art, as well as removal of material after molding. For example, it is desirable to have the top of the slider be formed with coring having a depth less than about 0.035 inches, more desirable for the coring to have a depth less than about 0.030 inches, and still more desirable for the coring to have a depth less than about 0.020 inches.
The slider 10 may be formed from suitable polymeric material such as, for example, nylon, polypropylene, polyethylene, polystyrene, polyethylene terephthalate (PET), Delrin, or ABS. The slider may be formed by injection molding, thermoforming, compression molding, extrusion, or machining or patterned material deposition. The slider 10 is particularly suited for use with profiled polymeric reclosable fasteners or zippers and thermoplastic bags such as shown in FIGS. 7-10 .
The fastener 12 typically comprises one or more polymeric resins. The fastener may be comprised of polyolefins including, but not limited to, polyethylene, polypropylene, or combinations thereof.
Referring back to FIGS. 1-5 , the foldable slider 10 comprises an inverted generally U-shaped member that includes a transverse support member or body 50 from which a plurality of separating fingers 52 , 54 depends therefrom. A top, outer surface of the support member 50 may include the optional arrow 40 shown in FIG. 1 . The body 50 also includes two integral depending legs 56 , 58 and two hinged “wings” 60 , 62 . The wings 60 , 62 also have respective wing shoulders 68 , 70 (see FIG. 5 a,b ).
The separating finger 52 is wider than the separating finger 54 as shown in FIGS. 3 and 4 . The separating finger 52 is shown as a generally half-moon shape, while the separating finger 54 is shown as an elongated oval shape. The separating finger 52 may be circular shaped, an elongated oval shape, or elliptically shaped. The separating finger 54 may also be circular shaped, elliptically shaped, tadpole, or a generally half-moon shape. The separating fingers 52 , 54 generally have a surface or edge that is blunt (i.e., rounded).
The separating finger 54 as shown in FIG. 4 has a width W 1 that is generally greater than about 0.02 inch and, more specifically, the width W 1 is typically greater than about 0.045 inch. The width W 1 is generally from about 0.02 to about 0.05 inch. Similarly, the separating finger 52 as shown in FIG. 4 has a width W 2 that is generally greater than about 0.08 inch and, more specifically, the width W 2 is typically greater than about 0.09 inch. The width W 2 is generally from about 0.085 to about 0.11 inch. The distance between the first and second separating fingers 52 , 54 is desirably optimized to equal the tracks' “natural open-to-close shape,” as that term is understood by those of ordinary skill in the art.
The shape and width of the separating finger 52 assists in opening the top of the fastener and improving the end strength retention of the slider. The shape and width of the separating finger 54 assists in improving the end strength retention of the slider and also assists in placing the slider onto the track.
It is desirable to have at least two separating fingers, which reduces the cycle time by allowing additional ejector pin(s) to be used between the separating fingers. The cycle time is especially reduced by creating a larger generally flat surface between the separating fingers that allows the use of larger, flatter ejector pins. It is also desirable to have distinct separating fingers to reduce the cost of material and the mold cycle time by reducing the cooling time.
The separating fingers 52 , 54 interact with the first and second portions 32 , 34 ( FIGS. 7-9 ) of the fastener 12 to lock and unlock the first and second profiles 24 , 28 of the fastener 12 . The separating finger 52 in cooperation with the shoulders 68 , 70 spread the first and second portions 32 , 34 . The spread first and second portions 32 , 34 separate the first and second profiles 24 , 28 , thereby opening the fastener 12 as the slider 10 is moved.
To close the fastener 12 , the slider 10 is moved in the reverse direction and the second separating finger 54 cooperates with the shoulders 68 , 70 and the legs 56 , 58 and wings 60 , 62 of the slider 10 to bring the first and second portions 32 , 34 together. The first and second portions 32 , 34 when brought together lock the first and second profiles 24 , 28 . To close the fastener 12 completely, at least the separating finger 52 is removed from between the first and second portions 32 , 34 of the fastener 12 .
To assist in grasping the slider, the legs 56 , 58 and portions of the wings 60 , 62 form gripper ribs using hills and valleys. This is shown in FIG. 1 , for example, with a plurality of hills 58 c , 62 c , and a plurality of valleys 58 d , 62 d . The shape of the slider 10 assists in fitting the natural shape created between a user's index finger and thumb. The gripper ribs formed by the hills and valleys or other suitable protrusions or tactilely enhanced surfaces interact with the user's finger and thumb to increase friction. By improving the friction between the gripper ribs and the user's finger and thumb, the slider is more easily grasped in less than ideal circumstances such as wet and oily conditions.
The lower ends of legs 56 , 58 are provided with respective engaging shoulders 56 a , 58 a (see FIG. 11 ) and respective surfaces 56 b , 58 b adjacent to the respective engaging shoulders 56 a , 58 a.
The body 50 also includes a molded rear window 80 (see FIG. 3 ) that assists in closing the track. The molded rear window 80 increases the rigidity of the slider and assists in improving the slider-top and end retention strength. Thus, by having the molded rear window 80 , the slider is further inhibited or prevented from being removed from the track.
The wings 60 , 62 have a respective cross piece 64 , 66 that form respective latches 64 a , 66 a . The latches 64 a , 66 a are desirably sloped and solid ramps. To increase the latch strength, each of the latches 64 a , 66 a substantially extends across the full length of the respective legs 56 , 58 . The latches 64 a , 66 a may extend the full length of the respective legs 56 , 58 . By having the latches 64 a , 64 b substantially extend across the full length of the respective legs 56 , 58 , wing deflection is reduced, which increases end retention of the slider. It is also believed that the latches 64 a , 66 a substantially extending across the full length of the respective legs 56 , 58 also increase the top retention of the slider. Thus, it is more difficult for the slider to be removed by having a latch extending substantially across the full length of the respective legs 56 , 58 .
Portions of the inner surface of the cross pieces 64 , 66 form respective plurality of cored-out regions 64 b - 64 d and 66 b - 66 d . The cored-out regions reduce the weight of the slider, which reduces the cost in forming the slider. To assist in maintaining the strength of the slider, the cored-out regions 64 b - 64 d and 66 b - 66 d desirably form a plurality of triangles in the form of a truss. If desired, the cored-out regions 64 b - 64 d and 66 b - 66 d can form other shapes that maintain the strength of the slider and enhance the latching ability of latches 64 a , 64 b . For example, in some embodiments, the cored-out regions 64 b - 64 d and 66 b - 66 d can form one or more ribbed shapes.
By having cored-out regions, the cycle time of forming the slider is also reduced because cooling occurs faster. By coring the cross pieces 64 , 66 , the potential for shrinkage is reduced.
The cross pieces 64 , 66 also form respective cored-out wing eject pads 64 f , 66 f . The cored-out wing eject pads 64 f , 66 f are shown as being generally cylindrical in shape. It is contemplated that the wing eject pads may be of other shapes. The wing eject pads 64 f , 66 f may be formed by having wing eject pads mold the slider when the eject pins move, but the sleeves remain in place.
As discussed above, the shoulders 68 , 70 cooperate with the first separating finger 52 to assist in opening and closing the fastener. The shoulders 68 , 70 also engage the fastener 12 to inhibit or prevent the slider 10 from being lifted off the profile edges while the slider 10 straddles the fastener 12 . Specifically, the shoulders 68 , 70 engage with lower surfaces of the profiles to inhibit or prevent (a) the slider from being pulled off in a direction perpendicular to the sliding motion, and (b) the slider from being removed from the force required to open the profiles.
Referring specifically to FIGS. 3 and 4 , the wings 60 , 62 are connected to the body 50 via respective hinge structures 72 , 74 located on opposite sides of the body 50 . The hinge structures 72 , 74 are relatively thin sections of polymeric material as compared to the wall thicknesses of the wings 60 , 62 and the flexibility of the polymeric material makes possible the use of the integral hinge structures 72 , 74 , which are sometimes referred to as “living” hinges. The wings 60 , 62 form central openings to receive the respective legs 56 , 58 when the wings 60 , 62 are folded down to the closed sidewall position, as will be described below.
FIGS. 7-9 depict the slider 10 undergoing assembly on a bag according to one process. The slider 10 is mounted on the first and second tracks 20 , 22 of the fastener 12 in such a way that the separating fingers 52 , 54 are between the first and second profiles 24 , 28 of the respective tracks 20 , 22 . The depending legs 56 , 58 are positioned on the outside of the tracks 20 , 22 in such a way that the tracks 20 , 22 of the fastener 12 separate the plurality of separating fingers 52 , 54 from the respective depending legs 56 , 58 . The wings 60 , 62 are then rotated downward toward the bottom of the bag with the “living” hinges acting as the axis of rotation. FIG. 9 shows the slider 10 in an assembled condition with the wings 60 , 62 being folded down to their closed sidewall state.
To prevent or inhibit the wings 60 , 62 from continuing past the latched hinge rotational point, the body 50 includes wing closing stops 76 , 78 . The wing closing stops 76 , 78 may be molded in the legs 56 , 58 . The wing closing stops 76 , 78 limit or stop the wings 60 , 62 from continuing past the latched hinge rotational point. This limits potential pinching of the track when the user squeezes the slider 10 with too much force. By reducing the pinching on the track, the slider 10 moves along the track more easily.
When the wings 60 , 62 are folded down from their open position to their closed sidewall position, the wings 60 , 62 are held in place by a compression-type latch. FIG. 11 depicts a cross-sectional view taken generally along line 11 - 11 shown in FIG. 4 . FIG. 11 shows the slider 10 in an open position. FIG. 12 shows the slider 10 just before being in the closed position, while FIG. 13 shows the slider 10 in the closed position.
As shown in FIGS. 11-13 , when the wing 60 is rotated to the closed sidewall position, the latch 64 a comes into contact with the surface 56 b adjacent to the engaging shoulder 56 a . When the wing 60 is moved toward the closed sidewall position, the surface 56 b exerts a downward force on the latch 64 a as shown in FIG. 12 . This causes the sloped latch 64 a to flex or depress. In this embodiment, an upper edge 64 e of the wing 60 does not flex or depress. The latch 64 a remains depressed until the leg 56 has completely passed thereover. Then, the latch 64 a returns to its original shape that forces engagement with the engaging shoulder 56 a shown in FIGS. 11 and 12 , thereby locking the wing 60 and leg 56 into the closed sidewall position.
This compression-type latch offers many advantages. It allows for easier installation of the slider 10 and increases the difficulty in removing the slider from the bag. The latch 64 a , when depressed, acts similar to a spring in compression and, once released, is forced upward into a locked condition with the engaging shoulder 56 a of leg 56 . As the wing 60 is being latched, the surface 56 b depresses the latch 64 a . When attempting to disengage the wing 60 from the leg 56 , however, the direction in which the force acts is unable to depress the latch 64 a ; rather, it forces the leg 56 more strongly into engagement with the wing 60 . This increases the difficulty in disassembling the slider.
Similarly, the wing 62 has the latch 66 a , cross piece 66 , shown in FIG. 12 , which allow the latch 66 a to engage the shoulder 58 a of the leg 58 . This provides a compression-type latch to lock wing 62 in place with leg 58 . All of which functions in the same manner as for the wing 60 described above.
While the present invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. | A foldable plastic slider for straddling relation with a plastic fastener includes first and second profiles. The straddling slider is adapted to close or open the fastener by movement therealong. The slider comprises a transverse support member, first and second legs, first and second separating fingers, and first and second wings. The first and second legs depend from the respective first and second opposing sides of the support member. The first and second separating fingers extend from an interior surface of the support member. The first separating finger is adapted to open the first and second profiles. The first and second wings have respective first and second openings for receiving the respective first and second legs. The first and second wings are hingedly attached to the support member, and latches on each wing engage a respective one of the legs. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to improvements made to composite-shell pneumatic craft convertible into a closed box for their storage and/or their transportation, comprising a rigid hull, the upper edge of which extends approximately in one plane, and an inflatable buoyancy tube fixed to said edge of the rigid hull—excluding the rear thereof—by joining means, a removable rigid panel being additionally provided and configured to match the contour of said upper edge of the hull in order to form a closing element for the hull, inside which the deflated tube has been folded flat.
DESCRIPTION OF THE PRIOR ART
[0002] According to document FR-A-2 761 042, a craft of the aforementioned type which, by virtue of its general arrangement, satisfies the sought-after object of ease of storage and transportation by automobile and also of a rapid and uncomplicated passage from the storage and transportation configuration to the navigation and inversion configuration, is known.
[0003] A crucial problem in this type of craft is to ensure, in navigation configuration, a reliable sealing tightness between the rigid hull and the inflated tube in order to prevent water from penetrating into the rigid hull by passing between this and the tube.
[0004] Another problem lies in the method of connecting the inflatable tube to the rigid hull to enable the passage from one configuration to the other to be made without removing/refitting the tube on the hull, in other words by allowing the tube to be permanently joined to the hull (the removal capability being reserved, for example, for workshop maintenance) and by swinging it on one side or other of the hull as required (inner side for storage/transportation, outer side for inflating and navigation).
[0005] A solution to these problems had appeared to be attainable by constituting the aforementioned joining means, as proposed in document FR-A-2 777 531, in the form of a profile having a section in the general shape of an inverted U, overlapping the upper edge of the hull and comprising:
[0006] a first upwardly open groove, situated on the inside of the hull, configured with a narrow opening for holding a bead joined to the said tube, the bead being borne by a flexible skirt attached to the tube,
[0007] a second upwardly open groove, situated on the outside of the hull, suitable for receiving the lip of the aforesaid rigid panel affixed to the hull in the closed box configuration and suitable for maintaining the flexible skirt of the inflated tube situated outside the hull in the craft configuration,
[0008] and an elastomer strip situated externally beneath the second channel in order to form a seal-tight support for the inflated tube in the craft configuration.
[0009] In practice, however, the abovementioned profile did not adequately meet requirements. On the one hand, this profile is complex in shape and hence costly to produce. In addition, it requires the installation of a convex sealing strip designed to cooperate in a seal-tight manner with the buoyancy tube: not only does this strip add to the production cost, but the acquired sealing tightness, furthermore, is unsatisfactory and the water is able to penetrate, through there, into the craft. Finally, it has a part (holding groove for the bead) which is situated inside the craft and can hamper the occupants, or even be dangerous.
[0010] It has therefore proved necessary to modify the profile in question, whilst still preserving the principle of using a multifunction profile suitable for the hook-fastening of the buoyancy tube and for the cooperation with the edge of the lid in storage/transportation position, this multifunctionality having proved in practice to be effective and practical.
SUMMARY OF THE INVENTION
[0011] In this context, the object of the invention is therefore to propose an improved arrangement having a simply shaped and hence less costly profile, suitable for obtaining a seal-tight connection between the buoyancy tube and the rigid hull and preserving at least the aforementioned twin function.
[0012] To these ends, the invention proposes a pneumatic craft such as referred to above, which, being arranged according to the invention, is characterised in that the said joining means comprise a profile fixed to the outside of the hull, along the edge or close to the edge thereof, said profile comprising:
[0013] a supporting flank against the hull, and
[0014] a groove configured with a narrow opening which opens into an upper wall of the profile close to said supporting flank, said groove being suitable for holding a bead joined to a flexible skirt attached to the inflatable body,
[0015] said upper wall of the profile being suitable, in its part adjacent to said groove opposite to said supporting flank of the profile, for supporting a lip of said removable panel,
[0016] a portion of the supporting flank of the profile being configured to cooperate with members for fixing said profile to the hull.
[0017] Thus, owing to the fact that the profile no longer overlaps the upper edge of the wall of the hull but is fixed to the outer wall of the hull, the profile can be formed in a simple and relatively compact shape. Such a profile is easier to produce and is therefore cheaper and, furthermore, it has no part projecting inside the hull, likely to prove a nuisance, or even dangerous.
[0018] In navigation position, moreover, the whole of the flotation means (inflatable body, profile and connection between the two) are situated outside the rigid hull and there is no risk of water penetrating into the latter.
[0019] Advantageously, the profile can possess a second flank, opposite to said first supporting flank, and the two flanks can project above said upper wall, defining an upwardly open channel suitable for holding said removable panel transversely, such that, on the one hand, the supporting surface of the profile on the hull has grown and, on the other hand, the edge of the lid, in storage/transportation position, is enclosed in this channel and is held more effectively on the hull.
[0020] Also advantageously, the first supporting flank of the profile can comprise a wing projecting beneath the aforesaid groove and it is therefore this wing projecting at the bottom which is suitable for cooperating with members for fixing the profile to the hull. The inflatable buoyancy tube, whether in the inflated or deflated state, is therefore guaranteed not to come into contact with the fixing members, which can be protruding and aggressive (screws, rivets), and not to be torn to pieces.
[0021] It is therefore very interesting, moreover, to arrange for the profile to comprise a tubular part situated under said groove and for one wall of this tubular part to be formed by said wing. In effect, the connecting members which cooperate functionally with this wing are then protected in relation to the environment, and especially in relation to the inflatable tube. In addition, it becomes possible, once the profile is fixed on the hull, to seal off the ends of the said tubular part of the profile such that the water can no longer penetrate therein. The sealing tightness of the mechanical connections of the profile to the hull is thereby assured.
[0022] Finally, it is possible to provide for said two opposite flanks of the profile to extend at the bottom in the form of two lower wings situated opposite each other and defining a rail, and, by giving an appropriate configuration to these wings, it is possible to use them as hook-fastening elements for accessories.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention will be more easily understood by reading the following detailed description of certain preferred embodiments, given solely by way of non-limiting examples. In this description, reference is made to the appended drawings, in which:
[0024] [0024]FIG. 1 is a perspective view illustrating the craft forming the subject of the invention in its closed box configuration, installed and stowed on the roof of an automobile;
[0025] [0025]FIG. 2 is a perspective view of the same craft in its configuration as a composite-shell pneumatic craft ready for navigation;
[0026] [0026]FIG. 3 is a perspective view of the craft of the invention in an intermediate condition, inflatable body emptied and folded up in the tub and lid panel removed;
[0027] [0027]FIG. 4 is a larger-scale view, in cross section, of a profile according to the invention, suitable for equipping the craft of FIGS. 1 to 3 and shown in a functional configuration of the craft;
[0028] [0028]FIGS. 5 and 6 illustrate respectively two constructional variants of the profile of FIG. 4; and
[0029] [0029]FIG. 7 illustrates yet another constructional variant, which is preferred, of the profile of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Referring first of all to FIG. 2, the aggregate of elements allowing the composition of a craft forming the subject of the invention comprises a rigid tub 1 , of elongated general shape, made of any appropriate material, especially of synthetic material used for the construction of rigid hulls of composite-shell craft.
[0031] One of the ends of the tub 1 is profiled both horizontally (the side walls 3 progressively converging) and vertically (the bottom 4 rising progressively up to the height of the peripheral edge 5 of the tub), as can be seen more clearly in FIG. 1, in which the tub 1 is shown upside down.
[0032] The other end of the tub 1 is closed by a partition 6 approximately at right angles to the longitudinal axis of the tub.
[0033] The tub thus formed is therefore suitable for forming a rigid hull, the first end 2 of which constitutes the front and the second end of which constitutes the rear with the transverse partition 6 , which constitutes a stern panel, for example suitable for supporting an outboard drive motor (not shown in FIGS. 1 and 2).
[0034] Along the side and front edges of the tub 1 is fixed an elongated inflatable body 7 , made of flexible material, in the general shape of a tube, which constitutes an inflatable buoyancy body having the general configuration of a U which is open rearward. The fixing of the inflatable body 7 to the edge of the tub or rigid hull 1 is obtained by means of a bead/channel system according to a technique known for traditional semi-rigid crafts and which is discussed further below.
[0035] The inflatable body 7 can be designed and configured in similar fashion to the inflatable body of a traditional composite craft, as can be seen in FIG. 2. Similarly, the stern panel formed by the transverse partition 6 can be arranged and configured in the same manner as a stern panel of a traditional pneumatic craft.
[0036] Finally, as can be seen in FIG. 3, a removable rigid panel 9 , made, for example, of the same material as the tub 1 , is also provided, which has a peripheral contour matching that of the peripheral edge of the tub 1 and which constitutes a closing or lid panel allowing the tub 1 to be closed.
[0037] The contour of the upper edge of the rigid hull and of the stern panel extends approximately in one plane, such that assembly with the rigid panel 9 is facilitated.
[0038] All the elements which have just been described can be arranged in two different functional configurations.
[0039] On the one hand, it is possible to realise a transportation and storage configuration, illustrated in FIG. 1, in which the inflatable body 7 is deflated and folded up inside the rigid tub 1 (this configuration can be seen in FIG. 3). The tub 1 is in this case arranged in upside down position on the rigid panel 9 forming the bottom lid and is bolted thereon with the aid of fastening means, preferably of the rapid-fastening type not shown in the figures. In this position, the edge of the panel 9 matches the shape of the edge of the tub 1 . An outboard motor 13 can be joined to the inner face 11 of the rigid panel 9 , following folding or removal of its control handle 14 , by means of straps 12 and/or by means of its own motor screws screwed onto an appropriate projecting relief of the panel 9 .
[0040] A closed box is therefore formed, which facilitates the storage of the craft and the protection of the deflated tube and, more advantageously, furthermore, is fit to be placed and fixed on the roof of an automobile 10 , as shown in FIG. 1. The shape of the shell 1 , arranged with the prow 2 facing frontward in the direction of travel of the automobile, is appropriate from the aerodynamic aspect. The general shape of the box thus formed is close to that of a roof luggage box for an automobile and its use is similar.
[0041] On the other hand, it is also possible to realise a navigation configuration, illustrated in FIG. 2, in which the rigid panel 9 is detached and separate from the tub 1 . The inflatable body 7 is inflated under pressure for its shaping around the tub 1 , which in this case constitutes a rigid hull, the aggregate of the tub 1 and inflatable body 7 constituting a composite shell.
[0042] According to the invention, a rigid profile 15 (especially made of aluminium or plastics material), illustrated on an enlarged scale in FIG. 4, is fixed along the upper edge 5 , or close to the upper edge 5 , of the rigid hull 1 . The profile 15 is fixed on the outer face of the side walls 3 of the hull 1 .
[0043] The profile 15 has the general appearance of a tubular section, possessing a wall 16 (the left-hand one in the drawing) which is arranged to form a supporting flank against the wall 3 of the hull. This wall of the hull being, close to its upper edge 5 , substantially flat in the illustrated example, the wall 16 of the profile possesses an outer face which, in turn, is substantially flat.
[0044] The profile 15 also has an upper wall 17 , which, over the whole of its length, has an opening or slot 18 disposed along the aforesaid wall 16 or close thereto. In other words, the profile 15 comprises a groove 19 configured with a narrow opening 18 , the said groove 19 thus formed being suitable for holding a bead 20 joined by a flexible skirt 21 to the inflatable body 7 .
[0045] Moreover, the upper wall 17 possesses, in its part situated toward the outside of the groove 18 , an outer face which is suitable (that is to say of flat configuration, for example) for acting as support for a lip 23 of the aforesaid panel or removable lid 9 , as represented by dash-dot lines in FIG. 4.
[0046] The profile 15 is joined to the wall 3 of the rigid hull 1 by means of fixing members such as screws, bolts, etc. In FIG. 1, these joining members are represented by way of example in the form of rivets 24 engaged in mutually aligned holes made in the wall 3 of the hull and the wall 16 forming the supporting flank of the profile 15 .
[0047] For the rest, the profile 15 can be formed in any appropriate manner. In the example illustrated in FIG. 4, the profile 15 appears in the form of a profile of quadrangular, and especially square or rectangular, general section.
[0048] The arrangement according to the invention gives rise to a simple structure, having a profile of uncomplicated and hence uncostly geometric configuration, which is fixed to the outside of the hull such as to free the space inside it, on the one hand, and acquire a reliable sealing tightness when the whole is in navigation configuration.
[0049] The added advantage lies in the fact that, as shown in FIG. 4, in the storage/transportation configuration, the deflated tube 22 is swung inside the hull 1 , thereby freeing the upper wall 17 of the profile and allowing the lid 9 to be replaced there by its lip 23 .
[0050] In FIG. 5 is illustrated a constructional variant of the profile 15 , whose wall 16 , forming a supporting flank against the wall 3 of the hull, extends downward beyond the bottom wall 25 defining the groove 19 . This extension appears in the form of a lower wing 26 , which increases the supporting surface of the profile 15 against the hull, whereby the mounting of this profile is made more stable.
[0051] It is in this case advantageous for the fixing members (for example the rivets 24 ) to cooperate with this lower wing 26 , as illustrated in FIG. 5, in order to free the space in the groove 19 and, above all, prevent the ends of the rivets 24 (or the ends of the bolts or others) from projecting aggressively into the groove 19 and thus prevent the bead 20 from being damaged by these projections.
[0052] Provision can also be made, in a manner independent from the previous measures (although they are combinable, as is illustrated in FIG. 5), for the wall 16 , forming the supporting flank, and the wall 27 , which is opposite thereto, each to be extended upward beyond the upper wall 17 . These upper extensions of the walls 16 and 27 define a channel, jointly with the wall 17 , in which channel the edge 23 of the lid 9 is received and held transversely, as can clearly be seen in FIG. 5. In addition, the upper extension of the wall 16 helps to increase the supporting surface of the profile 15 against the wall 3 of the hull, and hence the stability of its mounting.
[0053] In conjunction with the lower wing 26 extending along the wall 16 of the profile, it is advantageous to add to the profile 15 , beneath the groove 19 , a tubular part of closed transverse profile which can be quadrangular (square or rectangular) in shape, as illustrated in FIG. 6. This tubular part 28 is in this case defined at the top by the bottom wall 25 of the groove, at the side by the aforesaid skirt 26 and by a lower extension of the aforementioned opposite wall 27 , and finally by a lower wall 29 .
[0054] This arrangement has the advantage that the ends of this tubular part 28 , following mounting of the profile 15 on the hull 1 , can be sealed off and the water is thereby prevented from passing through the holes traversed by the fixing members (rivets 24 ). Moreover, the profile 15 thus formed has better rigidity.
[0055] Finally, it may be interesting for the walls 16 and 27 opposite the profile 15 to extend at the bottom beyond the aforementioned lower wall 29 and for them to have respectively two opposite, mutually facing lips 30 , as illustrated in FIG. 7. A rail 31 is thus formed on the lower part of the profile 15 , which rail can serve as the hook-fastening of accessories and, to this end, is able, for example, to receive sliding shoes (not shown), to which accessories can be fixed or attached.
[0056] Thus, the profile 15 used according to the invention is suitable for assuring a multiplicity of functions which allow the formation of the craft to be simplified. | Composite-shell pneumatic craft convertible into a closed box, having a rigid hull and an inflatable float fixed to the edge thereof, a removable rigid panel constituting a lid for the hull containing the deflated float; a profile fixed along the outer edge of the hull comprises a supporting flank and a groove with narrow opening which opens into an upper wall close to the flank; the groove holds a bead joined to flexible skirt of the float; the upper wall, in its part adjacent to the groove opposite to the flank, can support a lip of the removable panel; a portion of the flank cooperates with members for fixing the profile to the hull. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application is a divisional application from U.S. patent application Ser. No. 11/629,509, filed Mar. 14, 2007.
TECHNICAL FIELD
[0002] The present invention generally relates to the field of washing gas turbine engines, and more specifically systems and a vehicle for washing a gas turbine engine installed on an aircraft.
BACKGROUND
[0003] A gas turbine aircraft engine comprises of a compressor compressing ambient air, a combustor burning fuel together with the compressed air and a turbine for powering the compressor. The expanding combustion gases drive the turbine and also result in thrust for propulsion.
[0004] Aircraft flying at high altitude ingest the clean air prevailing at these altitudes. However, at the aerodromes the air contains foreign particles in form of aerosols which enters the engine with the air stream. Typical particles found in the aerodrome air are pollen, insects, hydrocarbons coming from industrial activities and salt coming from nearby sea. While the aircraft is grounded at the airport there are additional particles to consider such as combustion residues in engine exhaust from taxing aircraft, chemicals coming from aircraft de-icing and ground material such as dust. The majority of the foreign particles will follow the gas path through the engine and exit with the exhaust gases. However, there are particles with properties of sticking on to components in the engine's gas path, especially in the compressor section of the engine. This is known as fouling.
[0005] Compressor fouling results in a change in the properties of the boundary layer air stream of the compressor components. The presence of foreign particles results in an increase of the component surface roughness. As air flows over the surface the increase of surface roughness results in a thickening of the boundary layer air stream. The thickening of the boundary layer air stream has negative effects on the compressor aerodynamics in form of a reduced mass flow. At the blade trailing edge the air stream forms a wake. The wake forms a vortex type of turbulence with a negative impact on the air flow. The thicker the boundary layer the stronger the turbulence in the wake and the more it reduces the mass flow. Further, a thick boundary layer and a stronger trailing edge turbulence result in a reduced compression gain which in turn results in the fouled compressor compressing air at a reduced pressure ratio. Anyone skilled in the art of heat engine working cycles understands that a reduced pressure ratio result in a lower thermal efficiency of the engine. The compressor fouling not only reduces the mass flow and pressure gain but also reduces the compressor isentropic efficiency. Reduced compressor efficiency means that the compressor requires more power for compressing the same amount of air. The power for driving the compressor is taken from the turbine via the shaft. With the turbine requiring more power to drive the compressor there will be less power to create thrust for propulsion. For the aircraft pilot this means he must throttle for more fuel as to compensate for the reduced thrust. Throttling for more fuel means the consumption of fuel increases and thereby increasing the operating costs. The performance loss caused by compressor fouling also reduces the durability of the engine. As more fuel has to be fired for reaching a required thrust level, follows an increase in the engine firing temperature. When the pilot on the runway throttles for take-off, the engine's hot section components are under critical high temperature load. Controlling the combustion gas temperature is a key issue in engine performance monitoring. The controlling temperature known as exhaust gas temperature (EGT) is measured with sensors in the gas path downstream of the combustor outlet. The EGT is carefully monitored by logging both temperature and exposure time. During the lifetime of the engine the EGT log is frequently reviewed. At a certain point it will be required that the engine is taken out of service for an overhaul where hot section components are inspected and replaced if required.
[0006] Compressor fouling also has a negative effect on the environment. The difference in fuel consumption of a virgin engine delivered from the factory and an engine with a fouled compressor may typically be 1%. With the increase of fuel consumption follows an increase of emissions of green house gas such as carbon dioxide. Typically combustion of 1 kg of aviation fuel results in formation of 3.1 kg carbon dioxide. Further, high combustor temperature has a negative effect to the environment. With the increase of firing temperature follows an increase of NOx formation. NOx formation depends to a large extent on the design of the burner and a general number can not be provided. However, any incremental temperature rise to a given burner design results in an increase in NOx formation. Hence, compressor fouling has negative effects to aero engine performance such as increasing fuel consumption, reducing engine life and increasing emissions.
[0007] A number of engine washing techniques has developed over the years as to reduce or eliminate the negative effects of fouling. The simplest washing method is taking a garden hose and spraying water into the engine inlet. This method has however limited success due to the simple nature of the process. An alternative method is hand scrubbing the blades with a brush and liquid. This method has limited success as it does not enable cleaning of the blades in the interior of the compressor. Moreover, it is time-consuming. U.S. Pat. No. 5,868,860 to Asplund discloses the use of a manifold for washing of aero engines. Further the patent discloses the use of high liquid pressure as means of providing a high liquid velocity, which together with rotation of the engine shaft will enhance the cleaning efficacy. U.S. Pat. No. 6,394,108 to Butler discloses a thin flexible hose which one end is inserted from the compressor inlet towards the compressor outlet in between the compressor blades. At the inserted end of the hose there is a nozzle. The hose is slowly retracted out of the compressor while liquid is being pumped into the hose and sprayed through the nozzle. However, the washing efficacy is limited by the compressor rotor not being able to rotate during washing. Despite existing wash technologies and patents there is a need for new technologies enabling practical washing to be conducted in a less labour intensive, low cost, simple and safe way.
SUMMARY
[0008] The commercial air traffic has developed into an efficient tool for carrying passengers and goods from one place to another. The aircraft fleet today comprises of a large number of aircraft types supplied by many aircraft manufacturers. The engines used for propelling these aircrafts are manufactured by several engine manufacturers, supplying engines of different size and with different performance characteristics. Engine manufacturers also supply engines that are compatible with engines from other manufacturers which mean that there are alternative engines, although not identical, available for the same aircraft. This result in a large possible combination of aircraft engines on aircraft types. This is found being a disadvantage when practising washing as the wash equipment need to be sized and engineered to meet the individual designs. It is the purpose of this invention to simplify washing of the engines.
[0009] The practising of engine washing described with reference to FIG. 1 is further regarded as common knowledge in this field. A cross section view of a two shaft turbofan engine is shown in FIG. 1 . Arrows show the gas flow through the engine. Engine 1 is built around a rotor shaft 14 which at its front end is connected to fan 15 and at the rear end to turbine 16 . Turbine 16 drives fan 15 . A second shaft 19 is in form of a coaxial to first shaft 14 . Shaft 19 is connected at its front end to compressor 17 and rear end to turbine 18 . Turbine 18 drives compressor 17 . Engine 1 has an inlet 110 where inlet air enters the engine. Cowling 11 serves as a guide for the inlet air stream. The inlet air flow is driven by fan 15 . One portion of the inlet air exits at outlet 11 . The remaining portion of the inlet air enters into the core engine at inlet 13 . The air to the core engine is then compressed by compressor 17 . The compressed air together with fuel (not shown) is combusted in combustor 101 resulting in pressurized hot combustion gases. The pressurized hot combustion gases expand towards core engine outlet 12 . The expansion of the hot combustion gases is done in two stages. In a first stage the combustion gases expands to an intermediate pressure while driving turbine 18 . In a second stage the hot combustion gases expands towards ambient pressure while driving turbine 16 . The combustion gases exits the engine at outlet 12 at high velocity providing thrust. The gas from outlet 12 together with air from outlet 11 together make up the engine thrust.
[0010] A washing device according to prior art consist of a manifold 102 in form of a tube which in one end is connected to a nozzle 103 and the other end connected to a coupling 104 . Hose 105 is at one end connected to coupling 104 while the other end is connected to a liquid pump (not shown). Manifold 102 is resting upon inlet cowling 11 and held in firm position during washing by securing it with a strap or similar means. The wash procedure begins by cranking the engine shaft with help of the engine's starter motor. The pump pumps a wash liquid to nozzle 103 where it atomizes and forms a spray 104 . The rotation of the shaft results in an air flow through the engine. This air flow will drive liquid through the engine and release fouling material. The fouling material is released by mechanical and chemical act of the washing liquid. The cleaning effect is enhanced by the shaft rotation as the wetting of blades creates a liquid film which will be subject to forces such as the air draught and centrifugal forces during washing.
[0011] Prior art describes the use of a manifold with nozzles for injecting the wash fluid into the engine inlet. It is common that the manifold is placed in the inlet cowling while using the cowling for its support. The manifold is thus temporarily installed for the washing process and is removed after completion of the wash. FIG. 2 shows an example of a prior art manifold when installed in a turbofan engine inlet. Similar parts are shown with the same reference numbers as FIG. 1 . Manifold 102 is resting on inlet cowling 11 of the air intake to engine 1 . Manifold 102 is fabricated to fit the shape of the inlet cowling as to be in firm position during washing. To ensure that the manifold is held in a firm position, a strap 21 is attached to the manifold outside of the inlet and tighten against a hook (not shown) hooked on to the engine outlet. Wash liquid is pumped by a pump (not shown) through hose 105 via coupling 104 to manifold 102 and further to nozzles 103 . Manifold 102 is in form of a tube which serves as a conduit for the wash liquid. Manifold 102 also act as a stiff support to the nozzles as to hold the nozzles in firm position during washing. For a good wash result a proper positioning of the manifold is mandatory. For this purpose the manifold has to be designed and engineered with respect to the shape of the inlet cowling and the characteristic geometry of the engine. Further, the manifold has to be designed and engineered as to appropriately support the nozzles against spray reaction forces during washing.
[0012] As mentioned above there are many different aircraft types and many different aircraft engines which result in many different inlet air cowling designs. As the manifold takes support on the inlet cowling this means that many different manifolds will have to be manufactured as to service a large fleet of aircraft. This is a disadvantage as an airline operator will have to stock a large number of manifolds.
[0013] This invention as described in the preferred embodiments discloses a manifold that has no contact with the inlet cowling. The manifold according to the invention then eliminate the requirement of matching the inlet cowling design and thereby the need for a large number of manifolds. It is the purpose of this invention to reduce the number of manifold the airline operator has to keep in stock.
[0014] The manifolds according to prior art are of large dimensions as a result of the large intake geometry of large aircraft engines. The manifolds thereby require significant storage space at storage.
[0015] The invention as described in the preferred embodiments discloses a universal manifold that is significantly smaller in size compared to prior art manifolds. It is the purpose of this invention to reduce the storage space by providing a small manifold.
[0016] The manifolds according to prior art design result in significant amount of labour hours to engineer, manufacture and test for fit. Further, the manifold is put in production in only small series as there may not be too many aircraft with a specific combination of engine and inlet cowling. This invention as described in the preferred embodiments discloses a universal manifold applicable to a large range of aircraft and aircraft engines. The manifold according to the invention is in principal engineered once and may be but in production in larger series. This will reduce the costs for the universal manifold. It is the purpose of this invention to reduce costs for the airline operator.
[0017] Washing aircraft engines may be conducted by the airline operator or by a specialist organisation like an Airport Engine Wash Service Centre. If the washing is conducted by a service centre the disadvantage by having many manifolds in stock is even more an issue of concern as the service centre will service a large number of different aircraft and aircraft engines. It is the purpose of this invention to reduce costs for the Airport Engine Wash Service Centre operator.
[0018] As disclosed in the preferred embodiment of this invention the universal, no-contact manifold according to the invention is put and held in position by the use of an arm such as a robotic arm. The robotic arm is operated from a control panel by an operator adjacent to the engine. The robotic arm allows the universal manifold to be positioned in the intake of the engine without physical contact between the aircraft and the universal manifold. The use of a robotic arm for positioning the manifold simplifies the set-up operations and makes the set-up safer. The wash operations can be viewed by the operator by direct eye contact with the engine inlet or by help of a viewing device such as an instant recording camera on the robotic arm. The use of a camera enables the operator to position the manifold and as well view details of the wash operation which he may not otherwise se.
[0019] There have been mentioned some issues of concern related to the use of the prior art manifold. The use of a robotic arm is a safety device reducing the risk of accidental damage. The prior art manifold can cause damage to the aircraft, e.g. a dent on the cowling, by accidental handling of the manifold during installation or removal. This invention as described in the preferred embodiments discloses the use of a robotic arm for a simplified and safer positioning of the manifold and thereby reducing the risk of accidental damage. It is the purpose of this invention to reduce the risk of accidental damage.
[0020] Any work done on the aircraft such as washing the engines requires that the operations comply with the instructions given by the Aircraft Maintenance Manual. This manual gives instructions on engine wash requirements and limitations such as installing an object like a wash manifold on the engine inlet cowling. By the use of a no-contact manifold according to the preferred embodiments of this invention it is not necessary to consult the Aircraft Maintenance Manual for purpose of installing the manifold. It is the purpose of this invention to avoid any conflict with any aircraft operational instructions such as the Aircraft Maintenance Manual by a manifold with no contact with the aircraft.
[0021] Conducting an engine wash requires that the aircraft has to be taken out of service for some time. It is in the interest of the airline operator to reduce the time the aircraft is out of service. The use of the universal and no-contact manifold according to the invention reduce the time for the wash operation as the set-up time for the manifold is shortened. Further, the universal and no-contact manifold can be operated by only one operator present at the aircraft or alternatively by remote control. It is the purpose of this invention to shorten the time for the wash operation and to reduce the labour requirement.
[0022] Further objects and advantages of the present invention will be discussed below by means of exemplifying embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Preferred embodiments of the invention will now be described in greater detail with reference to the accompanying drawings, in which:
[0024] FIG. 1 shows the cross section of a two shaft turbofan engine with manifold and nozzles for washing according to prior art.
[0025] FIG. 2 shows the manifold installed in the inlet of an aero engine according to prior art.
[0026] FIG. 3 shows the wash unit with the no-contact spray head according to the invention.
[0027] FIG. 4 a show the application of the invention when washing an ‘under wing’ mounted engine.
[0028] FIG. 4 b shows the application of the invention when washing a ‘tail’ mounted engine.
[0029] FIG. 5 shows spray head details according to the invention.
[0030] FIG. 6 shows an alternative embodiment of the spray head.
[0031] FIG. 7 a shows washing of the fan of a turbofan engine according to the invention.
[0032] FIG. 7 b shows washing of the core engine of a turbofan engine according to the invention.
[0033] FIG. 8 shows how the wash procedure is controlled by means of a camera and distance measuring device installed on the spray head.
[0034] FIG. 9 shows the universal, no-contact spray head according to the invention.
[0035] FIG. 10 shows the universal, no-contact spray head and a waste water collecting device with waste water treatment for reuse of the wash liquid.
DETAILED DESCRIPTION
[0036] The invention disclosed heir in describes a system including a manifold that has no contact with the inlet air cowling. Having no contact with the inlet air cowling eliminates the issue of manufacturing adapted manifolds to the large number of aircraft engine inlet cowlings. Further, the manifold disclosed heir in is universal in the meaning that it may service small engines as well as large engines as the manifold has multi size capabilities. A manifold having multi size capability eliminates the issue of manufacturing many manifolds for aircraft engines of varying size.
[0037] FIG. 3 shows the application of the universal and non-contact manifold according to the invention. An aero engine 1 installed on an aircraft (not shown) is subject to washing. Wash unit 31 is a unit for delivering wash liquid to a spray head 33 . Spray head 33 includes a manifold 36 for distributing the liquid to nozzles (not shown for clarity) on manifold 36 . The nozzles inject the wash liquid into the engine inlet. The nozzles may either atomize the liquid or inject liquid as a solid stream. Wash unit 31 comprises of the necessary equipment and components for enabling washing such as tanks for storing wash liquid, heaters for heating the liquid, a pump for raising the liquid pressure, controls required to enable and monitor the wash operation. The liquid may be water only or water with chemicals or chemicals only such as solvents. Typically the liquid is heated as washing with hot liquid as hot liquid enhances the wash result. The wash liquid is pressurized by the pump for distribution to the nozzles. The controls typically comprise of liquid pressure meter, liquid flow meter, liquid temperature meter and pump on-off switch. Wash unit 31 may be mobile as to make it practical for use for washing aircraft engines at an airport. Wash unit 31 may then be part of a vehicle 32 . Vehicle 32 may be a hand towed cart or a motor driven cart or a person carrying vehicle such as a small truck. Alternatively, wash unit 31 may not be mobile.
[0038] Spray head 33 is held in fixed position in the inlet of engine 1 by robotic arm 34 . Robotic arm 34 is at one end installed on wash unit 31 and has spray head 33 on the other end. Robotic arm 34 has at least one articulated joint and a wrist enabling appropriate positioning of spray head 33 in inlet 301 of engine 1 . The robotic arm is moveable with at least three degrees of freedom. Robot arm 34 operates by a hydraulic or pneumatic or electric or mechanically hand driven operating device (not shown) or may be moved by hand force. In an embodiment of the present invention, the robotic arm may comprise one or several telescopic parts. For example, a part between two joints may be telescopic.
[0039] Spray head 33 is sized to be smaller than the opening of inlet 301 . Spray head 33 is preferably positioned in inlet 301 by operating robotic arm 34 from a control panel (not shown) by an operator. Spray head 33 is positioned essentially in the centre of the opening of inlet 301 . When spray head 33 is in its appropriate position there is no contact between the aircraft and the spray head or any other parts of the washing device. Wash unit 31 delivers the pressurized wash liquid to spray head 33 via conduit 35 where conduit 35 comprises of a flex hose or similar device for that service. In spray head 33 the liquid is distributed to a multiple of nozzles via manifold 36 where the nozzles have the purpose of injecting the wash liquid into the engine.
[0040] FIG. 4 a exemplifies the invention when in position for use when washing an engine of an ‘under wing engine’ type aircraft. Similar parts are shown with the same reference numbers as FIG. 1 and FIG. 3 . Aircraft 40 has a wing 41 on which engine 1 is installed. Vehicle 32 with the wash unit is parked adjacent to the engine. Vehicle 32 is preferably parked at one side of the engine as not to be standing in the direct air stream during washing. This is to avoid that any loose objects on the vehicle may accidentally be brought by the air stream into the engine. Robotic arm 34 holds the spray head with its manifold 36 in position in the engine inlet. There is no contact between the aircraft and the manifold or any other parts of the wash unit. FIG. 4 b exemplifies the invention when in position for use when washing an engine of a ‘tail engine’ type aircraft. Similar parts are shown with the same reference numbers as FIG. 1 and FIG. 3 . Vehicle 32 with the wash unit is parked adjacent to the engine. Robotic arm 34 holds the spray head and its manifold 36 in position in the engine inlet. There is no contact between the aircraft and the manifold or any other parts of the wash unit. The invention is not limited to the illustrations in FIG. 4 a and FIG. 4 b as there are many other aircraft of different designs where the invention is equally applicable. Further, there may be aircraft where there is an advantage to arrange for the wash equipment to take support by the cowling or other parts of the aircraft.
[0041] FIG. 5 shows the details of spray head 33 . Spray head 33 is shown in a perspective view where the arrow shows the direction of the engine air flow. Similar parts are shown with the same reference numbers as FIG. 3 . Spray head 33 comprises of a unit with essentially rotational symmetry with axis 501 being the centre of symmetry. When spray head 33 is in position for washing axis 501 is essentially aligned with the engine shaft centre of symmetry. Spray head 33 has a central body 50 . Body 50 has a front end 58 faced towards the engine. Body 50 has a rear end 59 opposite to front end 58 . Rear end 59 is connected to robotic arm 34 . Body 50 includes optical sensing device 55 used as an aid for positioning spray head 33 and for monitoring the wash operation. Optical sensing device 55 is directed essentially towards the engine inlet. Optical sensing device 55 may comprise of a camera where the camera view can instantaneously be viewed by the operator at the control panel. Alternatively, the optical sensing device may comprise of a fibre optic device with the same purpose as the camera. Alternatively, there are other means of recoding the view form the spray head. Optical sensing device 55 serves the purpose to deliver a view of the engine inlet to the operator. The camera view is used for helping the operator to align the spray head with the engine shaft centre by manoeuvring the robotic arm from the operator's control panel. Further, the camera view enables the operator to position the spray head at the appropriate distance upstream of the engine. Further, the camera view enables the operator monitor the washing process by delivering a view from the engine centre line during washing. Further, the camera view helps the operator take decision in adjusting any wash parameter from the view that the camera delivers. Further, the camera view is a safety improving device as the operator may stop the wash process as of anything he observes in the camera.
[0042] Body 50 in FIG. 5 include a distance measuring device for measuring the distance to the engine. Typically the distance measuring device comprises of a transmitter 56 and a receiver 57 . The distance measuring device could comprise of a sound sensing device such as an ultra sound sensing device where the transmitter emits a sound beam which reflect on the engine nose bullet and where the reflected beam is received by the receiver. The distance from the transmitter and receiver is then estimated by the time difference for the signal from the transmitter to the receiver. Alternatively, the distance measuring device could be an optical measuring device such as a laser where the transmitter emits a laser beam which reflects on the engine nose bullet and is received by the receiver. Alternatively, there are other distance measuring devices that could be used. The recorded distance is delivered to the operating panel where the operator will use the information when adjusting the appropriate position of the spray head upstream of the engine. During washing the measured distance helps the operator control the wash process by reporting any changes in distances. The distance measure helps the operator take decision in adjusting any wash parameter if he finds the distance not to be appropriate. The distance measuring device is a safety improving device as the operator may stop the wash process if he finds the distance is not safe. The distance measuring device may include alarms which emit an alarm signal in form of an acoustic sound or a light flash if the distance is out of range. For example, if the measured distance decreases below a predetermined value. In one embodiment, this limit value can be adjusted by the operator by means of the control panel.
[0043] Body 50 include a lamp 52 for illuminating the engine inlet. The illumination improves the view from the camera as well as the view from direct eye contact with the engine inlet. Body 50 may include other device for improving the safety or for improving the wash operation.
[0044] As the man skilled within the art easily realizes, can each of the following features: the optical sensing device 55 , the distance measuring device 56 , 57 , or the lamp 52 be used independently of the others. That is, the spray head 33 may, for example, only include the optical sensing means 55 or only the distance measuring device 56 , 57 .
[0045] Spray head 33 in FIG. 5 shows the manifold as a ring shaped tube, i.e. a torus. Liquid is pumped from the wash unit (not shown) via a hose (not shown) to manifold 36 . Manifold 36 is essentially circular with the circle centre aligned with axis 501 . The plane of manifold 36 is essentially perpendicular to axis 501 . Manifold 36 is connected to body 50 . Manifold 36 has multiple nozzles arranged around the manifold for different wash services. For example, Nozzle 53 serves the purpose of washing the engine fan. Nozzle 54 serves the purpose of washing the core engine. Nozzle 510 serves the purpose of washing the nose bullet. Nozzle 511 serves the purpose of washing the cowling. In addition to nozzles 53 , 54 , 510 and 511 the manifold may comprise of other nozzles (not shown) for washing other engine details. Manifold 36 has at least one nozzle 54 . The nozzles may atomize the liquid into a spray of droplets. Alternatively, the nozzles may deliver the liquid as a non-atomized jet. The objective of using ring shaped manifolds is that the manifolds may be manufactured from one tube which is bent into a ring requiring only one joint (one weld). This is an advantage to alternative designs requiring many more joints. Any reduction in joints is regarded as a safety feature as joints may brake and can cause damage if loosened parts enter the engine. Further, the ring shaped manifold is considered safe as any accidental contact between the manifold and any aircraft parts would not imply contact with any sharp edges. Alternatively may the manifold be equipped with a cushion such as rubber foam material (not shown) as to pick up any force in case of an accidental contact with the engine.
[0046] FIG. 6 shows an alternative embodiment of the spray head. Similar parts are shown with the same reference numbers as FIG. 3 and FIG. 5 . The ring shaped manifold is here replaced by pipes 61 holding the nozzles in position. Alternatively, the manifold can be made differently.
[0047] FIGS. 7 a , 7 b and 8 shows the application of the invention when washing a turbofan engine. Similar parts are shown with the same reference numbers as previous figures. FIG. 7 a shows the washing of the fan of turbofan engine 1 by use of nozzles for washing of the fan. During washing the fan is forced to rotation by the use of the engine starter motor. Nozzle 53 is atomizing the wash liquid into spray 71 . The nozzles have a spray pattern resulting in a distribution of liquid limited on one side by streamline 75 and on the other side by streamline 76 . The spray's distribution at the leading edge of fan blade 72 is essentially equal to the total blade length limited by tip point 702 and hub point 701 . The spray thus covers the whole blade length. Manifold 51 may comprise of only one nozzle 53 which then only covers a portion of the engine inlet. Wetting of the whole fan is then accomplished by the rotation of the fan. FIG. 7 b shows the washing of the core engine of turbofan engine 1 . During washing the engine shaft is rotated by the use of the starter motor. Nozzle 54 is atomizing the wash liquid into spray 73 . The nozzles have a spray pattern resulting in a distribution of liquid limited on one side by streamline 77 and the other side by streamline 78 . The purpose of the spray is to deliver liquid into core engine inlet 74 . The core engine inlet is limited by air splitter 705 and a point 704 on the hub on the opposite side of air splitter 705 . The spray's distribution at the core engine inlet is equal to the core engine inlet opening limited by air splitter 705 and point 704 . Thereby will the liquid emanating from nozzle 54 enter core engine inlet 74 . Further, nozzle 54 is oriented as to enable the liquid to penetrate in between the blades during fan rotation. FIG. 7 a and FIG. 7 b describes washing of the turbofan engine by the use of the engine's starter motor. Alternatively may other starting device be used such as a separate APU starter. Alternatively, washing may be conducted without rotating the engine shaft.
[0048] FIG. 8 shows the use of the camera and the distance measuring device. Similar parts are shown with the same reference numbers as previous figures. A camera 55 has a viewing angle limited by lines 81 . The camera will provide a view of the engine nose bullet enabling the operator to move the spray head to the appropriate position for washing. When the engine is cranked by its starter motor the camera view is used for monitoring the shaft rotation. The camera may then be attached to a computing device (not shown) with software for estimating the rotational speed. The rotational speed serves as an input parameter to the operator when to start liquid pumping. Having control of the rotational speed is essential for a good wash result. Further, the camera view allows viewing of the liquid distribution onto the fan as well as the penetration of liquid into the core engine.
[0049] This view serves as an important input to the operator as he may adjust the positioning of the spray head or adjust the wash parameters as to better serve his objectives. To avoid that the camera lens is contaminated with air borne liquid, the lens is purged by an air stream supplied from a compressed air source (not shown). The distance measuring device comprise of a transmitter 56 emitting a beam 82 towards nose bullet 83 where it reflect and returns the reflected beam to receiver 57 . The signal is fed to a computing unit (not shown) for computing the distance. The computing unit may be set with alarm levels as to provide, e.g. an acoustic alarm, if the distance to any object becomes critically short. The distance measuring device may de directed towards other objects than the nose bullet in the engine inlet as to provide information on measured distances. To avoid that the measuring device sensors are contaminated with air born liquid they are purged by an air stream supplied from a compressed air source (not shown).
[0050] FIG. 9 shows the universal spray head which will service a large range of differently sized engines. Spray head 90 is shown in a perspective view where the arrow shows the direction of the air flow. Spray head 90 has a central body 91 with similar camera, distance measuring device and lamp as earlier described in spray head 33 in FIG. 5 . Spray head 90 comprise of multiple ring shaped manifolds 92 each with different diameters. Rings 92 are arranged in symmetry around central axis 501 . Rings 92 are all essentially in the same plane where the planes are essentially perpendicular to axis 501 . The rings are arranged with a gap in between the rings as to allow air flow through the spray head. Each ring comprises of one or multiple nozzles 93 where the nozzle type, number of nozzles and the nozzles spacing is according to the wash service the ring will do. Nozzles may be used for washing of the fan, the core engine, the cowling, the bullet nose or similar service. In principal, the inner rings are used for washing of smaller engines while the outer rings are used for washing of larger engines. Further, one ring may de dedicated to washing of a specific engine type or a specific family of engines. The ring with the largest diameter, i.e. the outer ring, has a diameter less than the diameter of the inlet cowling of the smallest engines that the spray head will service. For example, the engines of the popular passenger carrying commercial airlines have an inlet cowling diameter varying in between 1.5 to 3 meters. The spray head to service those engines would then have an outer diameter less than 1.5 meter.
[0051] For washing of an engine typically only one ring is in service. This is accomplished by having each ring 92 connected via a conduit to a distributor (not shown for clarity) on the spray head. The distributor comprise of individual valves for closing each conduit. Prior to set-up for washing the operator would activate the ring to be in use by opening the corresponding valve. All other valves would then be closed.
[0052] Although spray head 90 is universal in the meaning that it may service a wide range of aircraft types and engine types it is practical to have multiple spray heads that are exchangeable. This may be reasoned by different requirements set by the aircraft's instructions or other instructions. Another reason could be a separate spray head for meeting military aircraft requirements. There may be additional reasons. To accomplish changing of the spray heads the spray head is mounted on the robotic arm with a coupling enabling an easy exchange.
[0053] The invention as here disclosed provides means for reducing the time for washing as well as reducing labour requirement. FIG. 10 shows the arrangement for engine washing that is both less time consuming and less labour intensive compared to prior art. Similar parts are shown with the same reference numbers as previous figures. The process described heir in would typically require only one operator for conducting the wash. A wash unit 31 supplies wash liquid via conduit 35 to a spray head held by robotic arm 34 . During washing the operator controls the process from control panel 113 . Controlling includes viewing the spray head camera image from monitor 112 . The waste wash liquid emanating from the engine is collected by collecting device 114 at the rear of the engine. The collected waste liquid enters a tank (not shown) in unit 116 via conduit 115 . Unit 116 may be equipped with wheels for mobility. A suitable collecting device is described in the international application PCT/SE 2004/000922, wherein the content of said application hereby is included herein by reference. The waste liquid is pumped via conduit 118 to a tank in wash unit 31 where the released fouling material is separated from the liquid by an appropriate waste water treatment process. The treated water will then be used for washing of next engine or is alternatively dumped into a sewer. While the waste water is being treated the operator may move his vehicle 32 and other equipment to the next engine for set-up for the next wash.
[0054] Although specific embodiments have been shown and described herein for purposes of illustration and exemplification, it is understood by those of ordinary skill in the art that the specific embodiments shown and described may be substituted for a wide variety of alternative and/or equivalent implementations without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the preferred embodiments discussed herein. Consequently, the present invention is defined by the wordings of the appended claims and equivalents thereof. nsert text]
[0055] While the invention has been described with reference to an exemplary embodiment(s), 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(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. | System for washing a gas turbine engine. The system comprises a spray device including at least one nozzle adapted to inject liquid into an inlet of said engine during a washing operation; a wash unit adapted to distribute said liquid to said spray device; and a positioning device adapted to move said spray device in three dimensions, thereby enabling a positioning of said spray device in a washing operation position in said three dimensions relative said engine inlet without any contact between the spray device and the engine. The invention further relates to a vehicle for making the inventive system mobile and to a mobile system for serving a gas turbine engine comprising a mobile vehicle carrying the washing system and a liquid collecting unit comprising a collecting device adapted to collect waste wash liquid emanating from the engine during a washing operation of the engine. | 1 |
BACKGROUND AND SUMMARY OF THE INVENTION
Human Growth Hormone (hGH), also known as somatotropin, is an endocrine hormone produced by the pituitary. Its production peaks during adolescence and diminishes with age. Upon its release from the pituitary, hGH is converted by the liver and other tissues to its growth-promoting metabolite somatomedin C, commercially known as Insulin-like Growth Factor type 1 (IGF-1), so-called because it performs an insulin-like function of promoting glucose transfer through cell membranes in cell metabolism.
It is now understood that the physiologic effects associated with hGH occur primarily through the function of IGF-1, partly because serum IGF-1 has a half-life of about 20 hours in contrast to circulating Growth Hormone with a half-life of only about 20 minutes. Several factors are known to affect hGH release and IGF-1 response, and they include the hypothalmic hormone somatostatin, which limits hGH release, and Growth Hormone Releasing Hormone (GHRH), which stimulates such release, as well as somatotroph receptors, insulin regulation, hepatic function and the availability of IGF-1 receptors sites. Jamieson, J and Dorman, L. E., The Role Of Somatotroph-Specific Peptides And IGF-1 Intermediates As An Alternative To High Injections, American College for Advancement in Medicine, Oct. 30, 1997. Correlating these factors has led to the development of a proprietary product known as Symbiotropin, available from Jamieson Designs, St. Louis, Mo. Symbiotropin is an hGH secretagogue composed of anterior pituitary peptides, sequenced glycoamino acid complex, pharmaceutical saccharides, L-alpha glycerlphosphoryl choline, a plant-derived source of L-dopa, and botanical regulators of insulin and IGF-1 that has been shown in clinical tests both to promote and modulate IGF-1 levels within a physiologic range, revealing notable improvements in patients undergoing such hormone therapy in terms of muscle size and strength, fat reduction, energy increase, exercise endurance, improvements in skin elasticity, texture, and thickness, and healing capacity.
Another hormone linked to healthy aging, including healthy immune brain and cardiovascular functions, is dehydroepiandrosterone (DHEA), the most abundant hormone in the human body. It is produced by the adrenal cortex along with other steroids such as glucocorticoids (cortisol or hydrocortisone) and mineral corticoids (aldosterone). Concerns have been expressed about its use as a dietary supplement, however, because when it is ingested it is metabolized into various metabolites, some of which may convert into active male or female sex hormones, specifically, testosterone and estrogens.
A natual metabolite of DHEA is 7-keto dehydroepiandosterone (7-keto DHEA), also known chemically as 3-beta-acetoxyandrost-5-en-7,17-dione. 7-keto DHEA is not only a potent metabolite of DHEA but, unlike DHEA, cannot be converted to active androgens and estogens. Scientific research on 7-keto DHEA demonstrates that it has therapeutic applications in immune modulation, immune enhancement through T-cell upregulation, memory enhancement, and weight loss and management by means of its theromagenic-enhancing action. For further information on 7-keto DHEA, reference may be made to U.S. Pat. Nos. 5,290,730, 5,296,481, 5,585,371, and 5,641,766, the disclosures of which are incorporated by reference herein.
SUMMARY OF THE INVENTION
It is an object of the invention to provide new orally-ingestable dietary supplements that reduce or retard the effects of aging. More specifically, the invention is concerned with dietary supplements that replenish or stimulate the production and release of hormones that promote longevity, enhance wellness, and reduce the effects of aging at the cellular level.
Along with other ingredients, the food supplements of this invention comprise both 7-keto DHEA and a secretagogue for pituitary somatotrophs that contains anterior pituitary peptides, a sequenced glycoamino acid complex, a source of L-dopa, pharmaceutical saccharides, botanical regulators of insulin and IGF-1, and L-alpha glycerylphosphoryl choline (GPC). The supplements may also contain antioxidants and natural herbal ingredients that are believed to reduce damage at the cellular level caused by free radicals and which are believed to be active in reducing memory loss, promoting healthy brain function, and eliminating harmful toxins.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The secretagogue known as Symbiotropin (from Jamieson Designs, St. Louis, Mo.) has been found to promote hGH production by the pituitary and the release of IGF-1 in physiologic ranges, and generally to reverse many of the symptoms of human biological aging, by restoring muscle mass, decreasing body fat, thickening the skin and reducing wrinkles, increasing energy and sexual function, restoring the size of liver, pancreas, heart and other organs that shrink with age, improving vision and memory, elevating mood and improving sleep, normalizing blood pressure, increasing cardiac output and stamina, improving immune function, and assisting in wound healing. The secretagogue is known to comprise a combination of anterior pituitary peptides, a glycoamino acid complex, pharmaceutical saccharides, a plant-derived source of L-dopa, botanical regulators of insulin and IGF-1, and L-alpha glycerylphosphoryl choline (alpha GPC). By also including 7-keto DHEA, the dietary supplements of the present invention may provide further and significant anti-aging enhancements or improvements as compared to supplements and methods employing only the secretagogue. Although the present invention is not to be limited by any theoretical explanation, it is believed that a coaction exists between the glycoamino acid complex of the secretagogue and 7-keto DHEA. Such glycoamino acid complex consists of L-glutamine, L-arginine pyroglutamate, L-lysine monohydrochloride, glycine, and gamma aminobutyric acid. The combination of those amino acids with 7-keto DHEA is believed to bring the hypothalamus, pituitary, and adrenal axis into balance. This is accomplished by an interaction of 7-keto DHEA and the glycoamino acid complex resulting in the ability to down-regulate cortisol levels, which play an antagonistic role in the ability of receptor sites to be used, and helping to normalize insulin levels. With cortisol and insulin levels in the appropriate balance, the combination is believed to re-sensitize receptor sites on each of these three organs, as well as at the cellular level. When the cellular and organ receptor sites are at maximum sensitivity, they operate more efficiently, thereby allowing the rest of the ingredients of the dietary supplement to be more effective.
7-keto DHEA, whose scientific name is 3-beta-acetoxyandrost-5-en-7,17-dione, is a naturally-produced metabolite of DHEA, and scientists have postulated that it is the metabolites of DHEA that are the true active ingredients since no specific receptors in the body have been identified for DHEA itself. Researchers have since discovered that such hypothesis is correct and, more specifically, that in hormone therapy 7-keto DHEA significantly outperforms DHEA in areas such as immune modulation, memory enhancement, and thermogenesis for weight management, all without the unwanted side effects associated with DHEA. Reference may be had to the aforementioned patents for further information on 7-keto DHEA, identified generally under the designation “androstenes” in such patents. 7-keto DHEA is well known and commercially available, one such source being Humanetics Corporation, Chanhassen, Minn.
The dietary supplement compositions of this invention may be provided in liquid or powder form, with powders suitable for mixing with water or other liquids, and for ingestion as a beverage, being preferred. The amount of such powder needed for a recommended daily serving depends, of course, on the extent to which additional ingredients are included, and in that regard, the supplement of this invention is preferably formulated to include a complex of ingredients that deliver antioxidants to support the healthy functioning of major systems and to halt damage caused at the cellular level by the presence of free radicals, and natural herbs such as ginkgo, biloba and maca powder believed to play roles in reducing memory loss, promoting healthy brain function, and eliminating harmful toxins. Natural and artificial flavoring agents are also included, as well as agents that promote processing and increase solubility. The result is a blend in powder form of which a daily serving falls within the general range of about 10 g to about 30 g, the preferred serving size being approximately 16 g. In a serving of 10 g to 30 g, the secretagogue (Smybiotropin with GPC) should constitute about 600 to 1900 mg and the 7-keto DHEA component about 15 to 50 mg, so that it is believed in a preferred serving of 16 g total supplement there should be about 1000 mg secretagogue and about 25 mg 7-keto DHEA.
The antioxidant complex of a food supplement embodying this invention may include coenzyme Q10 (CoQ10), trans-resveratrol, alpha-lipoic acid, L-glutathione, and n-acetyl cysteine.
CoQ10 is a known antioxidant that is considered an important part of the metabolic process. It is involved in the energy process and can be synthesized in the body. Studies have revealed that CoQ10 holds promise in the treatment of a wide variety of degenerative diseases including diabetes, stroke, cancer and especially heart disease. In a dietary supplement embodying this invention, CoQ10 is preferably present in the range of about 4-10 mg per serving.
Alpha-lipoic acid is a recognized vitamin-like antioxidant that is sometimes referred to as the universal antioxidant because it is soluble in both fat and water. It is capable of coacting with and regenerating several other antioxidants over to their active states, including vitamin C, vitamin E, CoQ10, and L-glutathione. A synergistic effect is therefore believed to occur through the interaction of alpha-lipoic acid and such other antioxidants, with such interaction effectively boosting the power of CoQ10 and L-glutathione as well as other antioxidants found in this nutritional supplement and in fruits and vegetables that are part of a healthy diet.
L-glutathione is made up of three amino acids and is produced in all cells of the body. It functions to break down and dispose of potentially dangerous toxins and serves as an antioxidant to cleanse fatty foods of free radical hazards in the digestive track. In connection with the aging process, it has been noted that the blood levels of L-glutathione drop about 17 percent between the ages of 40 and 60. In a preferred dietary supplement embodying this invention, a daily serving contains about 30 to 95 mg of alpha-lipoic acid and about 18 to 57 mg of L-glutathione.
Resveratrol is an antioxidant, cardioprotectant and antimutagenic agent and is believed responsible for many of the health benefits attributed to red wine. A particularly potent form of resveratrol known as trans-resveratrol is derived from the root of Polygonum cuspidatum. A proprietary product, “Protykin” from Interhealth, Benicia, Calif., contains more than 400 times the resveratrol found in grape-derived sources. Protykin also contains emodin which is reported to have antimutagenic, antibacterial, and gastroprotectant properties. In a preferred embodiment of the dietary supplement of this invention, in which resveratrol, trans-resveratrol and emodin are provided by Protykin, the amount of such Protykin in a daily serving of the supplement may fall within the range of about 6 to 19 mg. Most desirably, a further antioxidant also believed to have antimutagenic properties, n-acetyl cysteine, may also be present in the range of about 125 to 375 mg.
Other ingredients included in the preferred dietary supplement of this invention because of their reported beneficial effects on sustained health and longevity are: s-adenosyl-L-methionine, omega-3 fatty acids, trimethyl glycine, a probiotic blend of Bifidobacterium bifidum and Lactobacillus acidophilus, fruco-oligosaccharides, and acetyl-L-carnitine. The first of these, s-adenosyl-L-methionine, is often referred to as SAMe and is a nontoxic natural metabolite of methionine and amino acid. Clinical trials involving more than 22,000 osteoarthritis patients support the efficacy and tolerability of SAMe in treating those suffering from the disease. Other clinical tests have produced similar results. In addition, SAMe has been shown to be an effective and quick-acting antidepressant for patients suffering from major depression.
Omega fatty acids are found in many kinds of fish oils and various other oils, including flaxseed oil and linseed oil, and numerous studies have shown clinical benefits following ingestion of omega n-3 fatty acids in patients suffering from rheumatoid arthritis. Omega-3 fatty acids, when administered orally in small doses, has also been shown to have significant positive effects on platelet activity, and such omega fatty acids are also believed to be useful in the treatment and prevention of cancer. Such omega-3 fatty acids are available in different forms, including powders consisting of fish oil distributed in a food starch-coated matrix of either gelatin or caseinate, with such powders being commercially available from BASF Corporation, St. Louis, Mo., under the proprietary designation “Dry n-3” powders.
Trimethylglycine (TMG)is being recognized for its cardiovascular benefits in promoting healthy homocysteine levels. Homocysteine is a toxic end product of the metabolism of methionine, an essential amino acid found in many foods. When the right cofactors are present, the body recycles homocysteine back to methionine, or to another essential amino acid, cysteine. However, if dietary insufficiencies exist, such insufficiencies can lead to abnormally high levels of homocysteine, which in turn may irrate the linings of vessels and arteries. Researchers now believe that such irritation can lead to cardiovascular deterioration. Studies have shown that TMG in combination with other dietary supplements helps to promote healthy homcysteine levels.
The probiotic blend of Bifidobacterium bifidum and Lactobacillus acidophilus, and the fructo-oligosaccharides, are included in the dietary supplement of this invention to promote intestinal health by increasing and maintaining intestinal flora. The components of the probiotic blend are commercially available from various sources, one such source being Nutraceutix, Inc., Redmond, Wash. The frutco-oligosaccharides are also available in different products, one such product being “BeFlora Plus” available from Roxlor International Manasquan, N.J., and consisting of frutco-oligosaccharide fiber from beets and soy protein extracts which are enriched with potassium salts and glycolate.
Acetyl-L-carnitine has been the subject of numerous scientific studies showing that such compound may be key in maintaining normal brain and nerve function during aging. These include its actions on acetylcholine synthesis, membrane stability, nerve growth factor production, and cerebral blood flow. In a preferred embodiment of the invention, acetyl-L-carnitine is present in the range of about 60 to 190 mg per daily serving, with the optimal amount being approximately 100 mg. For other ingredients discussed above, the ranges are as follows: s-adenosyl-L-methionine, 3 to 10 mg; omega-3 fatty acid powder (“Dry n-3”), 75 to 235 mg; trimethyl glycine, 60 to 190 mg; probiotic blend, 60 to 190 mg; fructo-oligosaccharides (“BeFlora Plus”), 250 to 750 mg.
The dietary supplement may also include a herbal blend composed of herbs having properties identified with anti-aging, such as ginkgo biloba ( Salsburia adiantifolia ), spirulina ( Spirulina platensis ), maca tuber powder ( Lepidium menyii ), wild yam root powder ( Dioscorea villosa L.), Chlorella powder, diosmin, and quercetin dihydrate. Ginkgo biloba is well known for its properties as an antioxidant and spirulina, which is the dried blue-green algae of Spirulina platensis (family Ooscillatoriaceae) is a nutritional substance that is known to remove toxins from the bloodstream. Maca is a Peruvian crop that displays a high nutritional value and is rich in sugars, protein, starches and minerals. In recent years it has found use as a dietary supplement in improving physical and mental health, enhancing metal clarity, and increasing energy, stamina, and endurance for athletes. Similar properties are ascribed to wild yam root powder and nettle leaf powder. Chlorella has a long list of recognized health benefits, including enhancing the immune system by stimulating the body to make more interferon, increasing the number of beneficial flora in the gastrointestinal tract, promoting better digestion, reducing serum cholesterol, and increasing energy. Diosmin is a bioflavonoid derived from hesperidin, which is found in plants or citrus rinds. In addition to enhancing capillary resistance and improving venous tone, it has anti-inflammatory and antioxidant activity. Diosmin is also understood to protect the venus wall matrix and smooth muscle integrity by inhibiting the enzymes that weaken vein walls. Quercetin dihydrate is also a flavonoid that has anti-inflammatory and antioxidant activity that is understood to detoxify and thereby assist the body's ability to inhibit cancer in all human organs. While the proportions of these ingredients may be varied considerably in a daily serving of a preferred embodiment of the nutritional supplement of this invention, each may be present in the general range of about 18 to 60 mg, with the preferred amount being about 30 to 35 mg.
Various natural or artificial flavoring components and conventional food supplement additives may be included in the total composition. Such ingredients may include maltodextrin—a free-flowing carbohydrate having low sweetness, a high rate of solution, and excellent particulate strength-fructose, citric acid, dipotassium phophate, and potassium citrate. Lecithin is a phospholipid that in this dietary supplement facilitates mixing and processing, plates the particulate ingredients of the mixture and improves solubility of the final product.
The following examples are not intended to be limiting in any way, but demonstrate certain of the preferred embodiments of the present invention.
EXAMPLE 1
An essentially dry powder constituting a dietary supplement of this invention, to be dissolved in water to provide a daily serving, comprising the following ingredients in the proportions indicated: 7-keto DHEA 25 mg, Symbiotropin 1000 mg, lecithin 200 mg, maltodextrin 7,227 mg, citric acid 640 mg, dipotassium phosphate 25 mg, potassium citrate 25 mg, probiotic blend 100 mg, fruco-oligosaccharides 400 mg, s-adenosyl-L-methionine 5 mg, acetyl-L-carnitine 100 mg, omega-3 fatty acids (Dry n-3) 125 mg, trimethylglycine 100 mg, coenzyme Q10 7.5 mg, resveratrol (Protykin) 10 mg, alpha-lipoic acid 50 mg, L-glutathione 30 mg, n-acetylcysteine 200 mg, flavoring agents 300 mg.
Using a conventional plow blender set for continuous mixing, the fructose is introduced into the mixing chamber with the blender in operation. Lecithin is then gradually added and the choppers are turned on for approximately 2 minutes, followed by the addition of the other dry ingredients in the following sequence: maltodextrin, citric acid, dipotassium phosphate, potassium citrate, 7-keto DHEA, Symbiotropin, probiotic blend, BeFlora Plus, coenzyme Q10, S-adenosyl-L-methionine, Protykin, alpha-lipoic acid, acetyl-L-carnitine, Dry n-3, glutathione, TMG, flavoring agents, n-actylcysteine, and xanthan gum. The choppers are again turned on for a period of an additional two minutes to produce a uniformly-mixed dietary supplement embodying the invention.
EXAMPLE 2
The dietary supplement of Example 1 may include a herbal blend composed of the following ingredients, each being present in the amount of 31.3 mg: ginkgo biloba leaf power, queracetin dihydrate, spirulina, maca tuber powder, chlorella powder, diosmin, nettle leaf powder, wild yam root powder.
The process is the same as described in Example 1 with such ingredients of the herbal blend being sequentially introduced into the mixing chamber after the addition of Symbiotropin and before the introduction of the probiotic blend.
The dietary supplement prepared in accordance with this example takes the form of a fine light-green powder to be consumed enterally as beverage. One scoop (about 16 g) of the essentially dry mixture is added to water while stirring vigorously until dissolved. This recommended daily serving should be consumed on a relatively empty stomach to maximize the effect and benefits of the Symbiotropin/7-keto DHEA combination, as well as that of the other ingredients of the dietary supplement.
While in the foregoing we have disclosed embodiments of the invention in considerable detail for purposes of illustration, it will be understood by those skilled in the art that many of these details may be varied without departing from the spirit and scope of the invention. | A dietary supplement for promoting healthy hormonal balance in adult human subjects, and especially in elderly subjects, that comprises a secretagogue for stimulating the release of human Growth Hormone (hGH) by the pituitary, and the conversion by hGH to Insulin-Like Growth Factor 1(IGF-1), in combination with 7-keto dehydroepiandosterone (7-keto DHEA). The dietary supplement also includes other interacting ingredients for delivering antioxidants for retarding damage at the cellular level caused by the presence of free radicals, and natural herbs for promoting physiological health. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority benefit of Korean Patent Application No. 2011-0076436, filed on Aug. 1, 2011 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
1. Field
Embodiments relate to a washing machine.
2. Description of the Related Art
A washing machine is an apparatus configured to wash laundry by use of electric power. In general, the washing machine includes a tub configured to store a washing water, a rotating tub rotatably installed inside the tub, a pulsator rotatably installed on the bottom of the rotating tub, and a motor and a clutch that are configured to rotate the rotating tub and the pulsator.
In a state that a laundry and a washing water containing detergent are input in the rotating tub, and if the rotating tub and the pulsator rotate, the pulsator stirs the washing water together with the laundry to remove dirt on the laundry.
In order to increase the washing capacity of a washing machine, the rotating tub needs to be larger, that is, the rotating tub needs to be increased in diameter or in height. If a rotating tub has a larger size, a tub accommodating the rotating tub and a cabinet accommodating the tub also need to be enlarged along with the increase of the rotating tub.
The enlarging of a cabinet, which corresponds to an external appearance of the washing machine, is limited by the space of an installation area. In addition, for a vertical-shaft washing machine, the increased height of a washing machine causes a difficulty in loading and unloading laundry. Accordingly, there is a need for a washing machine be capable of eliminating such an inconvenience and yet increasing the washing capacity.
SUMMARY
In an aspect of one or more embodiments, there is provided a washing machine capable of increasing the washing capacity without enlarging the external appearance.
In an aspect of one or more embodiments, there is provided a washing machine capable of discharging a washing water during a washing operation or a spin-dry operation while completely isolated from electronic parts and thus reducing the risk of a power failure and fire.
In accordance with an aspect of one or more embodiments, there is provided a washing machine includes a body, a rotating tub, a pulsator, a driving part and a base plate. The rotating tub is rotatably disposed inside the body. The pulsator is rotatably disposed inside the rotating tub. The driving part is provided on a lower portion of the rotating tub to selectively rotate the rotating tub and the pulsator. The base plate has the driving part fixed thereto. A waterproofing member is provided between the base plate and a bottom of the body to seal the driving part and to prevent water from being infiltrated into (reaching) the driving part.
The waterproofing member includes a diaphragm configured to absorb vibration of the driving part.
The waterproofing member includes a plurality of wrinkled parts, a first fixing part extending upward from the wrinkled part, and a second fixing part extending downward from the wrinkled part.
The base plate includes a first coupling part which is provided at a lower surface of the base plate such that the first coupling part is coupled with the first fixing part.
The washing machine further includes a mounting part configured to support the body, wherein the mounting part includes a bottom plate forming the bottom of the body and a second coupling part which is provided at a lower surface of the bottom plate to be coupled with the second fixing part.
The waterproofing member further includes a wire which is provided in a form of a ring and configured to press and fix each of outer sides of the first fixing part and the second fixing part.
The mounting part further includes a moisture infiltration preventing guide configured to prevent water from being infiltrated to (reaching) a cable that is withdrawn from the driving part.
The moisture infiltration preventing guide is vertically provided inside the body.
The rotating body includes a side wall that extends from a bottom of the rotating body while being slanted with increase of a diameter, and at least one drain hole is formed in an upper end portion of the side wall.
The bottom plate is provided with a first drain port configured to discharge a washing water that is discharged through the drain hole and fallen.
The driving part includes a motor, a clutch configured to selectively transfer a power of the motor to the rotating tub and the pulsator, and a flange connecting a driving shaft of the clutch to a bottom of the rotating tub, and
The flange includes a first through-hole, which is provided in a center of the flange to allow the driving shaft to be coupled thereto, and a second through-hole, which is formed around the first through-hole in a circumferential direction of the first through-hole to pass water during a washing operation and a rinsing operation.
The based plate is provided with a second drain port configured to discharge a washing water that is discharged through the second through-hole and fallen during a washing operation or a rinsing operation.
The washing machine further includes a suspension member connecting the base plate to a upper portion of the body, wherein the suspension member has a first end connected to at least one connecting bracket, which is provided on the base plate, and a second end connected to an upper edge of the body.
In accordance with an aspect of one or more embodiments, there is provided a washing machine includes a body, a rotating but, a base plate and a diaphragm. The body forms an external appearance. The rotating tub is rotatably installed inside the body and is provided at a lower portion thereof with a driving part. The base plate is connected to an upper portion of the body by at least one suspension member such that the driving part is fixed to the base plate. The diaphragm is disposed between the base plate and a bottom of the body to seal the driving part and to absorb vibration.
The diaphragm includes a plurality of wrinkled parts and a fixing part extending upward and downward from the wrinkled part.
The base plate includes a coupling groove that is formed by protruding a lower surface of the base plate such that a first side of the fixing part is fixed to the base plate.
The bottom of the body is provided at a center thereof with an installation hole that allows the driving part to pass therethrough, and wherein a rim of the installation hole is bent downward such that a second side of the fixing part is fixed to the rim.
The washing machine further includes a wire which is provided in a form of a ring and configured to press and fix an outer circumference of the fixing part.
The washing machine further includes a moisture water infiltration preventing guide which is provided on the bottom of the body to prevent water from being infiltrated to (reaching) a cable that is withdrawn from the driving part.
In an aspect of one or more embodiments, there is provided a washing machine which can increase the washing capacity without enlarging the external appearance and thus can wash a larger amount of laundry at one time, thereby enhancing the washing efficiency.
According to an aspect of one or more embodiments, the same washing capacity is ensured with a smaller external appearance, so that the installation is less affected by a limited installation space. In addition, the laundry can be easily loaded and unloaded, thereby improving the convenience of a user.
In addition, a washing water discharged during a washing operation or a spin-dry operation is completely isolated from electronic and installed parts, and the risk of a power failure and fire is reduced. In addition, one or more embodiments may prevent a rotating body from colliding with a wall surface in an abnormal vibration state, thereby ensuring the stability of the washing machine.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects of embodiments will become apparent and more readily appreciated from the following description, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a cross-sectional view schematically illustrating a washing machine according to an embodiment;
FIG. 2 is an exploded perspective view schematically illustrating the washing machine according to embodiment;
FIG. 3 is a cross-sectional view schematically illustrating a rotating tub of the washing machine according to embodiment;
FIG. 4 is a cross-sectional view schematically illustrating a driving part and a waterproofing member of the washing machine according to embodiment;
FIG. 5 is an enlarged view of a portion “A” of FIG. 4 ; and
FIG. 6 is a view showing the flow of water during a washing operation and a spin-dry operation of the washing machine according to an embodiment.
DETAILED DESCRIPTION
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
FIG. 1 is a cross-sectional view schematically illustrating a washing machine according to an embodiment.
Referring to FIG. 1 , a washing machine includes a body 1 forming an external appearance of the washing machine, a rotating tub 20 rotatably disposed inside the body 1 , and a driving part 100 disposed at a lower portion of the rotating tub 20 to rotate the rotating tub 20 .
The body 1 is provided at a upper portion thereof with a laundry input port 1 a , which allows laundry to be input into the rotating tub 20 therethrough, and with a door (not shown) configured to open and close the laundry input port 1 a.
The body 1 is provided at a lower portion thereof with a mounting part 2 having a leg 5 that enables the washing machine to be mounted on a floor.
The rotating tub 20 is rotatably disposed inside the body 1 . A plurality of drain holes 22 are formed at an upper portion of the rotating tub 20 along a circumference of the rotating tub 20 .
A pulsator 6 is rotatably installed at a bottom of the rotating tub 20 . The pulsator 6 serves to stir a washing water introduced into the rotating tub 20 together with a laundry.
A water supply apparatus 160 is installed at an upper side of the rotating tub 20 to supply a washing water to the rotating tub 20 . The water supply apparatus 160 includes a water supply valve 161 configured to regulate a supply of water and a water supply pipe 162 connecting the water supply valve 161 to a detergent supply apparatus 163 .
The water delivered through the water supply pipe 162 is supplied to the rotating tub 20 together with detergent by passing through the detergent supply apparatus 163 .
A first drain hose 231 and a second drain hose 230 are provided at the lower portion of the rotating tub 20 to guide a washing water, which has been used for a washing operation or a spin-dry operation, to the outside the body 1 .
The driving part 100 includes a clutch 120 , which rotates the rotating tub 20 and the pulsator 6 , and a driving motor 110 , which drives the clutch 120 .
The clutch 120 is connected to the driving motor 110 through a pulley 141 and a belt 142 such that a driving force of the driving motor 110 is selectively transferred to the rotating tub 20 or the pulsator 6 .
FIG. 2 is an exploded perspective view schematically illustrating the washing machine according to an embodiment. FIG. 3 is a cross-sectional view schematically illustrating a rotating tub of the washing machine according to an embodiment. FIG. 4 is a cross-sectional view schematically illustrating a driving part and a waterproofing member of the washing machine according to an embodiment.
Referring to FIGS. 2 to 4 , the rotating tub 20 is disposed inside the body 1 while being spaced apart from the inside the body 1 by a predetermined interval.
A suspension member 240 is installed on an outer side of the rotating tub 20 such that the rotating tub 20 is hung on the body 1 while being supported by the suspension 240 .
In order to support the rotating tub 20 , one side of the suspension member 240 is coupled to the upper portion of the body 1 and the other side of the suspension member 240 is coupled to a connecting bracket 241 of a base plate 200 that are to be described later.
The body 1 is provided at the lower portion thereof with the mounting part 2 that is configured to support the body 1 .
The mounting part 2 includes a bottom plate 3 forming the bottom of the body 1 and an installation hole 2 a formed through the center of the mounting part 2 in a predetermined diameter. The installation hole 2 a allows the driving part 100 to pass therethrough and then is installed on the mounting part 2 .
The bottom plate 3 has a first drain port 3 a that is connected to the first drain hose 231 to deliver the water discharged to the outside the rotating tub 20 during a spin-dry operation.
The first drain hose 231 is connected to the second drain hose 230 to discharge water passing through a second drain port 201 to the outside the body 1 during a washing operation and a rinsing operation.
The rotating tub 20 is rotatably provided on an upper side of the mounting plate 2 in a vertical direction.
The rotating tub 20 includes a bottom part 24 and a side wall 21 that connects to the bottom part 24 to form a space accommodating a washing water.
A through-hole 150 is provided in the center of the bottom part 24 to allow a driving shaft 124 to be coupled thereto. A liquid balancer 25 is provided at the upper portion of the rotating tub 20 to ensure the smooth rotation of the rotating tub 20 .
The side wall 21 is provided while being slanted with the increase of a diameter of the rotating tub 20 . If the rotating tub 20 rotates at a speed of 280 rpm or above in a spin-dry operation, water separated from the laundry reaches to the side wall 21 due to the centrifugal force and runs to the upper side of the rotating tub 20 along the inner side of the side wall 21 slanted.
In this case, the side wall 21 forms a slope angle θ of 2 degrees to 10 degrees with respect to a line (L) that is perpendicular to the bottom part 24 .
If the slope angle θ is smaller than 2 degrees, the water does not effectively move along the inner circumferential surface of the side wall 21 , and thus the spinning performance is degraded. If the slope angle θ is larger than 10 degrees, the upper portion of the rotating tub 20 is widened, and thus the overall width is increased.
As described above, a plurality of drain holes 22 are formed at the upper portion of the rotating tub 20 to discharge the water separated from the laundry to the outside the rotating tub 20 . The water discharged to the rotating tub 20 through the drain hole 22 flows to the bottom plate 3 of the mounting part 2 along an inner circumferential surface of the body 1 , and then is discharged to the outside through the first drain port 3 a and the first drain hose 231 .
The drain hole 22 is formed along the circumferential direction of the side wall 21 . The drain hole 22 is provided at a position corresponding to two-third of the height of the rotating tub 20 .
The driving part 100 is installed at the lower portion of the rotating tub 20 to drive the rotating tub 20 or the pulsator 6 disposed inside the rotating tub 20 .
The driving part 100 includes the clutch 120 , the driving motor 110 , a flange member 130 and the base plate 200 . The clutch 120 selectively rotates the rotating tub 20 and the pulsator 6 . The driving motor 110 drives the clutch 120 . The flange member 130 connects the driving shaft 124 of the clutch 120 to the bottom part 24 of the rotating tub 20 to transmit a torque of the driving shaft 124 to the rotating tub 20 . The base plate 200 is provided to fix the clutch 120 and the driving motor 110 (see FIGS. 1, 4, and 6 ).
Since the driving part 100 is fixed to a lower surface of the base plate 200 below the rotating tub 20 , the driving part 100 , after the spin-dry operation, may have a risk of being exposed to the water that runs down along the inner surface of the body 1 and then is discharged through the first drain port 3 a of the bottom plate 3 .
Accordingly, a waterproofing member 10 is provided between the base plate 200 and the bottom of the body 1 to seal the driving part 100 .
In addition, the mounting part 2 includes a moisture infiltration preventing guide 30 configured to prevent water from being introduced to (reaching) a plurality of cables (C) connected to electronic parts of the driving part 100 .
The moisture infiltration preventing guide 30 includes a cable accommodating part 30 a that allows the cable (C) to pass therealong. The moisture infiltration preventing guide 30 is provided in a direction perpendicular to edges of the bottom plate 3 of the mounting part 2 .
The waterproofing member 10 may include a diaphragm formed using elastically deformable material, such as rubber, to absorb the vibration of the driving part 100 .
Referring to FIGS. 4 and 5 , the waterproofing member 10 includes a plurality of wrinkled parts 11 and a fixing part 12 extending upward and downward.
The fixing part 12 includes a first fixing part 12 a extending upward from the wrinkled part 11 and a second fixing part 12 b extending downward from the wrinkled part 11 .
The waterproofing material 10 is provided in the form of a cylinder surrounding the outer side of the driving part 100 . The waterproofing material 10 is disposed between the base plate 200 and the bottom of the body 1 , that is, between the base plate 200 and the bottom plate 3 of the mounting part 2 .
The base plate 200 includes a first coupling part 202 having a coupling groove 202 a . The first coupling part 202 protrudes from the lower surface of the base plate 200 along the circumference of the base plate 200 while extending outward such that the coupling groove 202 a is coupled to the first fixing part 12 a of the waterproofing member 10 .
The first fixing part 12 a has an upper end which is bent outward to correspond to the coupling groove 202 a of the first coupling part 202 .
A wire 15 having a shape of a ring is configured to fasten the outer circumference of the first coupling part 202 of the base plate 200 and the first fixing part 12 a of the waterproofing member 10 , thereby allowing the first coupling part 202 to be closely fixed to the first fixing part 12 a.
The second fixing part 12 b of the waterproofing member 10 is coupled to a second coupling part 4 that is formed on the mounting part 2 .
The installation hole 2 a is provided in the center of the bottom plate 3 of the mounting part 2 . The second coupling part 4 is provided on the rim of the installation hole 2 a.
The second coupling part 4 extends downward from the bottom plate 3 . The second coupling part 4 is provided at an end thereof with a slanting part 4 a that extends while being slanted in a radial outward direction.
The second fixing part 12 b of the waterproofing member 10 has a shape corresponding to the shape of the second coupling part 4 such that the second fixing part 12 b is inserted into the second coupling part 4 . A wire 15 having a shape of a ring fastens the outer circumference of the second fixing part 12 b that is inserted to the second coupling part 4 , thereby allowing the second fixing part 12 b to be closely fixed to the second coupling part 4 .
The first coupling part 4 and the second coupling part 4 may be implemented in variety of shapes so that the fixing member 12 of the waterproofing member 10 can be firmly fixed to the first coupling part 202 and second coupling part 4 .
According to the above configuration, the waterproofing member 10 is provided between the base plate 200 and the bottom of the body 1 while surrounding the outer side of the driving part 100 to seal the driving part 100 and water is prevented from being infiltrated into (reaching) the driving part 100 , and the vibration of the driving part 100 is absorbed.
In addition, a vertical vibration is absorbed without impeding the rotation of the rotating tub 20 during the washing operation or the spin-off operation, thereby enhancing the washing efficiency.
When a draining process is viewed during the washing operation and the spin-off operation, a water (shown as a solid arrow line in FIG. 6 ) separated during the spin-off operation is discharged to the outer side of the rotating tub 20 through the drain hole 22 of the rotating tub 20 , flows downward along the inner surface of the body 1 , and then is discharged by sequentially passing through the first drain port 3 a formed through the bottom plate 3 , the first drain hose 231 and the second drain hose 230 connected to the first drain port 3 a.
The through-hole 150 of the rotating tub 20 is provided to allow the rotating tub 20 , the driving shaft 124 of the driving part 100 , and the flange member 130 to be coupled thereto. The through-hole 150 includes a first through-hole 151 , which is provided in the center of the through-hole 150 , and a second through-hole 152 disposed around the first through-hole 151 in the circumferential direction of the first through-hole 151 .
The first through-hole 151 is formed such that the driving shaft 124 is connected to the rotating tub 20 and the pulsator 6 by passing through the flange member 130 . The second through-hole 152 is formed to discharge water, which remains in the rotating tub 20 after the washing operation is finished, to the outside the rotating tub 20 through the second drain port 201 .
In addition, the driving shaft 124 includes a first driving shaft 124 a , which is coupled to the first through-hole 151 , and a second driving shaft 124 b , which extends from the first driving shaft 124 a and is coupled to the pulsator 6 .
The first driving shaft 124 a and the second driving shaft 124 b simultaneously or individually rotate depending on whether a washing operation is performed or a spin-off operation is performed.
In a washing operation, the second driving shaft 124 b operates to rotate the pulsator 6 that is coupled to the second driving shaft 124 b . During a spin-off operation, the first driving shaft 124 a and the second driving shaft 124 b operate such that the rotating tub 20 and the pulsator 6 simultaneously rotate.
One end of the driving shaft 124 is connected to the pulley 141 such that a driving force of the driving motor 110 is transferred to the clutch 120 .
In addition, the base plate 200 has a base plate cover 210 to guide water discharged through the second through-hole 152 .
The base plate cover 210 is disposed between the flange member 130 and the base plate 200 to house the second drain port 201 that is formed on the base plate 200 .
A drain case 220 is coupled to a lower portion of the base plate 200 to form a predetermined space. The space is configured to accommodate a washing water that is introduced by passing through a space formed between the base plate cover 210 and the base plate 200 .
One end of the drain case 220 is connected to the second drain hose 230 to guide a washing water introduced to the drain case 220 to the outside the body 1 .
A valve 221 is provided on the second drain hose 230 to selectively drain water.
In this manner, the water having been used for the washing operation or the rinsing operation (shown as a dotted line arrow in FIG. 6 ) is introduced into the space between the base plate cover 210 and the base plate 200 by passing through the second through hole 152 and then is discharged to the outside the body 1 by sequentially passing through the drain case 220 and the second drain hose 230 .
In each of the washing operation, the rinsing operation and the spin-off operation, the driving part 100 provided at the lower portion of the rotating tub 20 is completely sealed by the waterproofing member 10 provided between the base plate 200 and the bottom plate 3 of the body 1 , thereby preventing water from being infiltrated into (reaching) the driving part 100 .
In addition, the cable (C) connected to the driving part 100 is also prevented from being exposed to water by the cable accommodation part 30 a formed on the bottom plate 3 .
In addition, the waterproofing member 10 surrounds the outer side of the driving part 100 , thereby preventing vibration and noise from the driving part 100 .
As described above, a structure to accommodate water between the body 1 and the rotating tub 20 is removed, so that the spatial utilization in the body 1 is maximized. In addition, the waterproofing member 10 provided at the lower portion of the rotating tub 20 serves to absorb the up-and-down vibration of the rotating tub 20 and the vibration of the driving part 100 and also prevents the water from being introduced to the electronic parts of the driving part 100 .
Although a few embodiments have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined in the claims and their equivalents. | A washing machine capable of increasing the washing capacity without enlarging the external appearance and also discharging a washing water during a washing operation or a spin-dry operation while completely isolated from electronic parts and thus reducing the risk of a power failure and fire, the washing machine including a body, a rotating tub rotatably disposed inside the body, a pulsator rotatably disposed inside the rotating tub, a driving part provided on a lower portion of the rotating tub to selectively rotate the rotating tub and the pulsator, a base plate to which the driving part is fixed, wherein a waterproofing member is provided between the base plate and a bottom of the body to seal the driving part and to prevent water from reaching the driving part. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of to U.S. patent application Ser. No. 09/766,149, filed Jan. 18, 2001, entitled KEYBOARD IMPROVEMENTS THAT CAN BE IMPLEMENTED, to Parkinson, which claims priority to U.S. provisional application No. 60/177,747, filed Jan. 21, 2000. U.S. patent application Ser. No. 09/766,149, filed Jan. 18, 2001 is incorporated herein by reference in its entirety. Without further priority claim it uses letter allocations from related U.S. Pat. No. 6,053,647 entitled “User-Friendly and Efficient Keyboard”, which was filed Jul. 29, 1998 and issued Apr. 25, 2000.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] This invention relates to keyboards providing a manual interface between an operator and equipment such as typewriters, computers, communications systems, or other equipment using alpha-numeric data. More specifically, it relates to the standardization of keyboard design under ISO/IEC 9995, with particular regard to operating skill and other factors affecting the process of changing the standard.
[0005] For ease of understanding and economy of presentation, some reference to the prior art is made in the detailed description of the invention.
[0006] The present state of the art has three distinct components useful to understanding this invention. The first component includes the formally standardized features of International Standard ISO/IEC 9995, Information Technology—Keyboard layouts for text and office systems—Parts I and II. (Hereinafter, “the Standard”.)
[0007] The second component includes those other features, such as columns of keys all leaning to the left and the “QWERTY” letter arrangement, that are not required by the Standard, but are informally standardized in the real world by tradition or custom.
[0008] The third component includes proposed design improvements that have never been implemented or generally adopted, such as those illustrated in many published patents.
[0009] Interacting with these components and with each other, less clearly definable factors include the pool of existing typing skills, market forces, the historical difficulty of typing, and general perceptions and expectations.
[0010] Although discussion here is mostly limited to English-language word processing on typical U.S. computers, the Standard generally covers all keyboard applications in a multi-lingual world-wide market, and this invention is intended to do the same. Standardization, both formal and informal, has stifled progress, and is itself the major problem with the QWERTY or Standard keyboard. Prior artisans have failed to recognize this. They offer design solutions, but make no provision for implementing them in the real world. This invention addresses problems of implementation as well as those of design, and now, after a century of stalemate, provides a workable solution for progressing beyond the existing Standard to a proposed new and improved one (hereinafter, “the new standard”).
[0011] FIG. 1 (prior art) shows for discussion a typical Standard computer keyboard ( 11 ). It is well known that the design of the alphanumeric section ( 12 ) is firmly entrenched and has changed little in 130 years, even though it is grossly unsuited to its primary applications, which are now electronic, not mechanical. One problem is that the Standard uses some inappropriate technical requirements to define the keyboard, unnecessarily restricting design freedom and progress. For example, keyboard horizontal dimensions for the desired range of hand sizes could be regulated by the key spacing in the home row alone, but the Standard requires the spacing to be the same throughout the alphanumeric section. This restricts adjacent columns of keys to being parallel, which cannot adequately match the natural movements of adjacent fingers. The purpose of standardizing keyboards is to ensure compatibility between products and people, not between two products directly. Unlike a nut or bolt, the human half of the interface is highly adaptable, especially when a design variation makes the task easier. The critical relationship is between the mode of operation of the keyboard and the skill of the typist, and the measure of compatibility between keyboards lies not their identicalness, but in their shared operational compatibility with this external entity. Any future formal standard may benefit from such requirements being defined in terms of the elements of operator skill required, instead of in terms of specific technical features in the hardware.
[0012] However, the Standard itself is only one of several factors which together prevent any change. Another is the piecemeal approach in much of the prior art, which leads to incomplete solutions. The Standard requires that it be shown how a keyboard maps to the Standard's key position reference system, and requires that the alpha-numeric section has about a dozen features, most with inherent problems like poor shift positions and minimum counts of graphic keys in specific locations within that reference system. Other problems such as lack of symmetry are not formal requirements, but are equally entrenched informally. Any change must either conform to the existing standards, or solve all of these problems at once and create a new standard. However, both Herzog (U.S. Pat. No. 4,669,903) and Cleveland (U.S. Pat. No. 5,476,332) for instance, have arrangements with lateral symmetry but ignore long reaches and difficult, little-finger shift operations. They remain as hypothetical improvements that cannot be implemented because they are incomplete solutions that break the Standard without replacing it. The present situation is that Standard keyboards are supplied with computers largely because no-one can use any other, but no-one learns any other because none are readily available. It is a difficult loop to break, and doing so requires many conflicts and problems to be resolved simultaneously.
[0013] The physical layout makes it difficult to form a cognitive map, and the chaotic letters are hard to find, so hunt and peck typing is frustrating. There will always be occasional users; the keyboard should accommodate them. Despite the asymmetrical columns of keys, touch typing is a better method, and, recognizing today's dominant application, it should be refined and extended to include full computer control. It should be easy to master in elementary school, but is so difficult that 25 WPM can earn college credits. The need for the skill has spread from paid typists to the entire population, but the daunting prospect of learning to type discourages many people from trying to use a computer. The basic touch typing concept of not looking at the keyboard is ignored, e.g., this essential habit is undermined by providing lights as status indicators. Psychological factors are not recognized, e.g., the multiple choice (one row or two?) for upward movements slows the operation from simple to choice reaction time. It also adds complexity, reducing confidence and encouraging the typist to look at the keys for confirmation. Forcing the hands to move to peripheral subsets of keys undermines the technique of keeping the hands in home place, and it encourages looking at the keyboard. The keyboard is a unitary interface, not a collection of components; key locations should be based on use, not on arbitrary function classifications, e.g., editing keys should not be separated from typing keys since many people make corrections as they type.
[0014] Many poor design features are rooted in mechanical constraints. The large character groups dictated by a single shift need too many keys to reach easily. The logic suffers too because letters and numerals are mixed, and symbols are “upper case numerals”. For limited capacity segments, more was better, and the Standard calls for minimum numbers of character keys appropriate to those, instead of maximum numbers good for human hands. Binary codes now set the limit, but some are wasted on obsolete characters. On equipment not limited by the fixed mechanical spacing of a typewriter, two apostrophes work just as well as the double quote symbol; and on a computer the underscore character cannot even be used for its original purpose, and is not as good as other methods for drawing lines.
[0015] Conversely, other characters that should be provided are missing. In some countries the traditional decimal point is a middle-height dot, but it is not available on the international standard keyboard. There is a strong case for adopting it internationally. Whatever foreign conventions use for the decimal point, and no matter how bad the print quality may be, by virtue of its height above the line, the middle dot can never be confused with a comma, full stop (period), or apostrophe. So units cannot be misread as thousands, or vice versa, and decimal points cannot be confused with dimensions such as feet and inches. This dot also distinguishes conceptually between the mathematical decimal point and grammatical punctuation marks, helping children understand basic arithmetic. Providing characters on the keyboard is necessary to allow corresponding change in the binary codes.
[0016] Rapid change and haphazard growth have created anomalies, and the underlying organization of the keyboard defies all attempts to teach it logically; e.g., the unrelated Enter and Return functions are on the same key, and commands are confusing because they can be issued in several different ways.
[0017] Despite the large number of keys available, in order to assign a personal routine, a user may have to search for some unused, meaningless combination of keys intended for other purposes. Such non-standard requirements can only come from application software on one side of the keyboard interface, or the keyboard user on the other side of the interface; both sources should be recognized.
[0018] Although mouse and keyboard are standard with most desktop computers, they do not fit well when typing. The numeric keypad is exactly where the mouse pad should be, and with repetitive use, shoulder problems are increased by the excessive distance between home keys and mouse. A separate problem is the desktop required even when a task only rarely needs a mouse. Even a moderately efficient mouse alternative would allow occasional use of a keyboard on the knee.
[0019] Computer requirements now seem stable, and the whole keyboard should be rationalized. Although it alone cannot provide software dependent features, it must provide the capability so that software can be developed.
[0020] The prior art shows many failed attempts at improvement. Good design is the optimum compromise between all requirements, and this balance has generally been lacking. Dvorak (U.S. Pat. No. 2,040,248) focused exclusively on robot-like efficiency, and his scattering of letters looks random and no better than qwerty. He should have balanced efficiency against user-friendliness. At the opposite extreme, Stonier (UK patent 2,110,163) aims exclusively at user-friendliness and completely ignores the physical efficiency of finger movements.
[0021] In prior-art “ergonomic” over-reaction, much effort has been misdirected, e.g., elaborate designs raise the center of the keyboard when the need can be eliminated by simple work-station adjustment: setting the keyboard lower turns the hands flatter. Other designs fail to balance the abilities of the hand against its limitations, fail to recognize that individual differences and other priorities render anatomical perfection impossible and irrelevant, and rely on inaccurate analysis. For example, Lichtenberg (U.S. Pat. No. 5,336,001) wrongly assumes that rows of keys should be “perpendicular to the forearms” in a deep vee formation. Clearly, with the relaxed hands over the keyboard, the home row should align with the fingertips, but this indictates an angle of less than seventy degrees to the forearm, not perpendicular. This angle almost filly compensates for the inward angle of the forearms, resulting in an “ideal” home row with each half at an angle of no more than four or five degrees in a very shallow vee. However, the angle of the rows (and curvature, if any) is easily accommodated by finger curl or extension, so the exact layout is not very critical, and traditional simple straight rows across the board are a good compromise in a standard design for broad application. What's more, for keys within easy reach, little is gained by fine-tuning their locations, but if a row is beyond easy reach, fine tuning its shape or angle will never make the key locations acceptable. The real problem is too many rows. Solving that eliminates many others.
[0022] The column angles are more critical because the fingers do not adjust so readily sideways, but once again the typical prior-art analysis comes up lacking. The natural movements of the finger-tips indicate proper column alignment, but this is not the direction pointed by the forearms, shown in UK patent 1,016,993 in IBM's figure six at 30.degree., nor is it directly away from the typist as seen in Harbaugh (U.S. Pat. No. 5,584,588), Malt (U.S. Pat. No. 4,244,659) and Crews (U.S. Pat. No. 5,017,030 and D 287,854). Normally the palms are not parallel to the desk top, so curves traced by the finger-tips are not in vertical planes and do not project straight lines onto the desk. Straight lines substituted for the curves projected onto a keyboard show that the little finger tips move almost vertically up the keyboard, the lines leaning inwards slightly. Working towards the center of the keyboard, the line of movement for each successive fingertip leans in about an additional four degrees. An average for parallel columns for one hand is less than twenty degrees, roughly half the angle favored by workers who simply follow the angle of the forearms.
[0023] Some proposals abandon qwerty but introduce a new set of problems. IBM, Malt and Crews show variations of hand-print designs, but the better they fit one hand, the more problems they create for hands of a different shape or size. Crews also has a chording system using either one key, or two keys simultaneously, but the skill required to strike two at once without first getting an unwanted single-key character prohibits this system for people of ordinary ability. Also, chords are counter-intuitive, difficult to label, and unsuitable for occasional or new users. Further, using at least two key-strokes per character can, by that measure, be no more than half as efficient as traditional keyboards. Hand-prints and chords are not suitable for a general-purpose standard for use by adults and children of all races, and all skill levels.
[0024] The concave IBM shape and radical formats such as pyramids and balls are also unsuitable. A standard must lend itself to economical production, and suit portable as well as desk-top computers. This prohibits compound curves or significant third dimensions as essential design features. The new standard must first work well as a basically flat keyboard, which can then be adapted as desired.
[0025] Even if it is suitable as a new standard, a well-designed, purpose-built computer keyboard is not a complete solution; public demand will not take care of the rest. If competing old and new standards were in the market together, no-one would know which one to support. Any transition would be slow, confused and uncertain. Disruption would be maximized. Personal lives, job skills, and business are all affected, and a slow and uncertain transition is not an acceptable or workable solution.
[0026] The only workable solution is if the old and new standards co-operate to implement a rapid transition with minimum disruption. Allowance must be made for typists to retain their old skills, or learn new ones compatible with the new standard, according to individual needs. Equipment shared by different users raises uniquely difficult problems. Switching letter arrangements electronically is easy, but re-aligning the keys is impracticable. A unified design concept is needed, versatile enough to meet all market demands within the spirit, and skill transfer requirements, of the new standard. Understanding of skill transfer, lacking in the prior art, is needed before this can be contemplated.
[0027] The mental and physical components of touch-typing skill have different learning and modification characteristics. Mental information about which finger goes to which row for a given character is either right or wrong. If a change makes it wrong, errors provide no self-correcting feedback. The old knowledge must be “buried” by learning and strongly reinforcing new information. Minor changes with few cues from associated major changes are more likely to allow old information to surface. Moving the shift key up just one row (Cleveland) or sliding all the numerals just one place to the left (Lichtenberg, also Zilberman in U.S. Pat. No. 5,156,475) is confusing, difficult to assimilate, and may cause more long-term problems than a dramatic change, such as moving the shift to a completely different finger or reversing the entire sequence of the numerals.
[0028] In contrast, physical motor skills are very much subject to partial errors, and inaccuracy gives instant biofeedback for error correction. In his split-qwerty design, Louis (U.S. Pat. No. 5,503,484) teaches exact physical replication of the qwerty key layout for the left hand, but three factors combine to render this unnecessary. First, motor skills are learned using repeated bio-feedback to correct inaccuracy, and are perpetually monitored and corrected the same way. Tactile feedback from features like concave keytops enhances the process. Minor changes in key locations can be assimilated without conscious effort, and even major physical changes are easier than letter assignment changes. Like driving an unfamiliar vehicle, the pedal height, angle, and operating pressure may be different, but the driving skill tranfers so long as the brake is not on the right. Second, the body is naturally “lazy” (or efficient), so repetitive movements reduce to the easiest possible. This is part of the higher error rate for the left hand as it makes easier movements than needed by qwerty. Adaptation is natural if the new movements are easier than the old ones. Third, symmetrical operations are natural to our symmetrical bodies, and there is transfer of learning by symmetry between opposing limbs. Right-hand experience will aid the left hand if the left keys are made symmetrical to the right. Thus, key layouts can be substantially changed (in the right direction!) without unduly compromising skill transfer. Exact replication is only necessary for arbitrary conformance to the traditional layout.
[0029] To construct a new standard, all this must be weighed and balanced in combination. The problem is complex and its solution challenging, but the right new standard should be known by its elegant simplicity. The computer is not only a business machine for trained professionals, it is a toy and a tool for everyone from astronauts to children. Making notes on Martian topography affects few, but for children learning the alphabet and more, the keyboard can affect entire populations.
BRIEF SUMMARY OF THE INVENTION
[0030] In accordance with the above, the main object of this invention is to balance all conflicting requirements and solve all identifiable problems, in a simple and complete keyboard design suitable for adoption as a new standard and supported by dual-standard and transitional models to facilitate the implementation of that standard. Many subsidiary objects are necessary to meet the primary goal. For example, having recognized the diversity of individual needs, a further object is to provide adaptable design concepts enabling selection of innovative features, singly or in combination. Another object is to maintain compatibility for skill transfer. Yet another is to provide a new standard so easy to learn and use that people can abandon their skills and start again. Further objects will become obvious later. To this end I have invented a series or family of compatible keyboards.
[0031] The series starts with the prior-art Standard ( FIG. 1 ) and ends with a new design ( FIG. 19 ) optimized for adoption as a new standard. The series allows existing typists to adjust their skills towards the new standard, partially, completely, or incrementally according to individual needs, and also provides dual-standard and multi-mode keyboards that can be shared by users with different skills. The primary benefit of the series is that it enables and facilitates the implementation and adoption of an improved new standard keyboard with a minimum of disruption, whereas all previous attempts to progress beyond the existing Standard have failed. Families or series of related keyboards are unknown in the prior art.
[0032] In changing between standards, existing technology allows easy switching of letter allocations as desired; what is needed is a corresponding easy way to physically re-arrange the key layout. This is in effect made possible in this invention by a basic key arrangement that is very versatile. The keys in successive rows are offset horizontally from keys in adjacent rows by half the horizontal center spacing of the keys, in a pattern having internal symmetry ( FIG. 4 ). Prior art has symmetrical columns of keys, but only about a vertical centerline; this pattern allows the selection of symmetrical pairs of columns anywhere in the array, including having the same symmetry when inverted. Using this pattern of keys, parallel sets of columns compatible with traditional keyboards can be provided ( FIG. 5 ), and conform to the Standard. Symmetrical sets of columns can also be provided ( FIG. 6 ) compatible with the new standard, as if with a different physical layout of the keys. Since the basic key pattern is identical for either set of columns, dual-standard keyboards can also be provided on which the user may select either kind of sets of columns. One way to do so is by reversing a segment of the keyboard ( FIG. 7 ), in which case permanent dual labeling on the key-tops allows the appropriate character to be automatically selected for easy reading, eliminating the need for make-shift temporary labels. Another method uses a fixed array of keys ( FIG. 14 ); the effect is still as if the keys were physically re-arranged, but the keyboard is simple and cheap.
[0033] The same key pattern is a common feature of all the family members for at least a group of four keys in a symmetrical cross on three rows in the central zone of the alphanumeric section ( FIG. 14 ). In some models the cursor arrows are assigned to these keys. Whatever their assignment, they control the angle of the adjacent columns of keys assigned to the index fingers, and thereby establish an appropriate orientation of the hands. Since this is a fundamental factor when using a keyboard, it establishes a basic level of operational compatibility for skill transfer between models, while allowing some design freedom outside the central zone of the keyboard.
[0034] Although symmetry is a common goal in the prior art, no symmetrical keyboard has yet been provided that can be used where conformance to the existing Standard is mandatory. This series provides a symmetrical keyboard that does conform to the Standard ( FIG. 13 ), and can therefore be implemented anywhere immediately. With known means to switch the letter allocations, this provides under the old Standard a keyboard with the two most fundamental elements of typing skill for the new standard, i.e., hand orientation and letter arrrangement.
[0035] A further transitional feature within the series is the capability for redundancy at many levels. This can be physical or operational, for multi-mode keyboards or for mere user preference. Examples are: retaining a redundant row of numerals keys while also providing a new thumb shift to select numerals on the home row; and arranging shift keys for a choice of operation by index finger or thumb, and choice of one hand or two for shift operations.
[0036] While the majority of the market may be served by the proposed new standard and one dual-mode model offering both symmetrical and asymmetrical columns, the inherent versatility allows other embodiments to cater to every significant group of existing users, whatever their preferences. For example, one embodiment of FIG. 6 provides for qwerty typists who want to relieve their aching wrists with improved bio-mechanical alignment, but who do not want to learn a different letter arrangement or new shift operations. However, the compatibility between the keyboards ensures that any new skills taught by such transitional models will transfer to the new standard should an individual subsequently choose to make the complete change. This approach is important to ensure that objections from various groups do not altogether prevent any change from the present Standard; implementation depends on popular perceptions, confidence and consensus, as well as on technical superiority.
[0037] The design of the efficient new standard enormously simplifies learning and use of the keyboard, and encourages the spontaneous development of touch-typing skill. The same easy skill is then applied to editing and full computer control, with a total of only fifty keys. Other advantages over the existing Standard include: increased speed; reduced fatigue and industrial injury; logical organization; suitability for all, including adults or children and occasional or full-time users; and savings in size, weight and cost.
[0038] Other individual keyboard designs may have some of the same benefits, but in the broader context the prior-art alternative is still “no change”. The thoroughness and completeness of this total solution brings about a synergy where the whole is greater than the sum of the parts. The historical stalemate, the great benefits of the new standard, its ease of implementation through transitional models, and the extreme unlikelihood of any possible alternative, are all readily apparent. Adoption of this new standard to meet the great existing need will therefore be perceived as secure, and this in its turn will help to generate the confidence and support required to ensure the smooth and rapid transition for which the series was created. The self-sustaining loop of stagnation will be replaced by self-propelled progression to a new and better standard.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0039] FIG. 1 (Prior art) shows a computer keyboard typical of the existing Standard.
[0040] FIGS. 2 and 3 (Prior art) show column structures with lateral symmetry about a centerline.
[0041] FIG. 4 shows a new column structure with vertical and lateral symmetry anywhere in the array.
[0042] FIG. 5 shows a modified parallel column structure in a portion of the FIG. 1 Standard keyboard.
[0043] FIG. 6 shows symmetrical columns on the key configuration of FIG. 5 rotated 180.degree.
[0044] FIG. 7 shows a multi-mode keyboard having a removable, reversible segment.
[0045] FIG. 8 is a detail of dual labeling for keytops in the reversible segment of FIG. 7 .
[0046] FIGS. 9A and B are end elevations of a keyboard with a non-reversible profile.
[0047] FIGS. 10 and 11 are end elevations of keyboards with reversible profiles.
[0048] FIG. 12 shows the symmetrical columns of FIG. 6 in an array with all keys the same size.
[0049] FIG. 13 shows how FIG. 6 or 12 configurations map to the key numbering system of the Standard.
[0050] FIG. 14 shows alternate column selections on a fixed array of keys for a multi-mode keyboard.
[0051] FIG. 15 shows an array of keys with the maximum column spread attainable under the Standard.
[0052] FIG. 16 shows full column spread in a rectangular array of keys.
[0053] FIG. 17 shows an arrangement with an additional shift function and fewer rows.
[0054] FIG. 18 shows a fully rationalized arrangement optimized for easy touch-typing.
[0055] FIG. 19 is the complete proposed new standard keyboard with all subsets of keys integrated.
DETAILED DESCRIPTION OF THE INVENTION
[0056] While the best mode of the series contemplated by the Applicant is illustrated in FIG. 4 through FIG. 19 , the examples presented do not exhaust the series. As will be obvious to a person skilled in the art, features may be used alone or in other combinations to suit applications in any particular market niche. Also, many of the features are tailored to the requirement of being adaptable, and although primarily intended for conventional two-handed and able-bodied operation, this should not be regarded as a limitation. The order of presention was not arranged to reflect importance, but to introduce inventive features by comparison with familiar concepts, starting with a Standard keyboard. While one or two models or features may be considered the most important or popular, they alone do not constitute a “preferred embodiment”, since the completeness of the solution, and of the series, is fundamental to the success of the invention.
[0057] The Standard keyboard ( 11 ) in FIG. 1 (prior art) has an alpha-numeric section ( 12 ) with rows identified here as A through E following the Standard convention. In ten columns headed by ten numeral keys in row E, twenty-six letters and four punctuation marks make up the recognized basic alpha-numeric set on forty keys. Six letters in row D identify this as a “qwerty” keyboard. The Standard accepts other letter arrangements, including Dvorak.
[0058] In touch-typing each hand is assigned five columns of keys, the two inner ones near the keyboard center being assigned to the index finger, and one each to the other three fingers. The home keys are in row C.
[0059] The columns are not vertical because the keys are offset horizontally from the keys in adjacent rows. They are not straight because the offset varies for different pairs of rows. For rows B and C the offset is one half of the key center-spacing (½-key). For rows C and D it is only ¼-key. Lines ( 13 ) up the keys of any column therefore zigzag. With the same offset between all rows, say, ⅜-key, the columns would be straight.
[0060] For row D relative to row C, the ¼-key offset is always to the left. The overall angle of slope of lines ( 13 ) therefore depends on column selection, leaning either to the left about 23.degree. away from vertical, or to the right about 30.degree. from vertical. No symmetrical columns exist. Herzog (Col 4, lines 26-47) achieved lateral symmetry by using a symmetrical offset in left and right halves of the keyboard, instead of always to the left.
[0061] A symmetrical constant offset of ⅜-key can create two different arrays. FIGS. 2 and 3 (prior art) show part of FIG. 1 , with possible re-arrangements of the basic set of forty keys according to prior art. FIG. 2 is an array with a ⅜-key offset ( 20 ) measured outwards going down the rows. FIG. 3 is an array with a ⅜-key offset ( 30 ) measured outwards going up, which is the same as a ⅝-key offset measured outwards going down. Lines ( 23 ) in FIG. 2 and ( 33 ) in FIG. 3 differ only in their angles of slope. Other values of offset can create any desired angle.
[0062] Herzog shows a keyboard similar to FIG. 2 . Columns leaning 10.degree. away from vertical leave no room for a key in space ( 24 ) in row D, i.e., it has less than ½-key offset measured outwards going down.
[0063] Cleveland (col. 1, line 23) says Herzog makes inefficient use of the triangular space located in the center of the keyboard, and he modifies a conventional, Standard keyboard to create the type of array shown here in FIG. 3 . Specifying (col. 4, line 8-9) “a new alignment of . . . fourth row 40 in relation to third row 30 ,” (corresponding to rows B and C here) Cleveland rejects the standard ½-key offset between these rows in favor of any other symmetrical offset sufficient to make room for more keys in the middle, i.e., any offset greater than ½-key measured outwards going down.
[0064] Herzog and Cleveland each show prior-art keyboards having a symmetrical, constant, horizontal offset between the keys in adjacent rows. Each has lateral symmetry about a common centerline for several pairs of columns of keys.
[0065] In FIG. 4 , this invention shows an improvement wherein said offset ( 40 ) is ½-key. Pairs of lines ( 43 ) can be anywhere and be symmetrical. Two positions are shown by way of example. Inverted columns such as lines ( 44 ) are equally symmetrical. FIG. 4 has a higher level of symmetry than FIG. 2 or FIG. 3 , an internal symmetry in the key pattern. Different column configurations can be selected without physically changing the key layout. The ½-key offset ( 40 ) also permits the selection within the array of a group of four adjacent keys in a symmetrical cross, for example, group ( 45 ) identified by triangles.
[0066] FIG. 5 shows internal symmetry applied to part of FIG. 1 in an otherwise traditional keyboard made physically compatible with others in the family, while being operationally compatible with traditional models. In row A, only a spacebar is shown. In rows D and E, a key is omitted for clarity. The key count is 12, 13, 14, 14 in rows B, C, D, E respectively. In FIG. 5 compared to FIG. 1 , one change is made: the horizontal offset ( 50 ) from row C to D is changed from ¼-key to ½-key. Other offsets remain unchanged at ½-key. This conforms to the Standard, and does not much affect existing skills. Traditional touch-typing uses the straightened columns of groups ( 51 ) and ( 52 ) for the left and right hands respectively. For neat appearance at the ends of the rows, keytops such as key ( 53 ) may be adjusted in size in the usual way.
[0067] Rotating 180.degree. about an axis perpendicular to the strike surface of the keys, both lateral and inverted symmetry are applied to FIG. 5 . Key ( 53 ) moves from the top right corner to the bottom left corner. The key count per row is reversed. In this reversed orientation in FIG. 6 , two standard-sized keys ( 64 ), ( 65 ) replace the oversized key ( 53 ) of FIG. 5 , making the E to B key count 12, 13, 14, 15. Symmetrical groups of five columns ( 61 ), ( 62 ) can now be selected for the left and right hands. Key ( 64 ) becomes the shift key, and key ( 65 ) is included as a character key in the basic set.
[0068] The symmetrical columns of FIG. 6 can be used in a single mode keyboard for qwerty typists wishing to relieve their aching wrists with a minimum of retraining if columns ( 61 ), ( 62 ) have characters that maintain the qwerty relationship with each finger. Characters from a group ( 55 ) of five keys in FIG. 5 are re-assigned in FIG. 6 to five of the six central keys ( 63 ). The sixth key ( 66 ) can be eliminated so all the finger keys are in or next to the ten primary touch-typing columns, thus eliminating all the long sideways reaches. Skilled Dvorak typists can receive the same benefits.
[0069] Another embodiment has the alphabetical letter allocations seen in FIG. 19 , as original allocations or by switching software. This embodiment is then compatible with two major features of the new standard, i.e., ergonomically sound symmetrical columns, and user-friendly and efficient letter allocations.
[0070] Another application combines FIGS. 5 and 6 in the multi-mode reversible keyboard ( 71 ) shown in FIG. 7 . This is a luxury model with automatic self-selecting permanent dual labeling. A portion or segment ( 73 ) of the alpha-numeric section is easily removed. The segment can be turned 180.degree. and replaced in the reverse orientation, offering a choice of symmetrical or traditional columns. As shown in FIG. 7 , traditional columns ( 51 ), ( 52 ) from FIG. 5 are available for use, and the qwerty letters appear in row D. When the segment ( 73 ) is reversed, symmetrical sets of columns ( 62 ), ( 61 ) from FIG. 6 are ready to use, and letters ABC replace QWE in row D.
[0071] In the traditional mode, key ( 66 ) is used for the numeral seven in the middle of row E, so it cannot be eliminated in this embodiment and may be left unused in symmetrical mode. Similarly, one of the keys ( 64 ), ( 65 ) may be left unused in traditional mode, or both can have the same function as key ( 53 ).
[0072] If all the keys are similar, the removable segment is a simple rectangle that includes them all. Any special key, say, a locking shift, would be wrongly placed when the segment was reversed. In this case, the segment ( 73 ) has a gap at each end as shown. The removable segment has all of rows B, C, D and E, except for the left-hand key of row C and the right-hand key of row D. These keys are permanently mounted in the fixed portion of the keyboard. Each gap must fit round each fixed key according to the orientation in use, so the sizes must be matched. In FIG. 7 the right-hand key of row D has been increased in size to make both keys the same. End keys in the other rows are also extended to maintain the overall rectangular shape of the array.
[0073] FIG. 8 shows self-selecting dual labeling on a single keytop ( 81 ), with the letter K in the top left-hand corner, and an inverted D in the bottom right-hand corner. Other positions are possible. On reversal of the segment containing the key ( 81 ), D is the right way up at the top left, and K is inverted at the bottom right and easy to ignore. Makeshift temporary labels are eliminated.
[0074] FIG. 9A is an end view showing rows A, B, C, D and E with horizontal strike surfaces at different levels. When the segment ( 73 ) is reversed as shown in FIG. 9B , the strike surfaces of the keys are no longer horizontal, so such a profile is not suitable for reversing.
[0075] FIGS. 10 and 11 show end profiles with straight or constantly curved lines ( 100 ), ( 110 ) along the key strike surfaces. These lines could be symmetrical about an axis of reversal, so the profiles are suitable for reversing.
[0076] Reversibility can be applied at any level from factory to end user. Common stocks of parts for different models of fixed keyboard may save cost. Big companies may program one-time reversal of many keyboards. Individual pieces of equipment may undergo regular reversal by different users. Whether tools are required, or whether thumbscrews or spring latches are used to retain a segment in a keyboard, depends on the needs of the specific application.
[0077] On existing keyboards, irregular oversized keys are used to present a neat appearance. With a constant offset between rows, this is not necessary. FIG. 12 shows the same columns ( 61 ), ( 62 ) as FIG. 6 , but the oversized keys in the end columns ( 120 ) have been replaced by normal keys. This allows cost savings, and the trapezoidal style may be preferred, or fit better into portable equipment.
[0078] FIG. 6 or 12 can conform to the Standard. FIG. 13 maps FIG. 12 to the Standard row-and-column key position reference system, which allows columns at any angle. These are not the numbered columns of FIG. 19 , or the touch-typing columns in any figure. Examining FIG. 12 for meeting the Standard, one skilled in the art will find that it conforms in all respects except at locations marked with a large X. The spacebar must be extended leftward about two columns to at least partially occupy position A03. For symmetry, it can be extended equally to the right. The Standard also requires that a left-hand shift key at least partially occupies position B99. The shift key shown must be extended to the left into the adjacent column. For neat appearance and symmetry, other end keys may also be extended. In other respects the layout meets the requirements for the minimum number of keys per row, the columns they must occupy, etc. With no more than normal attention to detail, for example, extending keys as necessary and locating unrestricted functions where keys are available, the configuration provides a symmetrical keyboard conforming to the existing Standard.
[0079] FIG. 14 shows a simple, fixed, low-cost multi-mode configuration without the benefit of self-selecting, dual labeling. Typed characters can easily be checked on the screen and then erased, and if one mode has maximum resemblance to qwerty for typists with long experience, labels for that mode are superfluous anyway; single labeling is then all that is required. Other versions that need dual labeling can still use existing methods such as plastic overlays or color-coded labels.
[0080] In FIG. 6 oversized keys at each end of rows D and E waste space. In FIG. 14 each of those four keys has been replaced by two keys, thus providing four additional keys within an array of the same size. The key count per row is now 14, 15, 14, 15 going from row E to row B.
[0081] Symmetrical groups of columns ( 61 ), ( 62 ) can be selected. If the array was inverted (or if we started with FIG. 5 instead of FIG. 6 ) so the top to bottom key count was 15, 14, 15, 14 it would not be possible to select symmetrical columns and still have room for two shifts in row B.
[0082] To select parallel or asymmetrical groups of columns similar to groups ( 51 ), ( 52 ) in FIG. 5 , there are several possible choices. Adjacent groups can be selected identical to FIG. 5 , or moved in unison one key position either way; or the groups can be separated by one key or by two keys. The choice depends on the primary use. FIG. 14 provides maximum separation between the group ( 141 ) for the left hand and the group ( 62 ) for the right hand, while leaving the right-hand end key of row B available for the shift function. No similar extra key is needed in row E, so the group ( 141 ) can include the left-hand end key of the array in row E.
[0083] With suitable electronic switching of key functions, the keyboard user can select the preferred column arrangement, thus providing a very simple multi-mode keyboard on a fixed array of keys.
[0084] Adjacent groups of left and right-hand columns maximize qwerty compatibility. For typists with existing skill, separating groups ( 141 ) and ( 62 ) as shown in FIG. 14 has the disadvantage of displacing a character key from the left end of row E, and three more from beyond the right side of group ( 62 ). These keys are relocated between groups ( 141 ), ( 62 ). Since they were in poor locations to begin with, relocating them more conveniently between the index fingers is not much of a disadvantage.
[0085] With this particular choice of asymmetrical columns, left and right groups are separated by two keys. This separates the hands and reduces wrist strain while retaining the angle between rows and columns. The identical home row including any tactile indicators, and the same right hand portion, is used for both modes. The home keys are symmetrically disposed within the home row C, and are adjacent to the Return/Enter key for a shorter sideways reach. Labeling is simplified, particularly for asymmetrical qwerty/symmetrical qwerty combinations.
[0086] The FIG. 6 arrangement had one more key than the usual qwerty keyboards, and in FIG. 14 this is used as follows. In the mode using the asymmetrical left-hand columns ( 141 ), the adjacent key ( 65 ) in row B becomes the left-hand shift. The end key ( 64 ) duplicates the shift function. In the symmetrical mode, the two keys ( 145 ), ( 146 ) at the left end of row D are similarly used for the tab function. Duplicating keys in this manner allows the typist to find the function either from the end of the row, or if preferred, as the key adjacent to the little-finger home column.
[0087] Since four more keys have been added, there are enough to incorporate four cursor control or arrow keys, which are usually in a separate editing subset in an inverted “T” on two rows. Schmidt (U.S. Pat. No. 4,522,518) shows a central matrix of keys including arrow keys in a single column across four rows, or split for left and right hands in three rows. A cross formation on three rows with “up for up” and “down for down” is better, especially when readily accessible to the index fingers of either hand. Harbaugh shows such a cross in a keyboard having cursor arrow keys arranged on three rows within an alphanumeric section. However, Harbaugh's cross formation has an undesirable fifth key at the center. FIG. 14 shows arrow keys identified by triangles, in a group ( 144 ) that eliminates the undesirable fifth key from the symmetrical cross. This illustrates an improvement having a left arrow key immediately adjacent laterally to a right arrow key.
[0088] This embodiment uses the same cursor group in both modes, so it can have permanent labels.
[0089] If this cross determines the pattern of keys at the center of a keyboard, it provides a simple way to ensure compatibility between different keyboards without unduly restricting design freedom. Any sensible configuration built around it will have adjacent columns assigned to the index fingers that establish a constant and reasonable orientation of the hands with respect to the keyboard. At the same time, significant opportunity remains for variations for design improvement or preference outside the central zone. Non-identical, compatible keyboards are unknown in the prior art.
[0090] The column alignment can be fine tuned. FIG. 12 has all five columns parallel within each group ( 61 ), ( 62 ). It has gone almost as far as it can go under the Standard, but the bio-mechanical alignment is only a first approximation of what is wanted. FIG. 15 is similar, but takes advantage of permitted dimensional tolerances. The horizontal key spacing is increased to the maximum in row E, and reduced to the minimum in row B. Intermediate rows are adjusted to maintain straight columns. Going up the rows from B to E, this yields columns that spread out to the maximum extent allowed by the Standard.
[0091] In FIG. 16 key spacing is adjusted so rows B through E are the same length in a rectangular array. The spreading columns in each group ( 161 ), ( 162 ) closely match the natural movement of the respective fingertip. With respect to home row C, they all lean inwards towards the center of the array. Lichtenberg has spreading columns, but some lean outwards with respect to the home row, effectively sharing the qwerty left-hand misalignment between both hands instead of correcting it. This arrangement has about four degrees of inward lean for columns ( 165 L), ( 165 R) assigned to the little fingers. For the columns towards the center, the angle progressively increases. Variations are possible and a range of angles is acceptable.
[0092] Shown for the right hand only in group ( 162 ) is a possible variation for column ( 163 ). The two innermost columns ( 163 ), ( 164 ) are assigned to the index finger. The longest reach, from the home key to the upper key in column ( 163 ) row E, may be slightly reduced in a number of ways, and in FIG. 16 columns ( 163 ), ( 164 ) are shown parallel. They lean about 20.degree. away from vertical. If this feature is used for the right hand, it would also be used for the left hand for symmetry.
[0093] Using home row C for comparing keyboard sizes, if the key spacing in row C is normal, then this array is fourteen key-spaces long. Since row B of the same length contains fifteen keys, the key size may be reduced to maintain clearances. Using the same size keytops throughout the keyboard and maintaining substantially even spacing within any one row, the clearances are greater in row C than in row B, and greater still in row D which has only thirteen keys spread out over fourteen key spaces, etc.
[0094] For a general application, the column alignment of FIG. 16 has reached the useful limit of development. It will work very well in any application if 12, 13, 14 and 15 keys per row are simply distributed across the length of the keyboard.
[0095] FIG. 17 has only three rows of character keys, with an additional shift function to select numerals on the home row. For upward movements with row E eliminated the decision tree is simplified. Long stretches are eliminated and finger movements reduced to “one up or one down”. This also effectively perfects the column alignment since it is less critical with the maximum movement halved from two spaces to one. The keyboard becomes far more tolerant of bad posture and variations in hand shape and size. For multi-mode models a redundant row E can be retained. Numerals and symbols may then be typed traditionally on row E, or by using the new shift. The embodiment shown is arranged to maximize similarity to traditional keyboards. The backspace displaced from row E moves to key ( 177 ) of row D, displacing the characters from that key, but other keys in the end columns keep the same functions. Groups of columns ( 171 ), ( 172 ) are shortened versions of groups ( 161 ), ( 162 ) in FIG. 16 , and carry the same set of letters and punctuation marks. This basic set now contains thirty keys instead of forty.
[0096] Row A has a new symmetrical pair of thumb-operated shift keys ( 175 L), ( 175 R) either side of spacebar ( 176 ). This shift selects a new set of thirty characters. Numerals are selected in order from left to right on home row C. The traditional symbols are selected on row D above the associated numerals. Ten of the graphic characters displaced from positions outside the basic ten columns are selected on row B below the numerals. This includes all but four of the characters on present keyboards. The remaining four are assigned to a pair of keys ( 174 ) either side of center in row B; with the new second shift, these keys have spare capacity for two more characters.
[0097] The cursor control arrows are assigned to the remaining group of four central keys ( 173 ). They are mounted with their strike surfaces raised slightly above the level of the character keys to provide a tactile landmark that distinguishes them from the character keys and permits home row and home place to be found with the index fingers.
[0098] FIG. 18 optimizes keyboard operation for easy touch-typing, and establishes the basic layout of the proposed new standard keyboard. Columns ( 171 ), ( 172 ), and cursor keys ( 173 ), are the same as in FIG. 17 , and already in an excellent touch-typing configuration. The traditional spacebar is replaced by two ordinary keys ( 184 L), ( 184 R), symmetrically disposed in convenient home positions for the respective thumbs. Other keys and the keyboard organization are also changed.
[0099] All graphic characters, and only graphic characters, are assigned to the thirty keys in groups ( 171 ), ( 172 ). The traditional two shift levels each containing sets of forty-plus mixed characters are replaced by four natural sets of thirty characters each, giving adequate capacity in each set and in the 120-character total. The sets provided relate clearly to these natural divisions: small letters; capital letters; numerals; and symbols. The default set is small letters, and in English language versions includes four punctuation marks with the twenty-six letters of the alphabet, as is customary. Three independent shift functions each select a different character set. A Capitals shift function (Cap) changes small letters to capitals, but does not change the punctuation marks. Increased capacity allows duplication of punctuation in both sets. This is easier to learn and use, and eliminates the need for differences between shifted and shift-locked character sets. As early as 1917, Banaji (UK patent 116,538) had patented two identical punctuation marks per key. A Numerals shift function (Num) selects ordinary numerals in place of the letters on the home row C. If superscript and subscript numerals are available, these are respectively assigned above and below the home row in rows D and B. Thus an entire column of three keys is associated with each numeral. A Symbols shift function (Sym) selects a fourth character set including all the symbols on many present keyboards except the four punctuation marks assigned to the alpha sets. These twenty-eight symbols leave room on the keys for two more. If sufficient character codes are available, additional symbols like a middle dot for the decimal point can be provided. Otherwise some keys are not used in Sym shift mode, and the middle dot may replace, say, the double quote character.
[0100] The shift and shift-lock functions have identical character sets and are combined on one key. Each shift function operates normally by holding down the key while typing a character. The lock is engaged electronically by double-clicking the same key, i.e., two operations of the key within a pre-determined time interval that is preferably user-adjustable. The lock is disengaged by a single touch. This combines knowledge of results with the physical simplicity of one plain keyswitch, all without having to look. If in doubt about the shift status, the typist simply touches the key once, which always leaves the lock disengaged.
[0101] To permit choice according to preference, especially for disabled users, alternative methods can be provided where the release uses a half measure of the locking method. If the lock is engaged by four shift key presses with no intervening operations and no time limit, it is released by pressing the key twice. If it is engaged by holding down the shift for two seconds without any other key operations, it is disengaged by holding down the key for one second.
[0102] Each shift function (Cap, Sym, Num) can be locked independently of the other two, and remains engaged until the lock is released. When more than one shift function is engaged, the one most recently engaged takes precedence as the active set. This permits the shift-selection of individual characters from other sets while a predominant set remains locked in. For example, the Cap or Sym shifts can select occasional punctuation or mathematical symbols between long numbers while the Num shift remains locked in.
[0103] Traditionally difficult, two-handed, little-finger shift operations are replaced by much easier index-finger or thumb shifts using central shift keys, which also provide the option of either two-handed or one-handed shift-character combinations. Variations in shift key locations are possible. Those shown reinforce understanding of the underlying classifications and permit choice of method of operation. For easy operation by the index fingers, the Cap shift keys are either side of center in row B, assigned to a pair of keys ( 183 L), ( 183 R). Their strike surfaces are raised above the level of the keys in row A to distinguish them from the character keys and to permit easy thumb operation without inadvertently operating the keys in row A. Sym and Num shifts are thumb shifts adjacent to the thumb home keys. The Sym shift function is assigned to keys ( 185 L), ( 185 R) inboard of the space keys, more or less below the Cap shifts. The Num shift is on keys ( 186 L), ( 186 R) outside the space keys, similar to the new shifts of FIG. 17 . The thumb shift locations are also convenient for the index fingers, and readily identified by touch from the adjacent spaces. Thus, all the shifts can be operated by index finger or thumb with little movement from home place, and a typist may use whichever of these dominant digits is preferred for any shift in a two-handed operation. However, if a typist prefers to focus attention on only one hand, it is also easy to use the correct finger for a character key and the thumb of the same hand on any of the shifts in a simple one-hand chord, to avoid two-handed operations altogether.
[0104] The two unrelated functions of the Return/Enter key are separated. “Enter” is not a typing function and will be dealt with later. The term “space down” is more apt than “Carriage Return” for the remaining function. “Space down” is assigned to key ( 187 ) at the right end of row B. The “extended space” or invisible Tab character is symmetrically opposite, assigned to the key ( 188 ).
[0105] The Command function is assigned to keys ( 189 L), ( 189 R) at the top corners of the array. In an easy two-key combination for one hand or two, the dedicated Delete or Backward Erase key is replaced by “CommandSpace”, setting an appropriate Command-(character) precedent for a consistent method of issuing all keyboard commands. This completes all the basic typing functions.
[0106] FIG. 18 can be incorporated in a traditional style keyboard similar to FIG. 1 , with additional subsets of keys dedicated to particular kinds of functions, Some benefits would be wasted.
[0107] FIG. 19 shows the physical layout of the complete proposed new standard keyboard ( 191 ), where subsets of keys are unnecessary. It can be used with any letter allocations, the exemplary set shown being an alphabetical “reads-like-a-book” arrangement that combines user-friendliness and efficiency in a way emminently suited to beginners and experts alike. The arrangement is fully disclosed in U.S. Pat. No. 6,053,647 to the present Applicant, of which the description is hereby incorporated by reference. The particular punctuation marks suggested in FIG. 19 for the default small-letter mode are the period, comma, semi-colon and question mark. Other selections are possible but these and the locations shown are preferred for their frequent usage, and their compatibility with other modes of operation. In this array and others with only three rows of character keys, numerals are selected as alternative characters on the home row C. When used with an array having four rows of character keys, such as FIG. 6 , numerals are on row E as with present keyboards.
[0108] The new standard has only fifty keys to remember and reach. They are symmetrically arranged and can be all the same size. It incorporates the physical configuration of FIG. 18 , and extends easy touch-typing to full computer control, integrating everything into the alphanumeric section. This is achieved by rationalizing the logic and providing only two more functions, AO and MO, on keys duplicated for left and right hands in symmetrical pairs ( 192 L&R), ( 193 L&R) at either end of row A. They are separated from the groups of typing keys near the center of the row by spaces that provide additional tactile landmarks.
[0109] AO is an Application Override that allows standard key functions to be overridden in ways defined by the Application, similar to the Alternate or Option function on existing keyboards. Manual Override MO has no direct equivalent on existing keyboards, and, in conjunction with the application, serves two purposes. It provides a full set of “Manual Override-(graphic character)” key combinations that can be assigned functions defined by the user; and it provides MOuse emulation on the arrow keys.
[0110] Ten columns of graphic keys are numbered 1 through 0 with labels ( 194 ) above the columns. For touch-typing, columns 1 to 5 are assigned to the left hand and columns 6 to 0 to the right. The gap in the column of keys at each end of the keyboard readily identifies the shorter home row C visually or by touch. Home keys EFGH and RSTU are the outer four keys immediately adjacent to these gaps, so the home positions can be found easily without looking.
[0111] The central key in row B, and in row D, and the central pair of keys in row C, together form a group of four keys ( 173 ) in a cross formation. Those in row C are offset horizontally by one half of their center spacing from those in rows B and D. This determines the approximate angle of slope of the nearby columns 5 and 6 that are assigned to the index fingers, which in turn determines the orientation of the typist's hands with respect to the keyboard, which in turn ensures a certain degree of operational compatibility between this keyboard and others with the same or a similar feature. In this case, the cursor control functions are assigned to these four keys, and they are marked with triangular arrow heads showing the direction of movement. Together with the Cap shifts, the arrow keys form a triangular group ( 196 ) of six keys with higher strike surfaces than the other keys.
[0112] For consistency of operation and to avoid unnecessary keys, dedicated command keys, including separate subsets of F-keys, are eliminated and the Command-(Character) format is used for all keyboard commands. Although letters and symbols are generally more meaningful than numeric commands, if numeric commands are preferred up to thirty are now available within the character sets. However designated, all commands are on familiar typing keys and within easy reach of the home row. “Delete” becomes “Command-Space”. The “Escape” key is replaced by “Command-Period”. With the period character now assigned to the right index finger in the home row, it will be found easily even by a beginner. Another command worthy of standardization is “Command-?” for accessing “Help”. Unlike Standard keyboards, in FIG. 19 this is correctly designated in both upper and lower case, and like the period, the question mark is easy to find with the right index finger.
[0113] So that all commands activated from the keyboard use the same key, the Enter and Command functions are combined. Unless the application detects Command key activity, at least when a command is pre-selected on the screen, a separate Enter signal is needed. One way to combine these functions is by taking advantage of their naturally compatible timings, one key sending first an Enter signal, then switching electronically to Command mode. If no command is pre-selected on the screen, etc., the Enter signal is ignored. On a human time scale, Command mode is instantly available for a Command-(Character) combination, much faster than the operator can ensure that the keys are pressed in the right order. To avoid “Carriage Returns” when the Command key alone is pressed, the Enter function must have its own code. One could be re-assigned from a non-essential character; however, since the Enter signal need only go as far as the computer, it need not be limited to seven-bit codes. With Enter and Command combined on one key by any method, Command selection can still be made beforehand on the screen, or concurrently on the keyboard, but the same key is always used to activate the command.
[0114] The preferred functional hierarchy of the keyboard has four levels. In general, Level 1 (the lowest) performs basic functions. Level 2 changes the way the same function is performed. Level 3 changes to a different function. Level 4 allows functions to be redefined by an outside source. All functions above Level 1 are provided for both hands on symmetrical pairs of keys.
[0115] Only one function per level can be active at any one time. Higher levels can modify lower levels, but not the same level or higher. Level 1 keys cannot affect other keys (except to inhibit them to avoid mixed signals). Level 1 has an inactive resting state and 37 active states comprising thirty graphic characters, three invisible characters, and four cursor control arrows. Level 2 has four states: the default state plus three shift functions. Level 3 has two states: the default typing mode and a Command mode. Level 4 has three states: the default state with functions as defined above; and AO and MO states with unknown functions dependent on an outside source.
[0116] In accordance with this hierarchy, shift keys can increase cursor movements and the Command key can change the function. Movement through the document to read it, and mouse emulation, conveniently done with the same arrow keys, are higher level changes that may not involve the cursor at all.
[0117] Default cursor movements of one character and one line are primarily text-related, so shift changes are consistently text-related as follows. For horizontal arrows, cursor movements are respectively increased by the Cap, Sym, and Num shifts to: either end of a word; either end of a phrase; and either end of a sentence. For vertical arrows, movements are respectively increased to either end of a paragraph, section, or document. In conjunction with the Command key, the text through which the cursor passes is selected in readiness for a command to be applied to it.
[0118] Document format and window size is linked to the application rather than the text, and is appropriate to AO mode, which may be locked for continued use. Within the hierarchy, there is plenty of scope to page, scroll or move to any part of a document, with or without inserting “bookmarks”, etc. For example, if AO-Command-B inserts a “Bookmark” at, say, the top of an open page or window, then in the same AO mode the following is possible: the Up arrow pages up one window; Cap-Up by one document page; Sym-Up to the first bookmark encountered; and Num-Up pages up to the beginning of the document. Command-Space deletes any bookmark at the present position, and Command-Cap-Space deletes all bookmarks in the document.
[0119] For effective mouse emulation on the keys, with MO selected and possibly locked, arrows control the pointer instead of the cursor. The space key is the left mouse button, and where applicable, space down or return is the right button. The extended space or Tab key tabs through fields in the usual way. Each arrow key causes the pointer to creep across the screen in the direction indicated. Speed is set as fast as can be controlled without overshooting. Key combinations reduce travel time by making the pointer jump if it has far to move. Command-Up or Command-Down centers the pointer vertically, and Command-Left or Command-Right centers it horizontally. A Num-(Arrow) combination produces a jump to an outer position which is always ⅙ of the screen size in from the edge. Any point can then be reached with no more than one horizontal jump, one vertical jump, and ⅙ of the screen creeping distance, which is acceptably short even at low speeds. For refinement, horizontal movements are modified to upward diagonals by the Cap shift. The Sym shift, being below the Cap shift key, modifies horizontal movements to diagonally downwards.
[0120] An improved numeric keypad takes advantage of keys optimally arranged for natural finger movements, and maintains similarity to the standard numeric keypad. As shown in FIG. 19 , small characters may be added to the bottom corner of the keytops, perhaps in a distinctive color, for numerals reading left to right and bottom to top in a three-by-three array. With the primary operators in the next column to the right, these four columns are the home columns for the respective fingers, and zero is assigned to the home key ( 184 R) for the right thumb, providing a more natural hand position than a standard keypad. The decimal point is assigned to the home row key in the inner column for the index finger, close to home for efficient operation. Mathematical operators and the decimal point are on the corresponding Symbols keys and need no additional labeling. Thus learning and labeling are minimized for a right-hand keypad.
[0121] The Delete combination “Command-Space” is appropriate as “Command-Zero” for “Clear” when using the keypad; or the Command key alone can be assigned this function. When Enter is a separate function from Equals, it falls on the Space Down (Return) key. A similar keypad can be provided on the keys arranged for the left hand. In that case the keys used, but not necessarily the functions assigned to the keys, would be a mirror image of the right-hand array.
[0122] Thus with the cursor control keys conveniently located for index finger operation, improved shifts, and logical organization, the keyboard provides the capacity and flexibility for all the editing, navigating, command, control and keypad functions to be fully integrated. Redundant subsets of keys can be eliminated, and the alphanumeric section becomes the entire keyboard. The mouse is effectively emulated, and a keyboard on the knee becomes a fully self-contained work station.
[0123] On the keytops, labelling styles classify functions. A capital letter on the upper portion of a character key represents both the Cap shift set and the default set. This holds good for the punctuation marks, since they are the same in both modes. The lower character shows the symbol selected by the Sym shift. The “above and below” locations of the characters on the keytops correspond to the locations of the shift keys that select them. The numeric labels may apply to all three character keys in a column, so the columns are labeled instead of the individual keys.
[0124] Invisible characters, normally perceived only as cursor movement, are represented by filled triangles pointing the direction of movement produced. Thus the space keys in row A are each marked with a black triangle pointing right, and space down (return) has one pointing down. Since Tab is an extended space it has two triangles pointing right. Cursor keys also produce cursor movement, but they do not type any character at all. Consistent with their “empty” movements, their triangles are empty or hollow.
[0125] Shift key labels share a common lettering style and a three-letter abbreviation of the group they select, Cap, Sym, Num. Selection of Command mode is indicated by a ship's wheel emblem. Application Override and Manual Override share a distinctive style for their two-letter initials.
[0126] The arrangement of symbols on the keys must take account of typing convenience, logic, symmetry, commands, numeric keypad compatibility, memory aids, expectations and associations. That shown in FIG. 19 is the best compromise between these contradictory considerations. With four punctuation marks duplicated in each set of letters, the thirty-character set increases the total symbol capacity to thirty-four. Assuming that binary code availability is a limiting factor; that the underline character code is re-assigned as Enter to the Command key; and that the redundant double quote is replaced by a middle dot; then three keys are not used in Sym shift mode. Row B has mathematical symbols and these three unused keys, including a symmetrical pair for possible future use. If retained, the double quote symbol belongs on the only double letter, W, and the underLine character on the L key. The home row has mostly punctuation and commercial symbols, and includes middle dot and apostrophe on the index fingers for countries using those decimal-point conventions instead of the period or comma. If no code is available for the middle dot, the character defaults to another period. The top row D has levels of parentheses in symmetrical pairs for left and right hands.
INDUSTRIAL APPLICABILITY
[0127] The capability for exploitation in all keyboard applications is clear, and by making it possible to bring a simpler computer interface to the public, the inventive series extends the computer market to users who were previously excluded. Methods of use are similar to, and easier than, existing methods. Existing methods of keyboard manufacture are adequate for this invention, and will present no difficulty to a person skilled in the art. | Family or series of compatible keyboards for computers, etc., progressively modifies Standard, introducing new standard keyboard ( 191 ) with rationalized logic, everything integrated into alphanumeric section (FIG. 19 ). Existing skills are entrenched. Radical change is unworkable. Standardization prevents undirected piecemeal change. This invention ends deadlock, provides direction, enables change by: versatility, allowing partial change for any market niche; compatibility, allowing transfer of new skills to new standard; transitional models teaching such skills; multi-mode models for different operators; ultimate universal design optimized for adults, children, novices and experts. Keyboard ( 71 ) has reversible segment ( 73 ) selecting traditional or symmetrical columns (FIG. 7 ). Same feature on fixed keys (FIG. 14 ) integrates central cursor keys ( 144 ). Symmetrical keyboard conforms to existing Standard (FIG. 13 ). Top row eliminated by selecting numerals on home row (FIG. 17 ). Multiple shifts for index finger or thumb, allow one-handed or two-handed operation, and select natural character groupings (FIG. 18 ). | 6 |
Latin name of the genus and species claimed: Dianthus Caryophyllus.
Variety denomination: FLORIAMETRINE.
FIELD OF THE INVENTION
The present invention relates generally to the field of genetic modification of plants. More particularly, the present invention is directed to genetically-modified carnation plants expressing unique color phenotypes in selected parts of the plants.
BACKGROUND OF THE INVENTION
The flower or ornamental plant industry strives to develop new and different varieties of flowers and/or plants. An effective way to create such novel varieties is through the manipulation of flower color. Classical breeding techniques have been used with some success to produce a wide range of colors for almost all of the commercial varieties of flowers and/or plants available today. This approach has been limited, however, by the constraints of a particular species' gene pool and for this reason it is rare for a single species to have the full spectrum of colored varieties. For example, the development of novel colored varieties of plants or plant parts such as flowers, foliage and stems would offer a significant opportunity in both the cut flower and ornamental markets. In the flower or ornamental plant industry, the development of desired (including novel) colored varieties of carnation is of particular interest. This includes not only different colored flowers but also anthers and styles.
Flower color is predominantly due to three types of pigment: flavonoids, carotenoids and betalains. Of the three, the flavonoids are the most common and contribute a range of colors from yellow to red to blue. The flavonoid molecules that make the major contribution to flower color are the anthocyanins, which are glycosylated derivatives of cyanidin and its methylated derivative peonidin, delphinidin and its methylated derivatives petunidin and malvidin and pelargonidin. Anthocyanins are localized in the vacuole of the epidermal cells of petals or the vacuole of the sub epidermal cells of leaves.
The flavonoid pigments are secondary metabolites of the phenylpropanoid pathway. The biosynthetic pathway for the flavonoid pigments (flavonoid pathway) is well established, (Holton and Cornish, Plant Cell 7:1071-1083, 1995; Mol et al., Trends Plant Sci. 3:212-217, 1998; Winkel-Shirley, Plant Physiol. 126:485-493, 2001a; and Winkel-Shirley, Plant Physiol. 127:1399-1404, 2001b, Tanaka and Mason, In Plant Genetic Engineering, Singh and Jaiwal (eds.) SciTech Publishing Llc., USA, 1: 361-385, 2003, Tanaka et al., Plant Cell, Tissue and Organ Culture 80: 1-24, 2005, Tanaka and Brugliera, In Flowering and Its Manipulation, Annual Plant Reviews Ainsworth (ed.), Blackwell Publishing, UK, 20: 201-239, 2006). Three reactions and enzymes are involved in the conversion of phenylalanine to p-coumaroyl-CoA, one of the first key substrates in the flavonoid pathway. The enzymes are phenylalanine ammonia-lyase (PAL), cinnamate 4-hydroxylase (C4H) and 4-coumarate: CoA ligase (4CL). The first committed step in the pathway involves the condensation of three molecules of malonyl-CoA (provided by the action of acetyl CoA carboxylase (ACC) on acetyl CoA and CO 2 ) with one molecule of p-coumaroyl-CoA. This reaction is catalyzed by the enzyme chalcone synthase (CHS). The product of this reaction, 2′,4,4′,6′, tetrahydroxy-chalcone, is normally rapidly isomerized by the enzyme chalcone flavanone isomerase (CHI) to produce naringenin. Naringenin is subsequently hydroxylated at the 3 position of the central ring by flavanone 3-hydroxylase (F3H) to produce dihydrokaempferol (DHK).
The pattern of hydroxylation of the B-ring of DHK plays a key role in determining petal color. The B-ring can be hydroxylated at either the 3′, or both the 3′ and 5′ positions, to produce dihydroquercetin (DHQ) or dihydromyricetin (DHM), respectively. Two key enzymes involved in this part of the pathway are flavonoid 3′-hydroxylase (F3′H) and flavonoid 3′, 5′-hydroxylase (F3′5′H), both members of the cytochrome P450 class of enzymes.
The production of colored anthocyanins from the dihydroflavonols (DHK, DHQ, DHM), involves dihydroflavonol-4-reductase (DFR) leading to the production of the leucoanthocyanidins. The leucoanthocyanidins are subsequently converted to the anthocyanidins, pelargonidin, cyanidin and delphinidin. These flavonoid molecules are unstable under normal physiological conditions and glycosylation at the 3-position, through the action of glycosyltransferases, stabilizes the anthocyanidin molecule thus allowing accumulation of the anthocyanins.
The substrate specificity shown by DFR can regulate the anthocyanins that a plant accumulates. Petunia and cymbidium DFRs do not reduce DHK and thus they do not accumulate pelargonidin-based pigments (Forkmann and Ruhnau, Z Naturforsch C. 42c, 1146-1148, 1987, Johnson et al., Plant Journal, 19, 81-85, 1999). Many important floricultural species including iris, delphinium, cyclamen, gentian, cymbidium are presumed not to accumulate pelargonidin due to the substrate specificity of their endogenous DFRs (Tanaka and Brugliera, 2006, supra).
In carnation, the DFR enzyme is capable of metabolizing two dihydroflavonols to leucoanthocyanidins which are ultimately converted through to anthocyanins pigments that are responsible for flower color. DHK is converted to leucopelargonidin, the precursor to pelargonidin-based pigments, giving rise to apricot to brick-red colored carnations. DHQ is converted to leucocyanidin, the precursor to cyanidin-based pigments, producing pink to red carnations. Carnation DFR is also capable of converting DHM to leucodelphinidin (Forkmann and Ruhnau, 1987 supra), the precursor to delphinidin-based pigments. However, naturally occurring carnation lines do not contain a F3′5′H enzyme and therefore do not synthesize DHM.
Nucleotide sequences encoding F3′5′Hs have been cloned (see International Patent Application No. PCT/AU92/00334 incorporated herein by reference and Holton et al., Nature, 366:276-279, 1993 and International Patent Application No. PCT/AU03/01111 incorporated herein by reference). These sequences were efficient in modulating 3′, 5′ hydroxylation of flavonoids in petunia (see International Patent Application No. PCT/AU92/00334 and Holton et al., 1993 supra), tobacco (see International Patent Application No. PCT/AU92/00334), carnations (see International Patent Application No. PCT/AU96/00296 incorporated herein by reference) and roses (see International Patent Application No. PCT/AU03/01111).
Carnations are one of the most extensively grown cut flowers in the world.
There are thousands of current and past cut-flower varieties of cultivated carnation. These are divided into three general groups based on plant form, flower size and flower type. The three flower types are standards, sprays and midis. Most of the carnations sold fall into two main groups, the standards and the sprays. Standard carnations are intended for cultivation under conditions in which a single large flower is required per stem. Side shoots and buds are removed (a process called disbudding) to increase the size of the terminal flower. Sprays and/or miniatures are intended for cultivation to give a large number of smaller flowers per stem. Only the central flower is removed, allowing the laterals to form a ‘fan’ of flowers.
Spray carnation varieties are popular in the floral trade, as the multiple flower buds on a single stem are well suited to various types of flower arrangements and provide bulk to bouquets used in the mass market segment of the industry.
Standard and spray cultivars dominate the carnation cut-flower industry, with approximately equal numbers sold of each type in the USA. In Japan, spray-type varieties account for 70% of carnation flowers sold by volume, whilst in Europe spray-type carnations account for approximately 50% of carnation flowers traded through out the Dutch auctions. The Dutch auction trade is a good indication of consumption across Europe.
Whilst standard and midi-type carnations have been successfully manipulated genetically to introduce new colors (Tanaka and Brugliera, 2006, supra; see International Patent Application No. PCT/AU96/00296), this has not been applied to spray carnations. There is an absence of blue color in color-assortment in carnation, only recently filled through the introduction of genetically-modified standard-type carnation varieties. However, standard-type varieties cannot be used for certain purposes, such as bouquets and flower arrangements where a large number of smaller carnation flowers are needed, such as hand-held arrangements, and small table settings.
One particular spray carnation which is particularly commercially popular is the Kortina Chanel line of carnations ( Dianthus caryophyllus cv. Kortina Chanel). The variety has excellent growing characteristics and a moderate to good resistance to fungal pathogens such as Fusarium. There are a number of varieties which have been released as “sports” of Kortina Chanel. These include Kortina, Royal Red Kortina, Cerise Kortina and Dusty Kortina. However, before the advent of the present invention, purple/blue spray carnations were not available.
SUMMARY OF THE INVENTION
The following traits represent the characteristics of the new Dianthus cultivar ‘FLORIAMETRINE’. These traits distinguish this cultivar from other commercial varieties. ‘FLORIAMETRINE’ may exhibit phenotypic differences with variations in environmental, climatic and cultural conditions, without any variance in genotype.
1. Dianthus ‘FLORIAMETRINE’ exhibits pronounced spray habit. 2. Dianthus ‘FLORIAMETRINE’ blooms profusely. 3. Dianthus ‘FLORIAMETRINE’ exhibits bright purple/violet flowers (RHS N78A). 4. Dianthus ‘FLORIAMETRINE’ exhibits green (RHS 137A) foliage. 5. At maturity, the height of the foliage mound of Dianthus ‘FLORIAMETRINE’ is 89 cm. The mature width about 15 to 18 cm. 6. Dianthus ‘FLORIAMETRINE’ is a perennial. 7. Dianthus ‘FLORIAMETRINE’ is suitable for use as a flowering plant in pots, containers, window boxes and the garden, but is primarily suited for the production of cut flowers. 8. Dianthus ‘FLORIAMETRINE’ is not hardy and is grown in a greenhouse.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying color drawing illustrates the overall appearance of the new variety Dianthus ‘FLORIAMETRINE’ showing colors as true as reasonably possible to obtain in colored reproductions of this type. Colors in the drawing may differ from the color values cited in the detailed botanical description, which accurately describe the actual colors of the new variety ‘FLORIAMETRINE’.
FIG. 1 is a photographic representation of the flower. Colors may appear different from the actual colors due to light reflection but are as accurate as possible by conventional photography.
FIG. 2 is a diagrammatic representation of the binary plasmid pCGP2442. Selected restriction endonuclease sites (AscI, PacI, PmeI) are marked. Abbreviations include LB=Left Border from A. tumefaciens Ti plasmid; RB=Right Border region from A. tumefaciens Ti plasmid; TetR=tetracycline resistance gene complex.
FIG. 3 is a photographic representation of a high resolution scan of a Southern blot autoradiograph showing 10 μg of EcoRI-treated genomic DNA from the transgenic carnation line 19907, in comparison to 10 μg of EcoRI-treated genomic DNA from the carnation lines Kortina Chanel, Vega and Purple Spectro, hybridized with the NtALS probe.
FIG. 4 is a photographic representation of the ‘Kortina Chanel’ control on the left and the cultivar ‘FLORIAMETRINE’ on the right.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to a new and distinct cultivar of carnation that is grown for use as a flowering plant for pots and containers. The new cultivar is known botanically as Dianthus caryophyllus and is referred to hereinafter by the cultivar name ‘FLORIAMETRINE’.
‘FLORIAMETRINE’ is a complex transgenic plant comprising genetic sequences encoding at least two F3′5′H molecules and at least one DFR. The vector pCGP2442 used to transform meristematic cells contains a chimeric AmCHS 5′: Salivia F3′5′H#47: petD8 3′ gene in tandem with a petunia genomic DFR-A gene, a chimeric carnANS 5′: BPF3′5′H#18: carnANS 3′ gene and the 35S 5′: SuRB selectable marker gene cassette of the plasmid pWTT2132.
The new variety originated in vitro by Agrobacterium tumefaciens -mediated transformation of meristematic cells of the Kortina Chanel (unpatented) carnation with the pCGP2442 vector at Florigene Pty Ltd., in Bundoora, Victoria, Australia. Cuttings of Dianthus caryophyllus cv. Kortina Chanel were obtained from Van Wyk and Son Flower Supply, Victoria or Propagation Australia, Queensland, Australia. Transgenic plants containing the chimeric AmCHS 5′: SaliviaF3′5′H#47: petD8 3′ gene in tandem with a petunia genomic DFR-A gene, and a chimeric carnANS 5′: BPF3′5′H#18: carnANS 3′ gene were successfully generated from the cells. In addition to these genes, the plants also contains genes for acetolactate synthase resistance (SuRB) transformation selection markers. The transformation and regeneration process is described in International Patent Application No. PCT/US92/02612; International Patent Application No. PCT/AU96/00296; and Lu et al., Bio/Technology 9: 864-868, 1991, the contents of each of which are incorporated by reference.
The primary focus of the carnation generation program was to produce new cultivars of carnations which exhibited a selected and desired purple/violet color in the spray background. The term ‘FLORIAMETRINE’ was selected because of its pronounced production of delphinidin or delphinidin-based molecules pigments.
The new variety was selected from a group of 74 transgenic lines of which only three produced flowers with a significant shift in color into the violet, purple/violet range. ‘FLORIAMETRINE’ is essentially similar to the parent in the morphological aspects of the flower, but can be further distinguished from the parent throughout the accumulation of pigment in the filaments and anthers of the flower. This is a new phenotype of the transgenic line. Some styles and anthers of ‘FLORIAMETRINE’ also have a shift in color to light purple, whereas the styles and anthers from flowers of the parent line were a cream-white color.
The new variety was originally selected in vitro as a regenerated shoot from a ‘Kortina Chanel’ carnation meristematic cell that had been transfected with Agrobacterium tumefaciens AGL0 (Lazo et al., Bio/technology 9:963-967, 1991) carrying the plasmid pCGP2442.
Asexual reproduction of the new cultivar was first accomplished in 2007 in a cultivated area of Bundoora, Victoria, Australia. The method of asexual propagation used was vegetative cuttings. Since that time the characteristics of the new cultivar have been determined stable and are reproduced true to type in successive generation of asexual reproduction.
BOTANICAL DESCRIPTION OF THE PLANT
The following is a detailed description of the new cultivar ‘FLORIAMETRINE’. Data was collected from plants grown indoors in Bundoora, Victoria, Australia. The color determinations are in accordance with the 2001 edition of The Royal Horticultural Society (R.H.S.) Colour Chart except where general color terms of ordinary dictionary significance are used. Growing conditions are typical to other species, sports and lines of Dianthus.
Botanical classification: Dianthus caryophyllus. Species: Caryophyllus. Common name: Kortina Chanel. Commercial classification: Dianthus caryophyllus 19907. Type: Perennial. Use: Used as a flowering plant for pots and containers. Parentage: ‘FLORIAMETRINE’ is a transgenic plant that resulted from the transformation of D. caryophyllus with the transformation vector, pCGP2442.
TABLE 1
Plant Description
Bloom period
All year
Plant habit
Spray type carnation
Plant height
Average plant height at flowering—
891 mm
Plant width
About 150 to 180 mm at flowering
Plant hardiness
Not tested for hardiness
Root system
Fine fibrous root system
Propagation
Vegetative propagation
Cultural requirements
Grown hydroponically in a
greenhouse. Plants fertilized via
drip irrigation system
Pests and diseases
Susceptible to known Dianthus pest
and diseases
Time and Temperature needed to
About 3 to 4 weeks to produce
produce a rooted cutting
rooted cuttings, bench heat: 18-22°
C., Air temp approximately 15 to
22° C.
Crop time
Average days to flowering: 107.
Stem shape
Cylindrical, Average stem length
782 mm, Average stem diameter at
5th node: 6 mm
Stem surface
Glabrous and glaucous
Stem color
137B
Branching
Little branching from the axils of
lower leaves
Internode length
Average length of 5th internode:
73 mm
Node color
192D
Node dimensions
About 6 mm diameter and about 3
mm in length
Foliage
Type
Evergreen
Shape
Linear
Division
Simple
Apex
Acute
Base
Decurrent
Venation
Not prominent
Margins
Entire
Attachment
Sheathing
Arrangement
Opposite and spiraling up stem
Surfaces
Glaucous
Leaf dimensions
3rd leaf from flower, Average
length: 40.5 mm, Average width: 7
mm
Leaf color
137A
Fragrance
Absent
Flowers
Inflorescence
Cymose
Flower type
Saliform, double and symmetrical
Flower dimensions
Average corolla height: 22.5 mm,
(including calyx)
Average calyx height: 32.5 mm
Fragrance
Absent
Bud color
191B
Anthocyanin
Present
Bud dimensions
Average bud length: 26.4 mm,
Average bud width: 9 mm
Bud shape
Cylindrical
Petals
Persistent, apopetalous, overlapping
Petal number
Average number of petals: 27
Petal margin
Denate
Petal shape
Obtetoid
Petal surface
Glabrous
Petal dimensions
Average petal length: 47 mm,
Average petal width: 22 mm
Ground color of blade
N78A
Color of band around centre
N78A
Color of middle of strap
145C
Color of base of strap
145D
Calyx dimensions
Average calyx length: 32.5 mm,
Average calyx diameter at apex:
14.5 mm
Calyx color
138B
Anthocyanin
Absent
Sepals
Average number of sepals: 6
Fused or Unfused
Unfused
Sepal color
138B
Anthocyanin
Absent
Peduncle dimensions
Average peduncle length: 33.6 mm,
Average peduncle width: 2 mm
Peduncle color
138A
Peduncle surface
Glaucous
Epicalyx
Present
Bracts
1 pair in number (2 individual
bracts)
Bracts dimensions
About 3 mm by about 20 mm
Bract color
138A
Anthacyanin
Absent
Bracteoles
1 or 2 pair
Dimensions
About 3 mm by about 25 mm
Anthocyanin
Absent
Stipules
Absent
Stipules dimensions
N/A
Stipule color
N/A
Anthacyanin
N/A
Lastiness of flowers
14 days
Reproductive Organs
Stamens
Average number of stamens: 10
Stamen dimensions
Average length of stamen: 21.5 mm
Stamen color
Upper: N80C, Lower: N155B
Anther number
Average of normal anthers: 2,
Average of abnormal anthers: 6
Anther attachment
Dorsifixed
Anther color
N80C
Anther dimensions
Average anther length: 1.84 mm,
Average anther width: 0.68 mm
Pollen
Little pollen
Pistil
One that divides into 2 above the
ovary
Pistil dimensions
Average pistil length: 34 mm
Styles
Average No: 2, Average length: 26
mm
Style color
N155B
Stigma number
Single
Stigma shape
A single stigma
Stigma color
N155B
Height above petals
Stigma does not protrude above
petals
Ovary postion
Superior
Ovary dimensions
Average ovary height: 8 mm,
Average ovary width: 5.5 mm
Ovary shape
Obovoid
Ovary color
Upper: 145A, Lower: 155A
Seed
Absent
TABLE 2
Floriametrine
Kortina Chanel control
Description
Bloom period
All year
All year
Plant habit
Spray type carnation
Spray type carnation
Plant height
Average plant height at
Average plant height at
flowering —895 mm
flowering —853 mm
Plant width
150 to 180 mm at
150 to 180 mm at
flowering
flowering
Plant hardiness
Not tested for hardiness
Not tested for hardiness
Root system
Fine fibrous root system
Fine fibrous root system
Propagation
Vegetative propagation
Vegetative propagation
Cultural
Grown hydroponically
Grown hydroponically in
requirements
in a greenhouse. Plants
a greenhouse. Plants
fertilized via drip
fertilized via drip
irrigation system
irrigation system
Pests and diseases
Susceptible to known
Susceptible to known
Dianthus pest and
Dianthus pest and
diseases
diseases
Time and
3 to 4 weeks to produce
3 to 4 weeks to produce
Temperature
rooted cuttings, bench
rooted cuttings, bench
needed to
heat: 18-22° C., Air
heat: 18-22° C., Air temp
produce a
temp approx. 15 to
approx. 15 to 22° C.
rooted cutting
22° C.
Crop time
Average days to
Average days to
flowering: 107.
flowering: 108
Stem shape
Cylindrical, Ave stem
Cylindrical, Ave stem
length 782 mm, Ave
length 713 mm, Ave.
stem diameter at 5 th
stem diameter at 5 th node:
node: 6 mm
6.7 mm
Stem surface
Glabrous and glaucous
Glabrous and glaucous
Stem color
137B
137B
Branching
Little branching from
Little branching from the
the axils of lower leaves
axils of lower leaves
Internode length
Average length of 5 th
Average length of 5 th
internode: 73 mm
internode: 73 mm
Node color
192D
192D
Node dimensions
6 mm diameter and
6 mm diameter and 3 mm
3 mm in length
in length.
Foliage
Type
Evergreen
Evergreen
Shape
Linear
Linear
Division
simple
simple
Apex
Acute
Acute
Base
Decurrent
Decurrent
Venation
Not prominent
Not prominent
Margins
Entire
Entire
Attachment
Sheathing
Sheathing
Arrangement
Opposite and spiraling up
Opposite and spiraling
stem
up stem
Surfaces
Glaucous
Glaucous
Leaf dimensions
3 rd leaf from flower, Ave
3 rd leaf from flower, Ave
length: 40.5 mm, Ave
length: 39 mm, Ave
width: 7 mm
width: 8 mm
Leaf color
137A
137A
Fragrance
Absent
Absent
Flowers
Inflorescence
Cymose
Cymose
Flower type
Saliform, double and
Saliform, double and
symmetrical
symmetrical
Flower dimensions
Ave. corolla height:
Ave corolla height:
including
22.5 mm, Ave calyx
23.5 mm, Ave. calyx
calyx)
height: 32.5
height: 31.5 mm
Fragrance
Absent
Absent
Bud color
191B
191B
Anthocyanin
Present
Present
Bud dimensions
Ave bud length:
Ave bud length: 24.9 mm,
26.4 mm, Ave bud
Ave bud width: 9.9 mm
width: 9 mm
Bud shape
Cylindrical
Cylindrical
Petals
Persistent, apopetalous,
Persistent, apopetalous,
overlapping
overlapping
Petal number
Ave number of petals:
Ave number of petals: 32
27
Petal margin
Denate
Denate
Petal shape
Obtetoid
Obtetoid
Petal surface
Glabrous
Glabrous
Petal dimensions
Ave petal length:
Ave petal length: 47 mm,
47 mm, Ave petal
Ave petal width: 22 mm
width: 22 mm
Ground color
N78A
65A
of blade
Color of band
N78A
65A
around centre
Color of middle
145C
145C
of strap
Color of base
145D
145D
of strap
Calyx dimensions
Ave calyx length:
Ave calyx length: 31.5 mm,
32.5 mm, Ave calyx
Ave calyx diameter at
diameter at apex:
apex: 14.9 mm
14.5 mm
Calyx color
138B
138B
Anthocyanin
Absent
Absent
Sepals
Ave number of sepals:
Ave number of sepals:
6
5.4
Fused or Unfused
Unfused
Unfused
Sepal color
138B
138B
Anthocyanin
absent
absent
Peduncle
Ave peduncle length:
Ave peduncle length:
dimensions
33.6 mm, Ave peduncle
45.2 mm, Ave peduncle
width: 2 mm
width: 2.4
Peduncle color
138A
138A
Peduncle surface
Glaucous
Glaucous
Epicalyx
Present
Present
Bracts
1 pair in number (2
1 pair in number (2
individual bracts)
individual bracts)
Bracts dimensions
3 mm × 20 mm
3 mm × 20 mm
Bract color
138A
138A
Anthacyanin
absent
absent
Bracteoles
1 or 2 pair
1 or 2 pair
Dimensions
3 mm × 25 mm
3 mm × 25 mm
Anthocyanin
Absent
Absent
The Dianthus ‘FLORIAMETRINE’ is now described by the following non-limiting Examples.
EXAMPLE 1
GENERATION OF DIANTHUS ‘FLORIAMETRINE’
In order to increase the levels of delphinidin-based anthocyanins and therefore increase the chance of violet/purple/blue color in the Kortina Chanel spray carnation flowers, a novel construct was prepared that included the use of two F3′5′H chimeric genes and a petunia DFR gene.
The DFR genomic fragments used in this application were isolated from petunia. The petunia DFR enzyme is only capable of using DHQ and DHM as a substrate, but not DHK (Holton and Cornish, 1995 supra). This ensures that most or all of the anthocyanidin produced is delphinidin.
The F3′5′H coding sequences in the chimeric genes used in the new construct were from pansy (carnANS 5′: BP F3′5′H #18: carnANS 3′ in pCGP2205) and salvia (AmCHS 5′: Salvia F3′5′H #47: petD8 3′ in pCGP2122) as these represent the two expression cassettes that were the most efficient in producing the highest levels of delphinidin in the Kortina Chanel spray carnation.
Preparation of the Transformation Vector, pCGP2442
The transformation vector pCGP2442 ( FIG. 2 ) contains a chimeric AmCHS: Salvia F3′5′H#47: petD8 3′ gene in tandem with a petunia genomic DFR-A gene, a chimeric carnANS 5′: BPF3′5′H#18: carnANS 3′ gene and the 35S 5′: SuRB selectable marker gene cassette of the plasmid pWTT2132 (see International Patent Application No. PCT/AU03/01111 incorporated herein by reference).
Agrobacterium tumefaciens Strains and Transformations
The disarmed Agrobacterium tumefaciens strain used was AGL0 (Lazo et al., 1991 supra).
Plasmid DNA was introduced into the Agrobacterium tumefaciens strain AGL0 by adding 5 μg of plasmid DNA to 100 μL of competent AGL0 cells prepared by inoculating a 50 mL LB culture (Sambrook et al., Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratories, Cold Spring Harbor, N.Y., USA, 1989) and incubation for 16 hrs with shaking at 28° C. The cells were then pelleted and resuspended in 0.5 mL of 85% (v/v) 100 mM CaCl 2 /15% (v/v) glycerol. The DNA- Agrobacterium mixture was frozen by incubation in liquid N 2 for 2 minutes and then allowed to thaw by incubation at 37° C. for 5 minutes. The DNA/bacterial mix was then placed on ice for a further 10 minutes. The cells were then mixed with 1 mL of LB (Sambrook et al., 1989 supra) media and incubated with shaking for 16 hrs at 28° C. Cells of A. tumefaciens carrying the plasmid were selected on LB agar plates containing appropriate antibiotics such as 50 μg/mL tetracycline or 100 μg/mL gentamycin. The confirmation of the plasmid in A. tumefaciens was done by restriction endonuclease mapping of DNA isolated from the antibiotic-resistant transformants.
Plant transformations were as described in International Patent Application No. PCT/US92/02612 or International Patent Application No. PCT/AU96/00296 or Lu et al., Bio/Technology 9: 864-868, 1991 each incorporated herein by reference.
Cuttings of Dianthus caryophyllus cv. Kortina Chanel were obtained from Van Wyk and Son Flower Supply, Victoria or Propagation Australia, Queensland, Australia.
EXAMPLE 2
DETECTION OF THE SURB CHIMERIC GENE FROM THE TRANSFORMATION VECTOR PGP2442 IN DIANTHUS ‘FLORAMETRINE’ PLANTS
In order to determine stable transformation of Dianthus caryophyllus with the T-DNA from the transformation vector pCGP2442, transgenic plants were analyzed by Southern blot. The results are shown in FIG. 3 .
Preparation of Genomic DNA and Southern Analysis
Genomic DNA was isolated from leaf tissues as described by Dellaporta et al., Molecular Biology Reporter 1(14):19-21, 1983. The genomic DNA (10 μg) was digested for 48 hours using 120 units of the restriction endonuclease EcoRI at 37° C. DNA fragments were separated by electrophoresis through a 0.8% w/v agarose gel. The DNA was transferred to Hybond NX membrane (Amersham) as described (Sambrook et al., 1989 supra).
The following samples were analyzed:
1. HindIII-treated λDNA standard markers (size range: 23.13, 9.42, 6.56, 4.36, 2.32, 2.03 kb), 2. 10 μg of EcoRI-treated genomic DNA from transgenic carnation line 19907 (FLORIAMETRINE), 3. 10 μg of EcoRI-treated genomic DNA from non-transgenic carnation parental line, Kortina Chanel, 4. 10 μg of EcoRI-treated genomic DNA from non-transgenic carnation line, Vega; and 5. 10 μg of EcoRI-treated genomic DNA from non-transgenic carnation line, Purple Spectro.
Following electrophoresis, the gel was prepared for blotting by a 15 minute depurination step in 0.25 M HCl, two 20 minute washes in denaturing solution (1.5 M NaCl, 0.5 M NaOH) and two 20 minute washes in neutralization solution (0.5 M Tri-HCl, pH 7.5, 0.48 M HCl, 1.5 M NaCl). DNA was capillary transferred to Hybond-NX nylon membrane (Amersham Biosciences, UK) in 20×SSC (3 M NaCl, 0.3 M Tris-Na citrate, pH 7.0).
Preparation of Probes
A probe corresponding to a 770 bp fragment of the ALS (acetolactate synthase) gene from Nicotiana tabacum (NtALS) was used for Southern blot analysis. The probe fragment was originally generated by PCR and subsequently sub-cloned into an amplification vector (pBluescript II, Stratagene, USA), given a reference number (pCGP1651) and the fragment sequenced. After confirmation of the correct sequence, the DNA fragment was isolated from the source plasmid using the restriction endonuclease HindIII. The fragment was separated by 1% w/v agarose gel electrophoresis and purified using the MinElute Gel Extraction kit and protocol (Qiagen, Australia).
32P-Labeling of DNA Probes
DNA fragments (25-50 ng) were labeled with 50 μCi of [α-32P]-dCTP (PerkinElmer Life and Analytical Sciences, USA) using a Decaprime kit (Ambion, USA). Unincorporated [α- 32 P]-dCTP was removed by chromatography on Sephadex G-50 (Fine) columns. The labeled probe fragment was counted using a BioScan radioisotope counter (QC:4000 XER, BioScan, USA).
Hybridization and Detection
Membranes were pre-hybridized in 10 mL hybridization buffer 50% v/v deionized formamide, 1 M NaCl, 1% w/v SDS and 10% w/v dextran sulfate) at 42° C. for 1 hr. Once denatured, 10,000,000 dpm of 32 P -labeled probe was added to the hybridization solution and hybridization was continued at 42° C. for a further 16 hours. Membranes were washed twice in low stringency buffer (2×SSC, 1% w/v SDS) at 65° C. for 30 minutes. Membranes were exposed to Kodax BioMax MS X-Ray film (Kodak, USA) with an intensifying screen at −70° C. for 16 hours. The exposed films were automatically developed using a Curix 60 X-ray developer (AGFR-Gevaert Group, Belgium). | A new cultivar of Dianthus plant named ‘FLORIAMETRINE’ is characterized inter alia by altered inflorescence with respect to tissue and/or organelles including flowers or flower parts. This trait sets ‘FLORIAMETRINE’ apart from all other existing varieties, lines, strains or sports of Dianthus. In particular, Dianthus ‘FLORIAMETRINE’ has bright purple/violet flowers. | 2 |
[0001] This application is a continuation-in-part of divisional application Ser. No. 11/774,560 filed on Jul. 7, 2007 which claims the benefit of and is a divisional application of Ser. No. 10/9805039, filed on Dec. 13, 2004, now U.S. Pat. No. 7,255,789 filed in the name of the same inventor.
BACKGROUND OF THE INVENTION
[0002] Presently, the quality of the global pure drinking water supply is decreasing at a faster rate than the population is expanding. The United Nations International children's Educational Foundation (UNICEF) estimates that 20,000 to 30,000 children die every day from waterborne diseases such as typhoid, malaria, e-coli, cholera and many other contaminants. These contaminants can also include such things as salts, halogens, organic solvents, pesticides, fertilizers, industrial chemicals, bacteria, protozoa, fungi and other foreign matters.
[0003] The extensive use of fertilizers and pesticides by farmers, runoffs from major animal husbandry sites, contamination spills by industries, the dumping of raw sewage into our lakes and streams and the significant number of landfill sites have caused many contaminants to percolate down through the soil and into the underlying water tables throughout the world. The result is that today many more wells and springs are now testing positive for a wide array of toxins and contaminants harmful to human, animal and plant health.
[0004] In many areas of the world, and in the United States of America, public water supply systems are monitored for diseases and toxins on a regular basis to assure the public that the water is safe to drink. However, cases are still reported in the U.S. of contaminated water supply systems. Furthermore the majority of the water piping and distribution systems in the U.S., and internationally, are many decades old and as the water passes from a main purification site to an end user, the water can pickup additional contaminants and toxins from the aging water distribution systems.
[0005] There have been a variety of attempts to provide purified water at a user or business' point of entry and/or point of use site. One such device is known as the Britta. It is a single stage filter utilizing the laws of gravity and a carbon block held in a container. Water is poured into a top holding container and gravity slowly draws the water through the carbon block to a lower container for consumption. Carbon does reduce some toxic chemicals and gases from water however it does not purify the water. This device is also greatly limited by the capacity of water that it can produce in a 24-hour period. It most certainly would not produce enough filtered water to supply a family of four with enough drinking and cooking water for an entire day.
[0006] There are other products available that provide two stage filtering devices consisting of a carbon block filtration and a paper filter surrounding or in line with the carbon block. However, these systems do not address the issue of microorganisms in the water, which can bypass the filtration systems.
[0007] Yet another product available to consumers is a device called the Pur water filter. This system utilizes a small and low wattage ultraviolet (UV) lamp and a carbon block filter. The UV light is known to kill microorganisms in the air and in water. Unfortunately, the UV lamp deteriorates over time to the point that it cannot produce the necessary wavelength to kill microorganisms in the water. Furthermore, the system does not provide a means to know when the UV lamp has deteriorated. As such, the end user may think that the device is adequately killing microorganisms when in fact the UV lamp has become useless as a biocide. The use of a laser for producing UV light for treating water has also been described by Goudy in U.S. Pat. No. 4,661,264
[0008] Another additional means of purifying water has been the use of what is known as KDF 85 and/or KDF 55 as a biocide and is described by Heskett in U.S. Pat. No. 5,951,869. This process utilizes a compound that is basically copper and zinc that creates and ion exchange and chelating (clumping together) producing properties in the water. This material is primarily used in large municipal water treating systems however there have been some attempts to have the KDF 85 or KDF 55 material impregnated onto a paper filter for point of use water treatment systems with limited success.
[0009] While all of the above presented means provide some degree for improving the water supply, none of them fully purify the water in an economical and efficient manner. As such, a technical need still exists to purify water, air or other fluids quickly, efficiently, over a long-term use and do so economically.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will be better understood by reading the detailed description of the preferred embodiments of the invention along with a review of the drawings, in which:
[0011] FIG. 1 is an overall view of the various components of the invention;
[0012] FIG. 2 is a planer view of the first and second photolytic light chambers used in the embodiment of FIG. 1 ;
[0013] FIG. 3 is a perspective view of an alternative assembled photolytic light chamber; and
[0014] FIG. 4 is an exploded view of the alternative photolytic light chamber.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Reference will now be made in detail to the description of the invention as illustrated in the drawings. Although the preferred embodiments of the invention will be described in connection with these drawings, there is no intent to limit the invention to the embodiment or embodiments disclosed therein. On the contrary, the intent is to include all alternatives, modifications and equivalents included within the spirit and scope of the invention as defined by the appended claims.
[0016] Furthermore, the order of the itemized steps in FIG. 1 are not meant to limit the scope of the invention to the specific itemized order of those steps, but rather to include those steps in any relevant order including any alternatives, modifications and equivalents included within the spirit and scope of the invention as defined by the appended claims.
[0017] To aid in the understanding of the invention, examples of some of the specific itemized steps are provided for clarification purposes only. In particular, some of the examples use water for the liquid being purified, however, these examples are not meant to limit the invention to only water, but rather to include any alternative, modification and equivalents included within the spirit and scope of the invention as defined by the appended claims.
[0018] The present invention provides a method and apparatus for treating water or other liquid to assure that the water or liquid is of a high degree of purity. The origin of the water or liquid can be from any source such as municipal water supply systems, independent well systems, tanker truck or rail car, a lake, a river, desalinized sea water, collected rail water or other like source.
[0019] FIG. 1 depicts an overall view of the liquid treating apparatus 1 without the cover for the apparatus. The liquid treating apparatus 1 contains a base 2 to which elements of the liquid treating apparatus are connected. The base 2 is constructed with a plurality of mounting holes 3 such that the liquid treating apparatus can be mounted to a wall (not shown) or a frame (not shown). Other equally effective mounting systems are well known in the art.
[0020] The water or other liquid (not shown) flows from a pressurized source (not shown) through the inlet pipe 4 through a pressure regulator 5 through a first transfer pipe 6 and then through a flow indicator 7 . The pressure regulator 5 assures that the liquid is maintained at or below a predetermined pressure setting for optimal operating efficiency of the liquid treating apparatus 1 . The flow meter 7 is connected 8 to the laser light source generator 9 such that the laser light source generator 9 only generates a laser light (not shown) in the ultraviolet range when the flow indicator 7 indicates that liquid is flowing through the liquid treating apparatus 1 . As the liquid exits the flow indicator the liquid travels through a second transfer pipe 10 to the first stage of the liquid treatment apparatus 1 .
[0021] The first stage of the liquid treatment apparatus 1 is the primary collective filtration unit 11 . The primary collective filtration unit 11 contains a 5.0 micron filter whose primary purpose is to prevent any chemical, particulate matter or other media 5.0 microns or larger from traveling any further than this stage in the liquid treating apparatus 1 .
[0022] The liquid then exits the primary collective filtration unit 11 and travels through a third transfer pipe 12 to the second stage of the liquid treatment apparatus 1 . The second stage of the liquid treatment apparatus 1 is a molecular reaction unit 13 , called the Hydro-Media Reaction Chamber that functions as an effective biocide.
[0023] The liquid then exits the molecular reaction unit 13 and flows through a fourth transfer pipe 14 to the third stage of the liquid treatment apparatus 1 . The third stage of liquid treatment apparatus is a first photolytic laser chamber 15 in which the liquid is subjected to ultraviolet light in the 100 to 300 nanometer range produced by a laser light source generator 9 and received by a laser light receiver 16 . This process acts as a biocide by altering the contaminants so that they can be filtered out later and removes volatile organic compounds. The ultraviolet light destroys organic compounds by breaking the covalent bonds in the chemical thereby forming free radicals which react with water and break down into harmless substances. Details of the first and second photolytic light chambers 15 and 22 are shown later in FIG. 2 .
[0024] The liquid then exits the first photolytic laser chamber 15 through a fifth transfer pipe 17 and enters a secondary collective filtration unit 18 . The secondary collective filtration unit 18 utilizes a 0.5 micron filter which traps or collects all of the destroyed microorganisms that were affected by the first photolytic laser chamber 15 and any particulate matter or other media that is 0.5 microns in size or larger.
[0025] The liquid then exits the secondary collective filtration unit 18 and travels through a sixth transfer pipe 19 to a carbon filtration unit 20 . The carbon filtration unit 20 utilizes a pharmaceutical grade granular activated carbon filter. This unit removes odors, chlorine, benzenes and other aromatic ring structures, pesticides and many other volatile organic hydrocarbons that may be found in various combinations in water and/or other liquids. The granular configuration of the activated carbon provides an effective method for maintaining a desired liquid flow rate with maximum beneficial results in eliminating the aforementioned odors and compounds.
[0026] The liquid then exits the carbon filtration unit 20 through a seventh transfer pipe 21 and enters a second photolytic laser chamber 22 . The second photolytic laser chamber 22 also operates in the 100 to 300 nanometer range. This second photolytic laser chamber 22 is the final stage in the liquid treatment apparatus 1 and assures that the liquid and/or water leaving the unit is free from microorganisms by subjecting the liquid or water to a second ultraviolet light process identical to the first photolytic laser chamber 15 . This provides additional protection to overcome any effects of colonization or of filtration failure. The water or other liquid then exits the unit through an eighth transfer pipe 23 .
[0027] The eighth transfer pipe 23 is then connected to a pressure gage 24 which is in turn connected to the out going liquid supply line 25 . The pressure gage 24 is color coded in red, yellow and green zones. When the pressure gage 24 indicates that the liquid pressure in the liquid treatment apparatus 1 is in the green zone, the filters do not have to be replaced. When the pressure gage 24 indicates that the liquid pressure is in the yellow zone, it is time to prepare for changing the filters or to change the filters. When the pressure gage 24 indicates that the liquid pressure is in the red zone, the filters should be replaced.
[0028] FIG. 2 depicts the preferred embodiment of the design of the first and second photolytic light chambers 15 and 22 . On one end of the second photolytic light chamber 22 is the laser light source generator 9 and on one end of the first photolytic light chamber 15 is the laser light receiver 16 . In between the generator 9 and the receiver 16 is a continuous hollow quartz tube 51 through which the laser light (not shown) travels in operation. A first tube 52 surrounds a first portion of the quartz tube 51 and is sealed around the quartz tube at both ends of the tube 53 and 54 . There is a space 55 through which the liquid will pass around the quartz tube 51 when the unit is in operation. This creates the first photolytic light chamber 15 . A second tube 56 surrounds a second portion of the quartz tube 51 and is sealed 57 and 58 at both ends of the tube 56 around the quartz tube 51 . There is a space 59 between the quartz tube 51 and the tube 56 through which the liquid will pass around the quartz tube 51 . The spaces 55 and 59 are the chambers through which the liquid passes and becomes exposed to the ultraviolet laser light (not shown) which is generated by the laser light generator 9 and received by the laser light receiver 16 .
[0029] In the first and second photolytic light chambers 15 and 22 , as the liquid flows under pressure as indicated by the flow meter 7 attached to the first transfer pipe 6 , the flow meter 6 sends a signal through the connection 8 to the laser light generator 9 which activates the laser light. A laser light, in the 100 to 300 nanometer range, travels through the inside of the quartz tube 51 to the laser light receiver 16 . As the liquid flows through the spaces 55 and 59 in the photolytic light chambers 15 and 22 , the liquid is exposed to the laser light in the 100 to 300 nanometer range. This range of light is known to act as an effective biocide and to reduce metallic salts by altering contaminants into harmless components which can be filtered out later. The light also destroys organic compounds by forming free radicals from the compounds which then react with water to break down into harmless substances.
[0030] When the liquid or water stops flowing as indicated by the flow meter 7 , the laser light generator 9 shuts off the laser light source so that the laser light source 9 and the power consumption is only used when there is liquid flowing through the system. In addition, the laser light generator 9 can be set to operate in a specific range such as 185 or 254 nanometers, or is can be set to oscillate or switch between two or more nanometer ranges for optimum performance. Some of the more obvious advantages to this design is the use of a single source of light for a creating a multitude of exposures and the ability to target a range of ultraviolet light on the liquid to be treated as opposed to a single wavelength. In addition, an ultraviolet light produced by a laser light source will not degenerate over time as does an ultraviolet lamp thus providing a long and economical useful life of the unit.
[0031] In an alternative embodiment to the photolytic light chambers 15 and 22 , there is only a short piece of quartz rod 51 or other lens like material that connects the end of the first photolytic light chamber 15 to the end of the second photolytic light chamber 22 and allows for the passing of the laser light in the 100 to 300 nanometer range, without inhibiting the laser light spectrum, from the first photolytic light chamber 15 to the second photolytic light chamber 22 . Usage of a lens or other device attached between the two photolytic chambers allows transfer of the laser beam through both chambers simultaneously and also denies crossover contamination of the liquid. Thus, instead of the liquid being exposed to the ultraviolet light radiating outward from the quartz tube 51 , the liquid is exposed directly to the ultraviolet laser light inside of the photolytic light chambers 15 and 22 . In addition, the lens or a thin piece of the rod 51 could be placed in front of the laser light generator 9 and in front of the laser light receiver 16 which would prevent any direct conductive connection between the liquid and the laser light generator 9 and/or the laser light receiver 16 . In another alternate embodiment, the inside of the first and second tubes 52 and 56 can be modified for the desired reflective capabilities allowing for greater exposure of the liquid to the desired ultraviolet light range thereby achieving a more through biocide coverage of the liquid. In a further embodiment, the first photolytic light chamber 15 can be placed in a horizontal position and the second photolytic light chamber 22 placed in a vertical position with a reflective material used to bend the laser light from a horizontal position to a vertical position.
[0032] In a further embodiment to the photolytic light chamber 15 as depicted in FIGS. 3 and 4 , the top portion of the photolytic light chamber 15 is removed or cut away 70 . On top of this opening is placed a sealing gasket 71 and a flat lens 72 made of the same material as the prior rod or tube. On top of the lens 72 is placed an ultraviolet light bulb housing 73 . The top of the light bulb housing 73 incorporates heat sink cooling fins 74 . There are access caps 75 and 76 at both ends of the light bulb housing 73 . One end cap 75 allows for the ultraviolet bulb socket ends. These end caps 75 and 76 allow for the replacement of the ultraviolet light bulb without draining the system of liquid as the bulb is effectively separated from the liquid while the ultraviolet light is allowed to penetrate the liquid through the lens 72 .
[0033] One end of the photolytic light chamber 15 has a removable end cap (not shown) which allows for the periodic cleaning of the lens 72 if contamination of the lens 72 should occur. The photolytic light chamber 15 also has liquid input 14 and liquid output 17 openings strategically placed on the bottom of the photolytic light chamber directly facing the flat lens 72 . This positioning, combined with the inner shape of the photolytic light chamber 15 that is partially rounded and partially flat, causes liquid flowing through the photolytic light chamber 15 to flow in a turbulent manner. The turbulent flow of the liquid aids in keeping the liquid side of the flat lens 72 free from contamination. As is known in the art, contamination of any lens between the ultraviolet light source and the liquid significantly compromises the effectiveness of the ultraviolet light's interaction with contaminants in the liquid as the contamination reduces or eliminates the ultraviolet wavelength and strength.
[0034] Additionally, an ultraviolet light bulb's effectiveness during the purification process is directly related to the temperature in which the ultraviolet light is operating. Maximum effectiveness for ultraviolet light transmission is in the range of 94 degrees Fahrenheit to 114 degrees Fahrenheit. The optimal temperature for ultraviolet light to act as a biocide is in the 103 to 105 degree Fahrenheit range. A level of ultraviolet transmission outside of the 94 to 114 degree Fahrenheit temperature range substantially reduces the effective dosage of ultraviolet light emissions needed for the destruction of microorganisms and metallic salts. In addition, the separation of the light bulb from the liquid by the flat lens 72 prevents condensate from accumulating in the bulb which is known to cause premature shorting of the bulb.
[0035] As depicted in FIGS. 3 and 4 , a preferred embodiment of the bulb housing includes heat sinks 74 on the top side of the bulb housing 73 to dissipate excess heat thereby assuring that the optimum heat range of 94 degrees Fahrenheit to 114 degrees fahrenheit is maintained. The screws 76 are utilized to assemble the bulb housing 73 , the flat lens 72 and gasket to the photolytic light chamber 15 . | An apparatus and means for separating an ultraviolet light source from a liquid and for controlling the temperature of the ultraviolet light source to its optimal temperature range for modifying contaminants in a liquid. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to a phosphor element including a phosphor inorganic material and a display device using the phosphor element.
BACKGROUND ART
[0002] There is a display device using an electro luminescent (hereinafter referred to as EL) element, as a display device in a flat panel display which has been focused on together with a liquid crystal panel, a plasma display and the like. The EL element includes an inorganic EL element using an inorganic compound as a light emitter and an organic EL element using an organic compound as the light emitter. The EL element has high-speed response, high contrast, vibration resistance and the like. Since the EL element has no gas in itself, it can be used under high or low pressure.
[0003] According to the EL element, although certain gradient can be implemented by driving in an active matrix method using a thin film transistor (TFT) because its driving voltage is low, the element is easily influenced by moisture and the like, so that it has a short life. In addition, the inorganic EL element is characterized in that it has a long life, a wide operating temperature range and excellent decay durability as compared with the organic EL element. Meanwhile, since a voltage required to emit light in the inorganic EL element is as high as 200V to 300V in general, it is difficult to drive it in the active matrix method using the thin film transistor (TFT). Therefore, the inorganic EL element has been driven by a passive matrix method.
[0004] According to the passive matrix driving, a plurality of scan electrodes extending parallel to a first direction and a plurality data electrodes extending parallel to a second direction which is perpendicular to the first direction are provided, a phosphor element is sandwiched between the scan electrode and the data electrode which intersect with each other, and one phosphor element is driven when an AC voltage is applied between the pair of scan electrode and data electrode. Since average luminance becomes low as a whole of the display device as the number of the scanning lines is increased in the passive matrix driving, it is necessary to improve the luminance as the phosphor element. In addition, the inorganic light emitter is provided by doping a phosphor material in an insulator crystal in general and it emits light when UV light is irradiated, but even when an electric field is applied, electrons are not likely to be spread and reaction against charging is strong, so that a high-energy electron is needed to emit light. Therefore, it is necessary to take measures to emit light with low-energy electrons.
[0005] According to the technique described in Japanese Patent Publication No. 54-8080, Mn, Cr, Tb, Eu, Tm, Yb or the like is doped in a phosphor layer including ZnS mainly to drive (flash) an inorganic EL element, so that emission luminance can be improved, but since it can be driven at high voltage of 200V to 300V only, the TFT cannot be used.
[0006] In addition, Japanese Patent Laid-open Publication No. 8-307011 discloses a phosphor element using silicon fine particles. According to the phosphor element, since a size of the silicon fine particle is very small such as 50 nm, a quantum effect is generated and a band gap width becomes a visible light region. Thus, the light is emitted in the visible light region.
SUMMARY OF THE INVENTION
[0007] When the phosphor element is used as a high-quality display device in a television and the like, it is necessary to drive the phosphor element at a low voltage so that the TFT can be used.
[0008] It is an object of the present invention to provide a phosphor element which can be driven at a low voltage and can use a thin film transistor.
[0009] A phosphor element according to the present invention includes a pair of electrodes opposed to each other, a phosphor layer sandwiched between the pair of electrodes and having silicon fine particles whose average particle diameter is not more than 100 nm. Then, at least a part of a surface of the silicon fine particle is covered with a conductive material.
[0010] When an external electric field is applied to the phosphor layer and electrons are spread in silicon fine particles, silicon emits light by a quantum effect. In this case, the inventor of the present invention found that when a surface of the silicon fine particle having a particle diameter of 100 nm or less was covered with a conductive material, the electrons could be easily spread in the silicon fine particles and light was emitted at a low voltage.
[0011] Each component of the phosphor element according to the present invention will be described.
[0012] The phosphor element may be fixed onto a substrate. The substrate is formed of a material having high electric insulation. When light of the phosphor element is emitted from the substrate side, the substrate is formed of a material having high optical transparency in a visible region. When a temperature of the substrate reaches several hundred of ° C. at a manufacturing step of the phosphor element, a material which has a high softening point, excellent heat resistance and thermal expansion coefficient which is almost the same as that of a laminated layer is to be used. Although glass, ceramics, a silicon wafer may be used in such substrate, non-alkali glass may be used so that alkali ion and the like contained in normal glass may not affect the phosphor element. In addition, alumina and the like may be coated on a glass surface as an ion barrier layer of alkali ion for the phosphor element.
[0013] The electrode is formed of a material in which an electric conduction property is high and there is no migration of ion by the electric field. For example, aluminum, molybdenum, tungsten may be used for the electrode. Since the electrode of the phosphor element on the phosphor side may be formed of a material having high transparency in the visible region in addition to the above performance, an electrode mainly formed of tin doped indium oxide (ITO) and the like can be used for the above electrode. In addition, when both of the pair of electrodes are transparent electrodes, both-side phosphor element can be provided. Furthermore, the phosphor element and the display device according to the present invention may be driven by a DC current, an AC current or a pulse.
[0014] For the conductive material, conductive inorganic material which is transparent in the visible region can be used. It is preferable that the conductive material includes an oxide or a composite oxide containing at least one element selected from a group of indium, tin, zinc, and gallium. The oxide material may include Ga 2 O 3 , GaInO 3 , In 2 O 3 , SnO 2 , In 4 Sn 3 O 12 , ZnO, CdIn 2 O 4 , Cd 2 SnO 2 , Zn 2 SnO 4 , MgIn 2 O 4 , ZnGa 2 O 4 , CdGa 2 O 4 , CaGa 2 O 4 , AgInO 2 , InGaMgO 4 , InGaZnO 4 , and the like. In addition, as another example, it is preferable that the conductive material includes a nitride (for example, titanium nitride) or a composite nitride containing at least one element selected from a group of titanium, zirconium, hafnium, gallium, and aluminum. As still another example, a thin film of metal such as gold, silver, platinum, copper, rhodium, palladium, aluminum, chrome and the like or an alloy containing mainly the above (magnesium silver alloy, for example) may be used. In addition, the silicon fine particles having the conductive material on at least one part of its surface may be dispersed in a transparent conductor matrix material. The transparent conductor matrix material preferably includes polyacetylene series; polyphenylene series such as polyparaphenylene, polyphenylenevinylene, poliphenylenesulfide, polyphenyleneoxide; heterocyclic polymer series such as polypyrrole, polythiophene, polyfurane, polyselenophene, polytellurophene; ionic polymer series such as polyaniline; polyacene series; polyester series; metal phthalocyanine series, these derivative, copolymer and mixture, and the like. As a more preferable example, there are poly-N-vinylcarbozole (PVK), polyethylenedioxythiophene (PEDOT), polystyrenesulfonate (PPS), polymethylphenylsilane (PMPS) and the like. Furthermore, a polymer having electron transport property which will be described in detail below may be used. Still furthermore, its electro conductivity may be adjusted by dispersing low-molecular organic material having the electron transport property, or conductive or semi-conductive inorganic material, in the conductive or semi-conductive polymer.
[0015] An electron transport layer formed of the material including the electron transport property may be formed between the electrode and the phosphor layer. The material including the electron transport property is a material having high electron mobility, which can promptly transport electrons in the electron transport layer. In a case of the organic material, a material mainly including aluminum quinolinate or oxadiazole derivative may be used, and in a case of the inorganic material, a single-crystalline body, polycrystalline body of an n-type semiconductor material and a resin diffused layer and the like of its particle powder can be used.
[0016] An electron hole transport layer formed of a material having electron hole transport property may be formed between the electrode and the phosphor layer. The electron hole transport layer may be provided between the electrode serving as a positive electrode and the phosphor layer. The material having the electron hole transport property is a material having high electron hole mobility, which promptly transports the electron hole in the electron hole transport layer, and a material mainly including polyvinyl carbozole series or polyphenylenevinylene series may be used.
[0017] A constitution of the phosphor element according to the present invention will be described.
[0018] As shown in FIG. 1 , the phosphor element includes a phosphor layer containing silicon fine particles having at least one part of the surface covered with the conductive material as the light emitter, between the pair of electrodes opposed to each other. That is, the phosphor element has a fundamental constitution in which the phosphor layer is sandwiched between the pair of electrodes and each electrode is connected to a power supply. In addition, the electrode may be formed on the substrate. Furthermore, the silicon fine particles having a surface covered with the conductive material may be dispersed in the transparent conductor matrix. In addition, the electron transport layer may be provided between the electrode and the phosphor layer. Furthermore, an electron injection layer may be provided between the electron transport layer and the electrode. In addition, the electron hole transport layer may be provided between the electrode serving as the positive electrode and the phosphor layer. Still furthermore, the electron hole injection layer may be provided between the electron hole transport layer and the positive electrode. Since the phosphor element is driven at the low voltage, when the thin film transistor (TFT) is provided in the structure, the display can implement active matrix driving at the low voltage.
[0019] Next, a condition to provide sufficient emission efficiency in the phosphor element will be discussed. The phosphor element is driven when the external electric field is applied to the electrode of the phosphor element, and the electrons are transported to the light emitter in the phosphor layer by the applied external electric field. Since the silicon fine particles having a size of 100 nm or less are provided in the center of the light emitter, when the electrons are spread in the center of the light emitter, silicon is excited by the quantum effect to emit light. Since the surface of the silicon fine particle is covered with the conductive material, the electrons are easily spread in the silicon fine particles of the center.
[0020] Here, the silicon fine particles are excited by transmitted electron energy, and then, the silicon fine particle emits light when it is changed from excited state to ground state. That is, as the particle diameter of the silicon fine particle becomes small, the quantum effect is more provided to enlarge the band gap. Thus, although the silicon fine particle having a particle diameter 100 nm or less emits light in a visible light region, as the particle diameter becomes small, its surface area is increased and the particles become unstable. Therefore, it is necessary to cover the silicon fine particle surface in order to keep the small particle diameter stably. In this case, it is preferable that the surface of the silicon fine particle is covered with the conductive material. Thus, energy can be effectively transmitted to the silicon atoms in the silicon fine particles.
[0021] In addition, when the electron transport layer is provided on the phosphor layer, the electrons can be effectively transmitted to the silicon fine particle. Furthermore, when the phosphor layer is sandwiched between the two electron transport layers formed of the material having the electron transport property, since the material serves as an electron hole stopper also, the transmitted electrons are not connected to the electron hole again, and the electrons can be effectively transmitted to the silicon fine particles.
[0022] According to the phosphor element of the present invention, at least one part of the surface of the silicon fine particle is covered with the conductive material, and the silicon fine particles are used as the light emitters. Thus, light can be emitted in the visible light region by the quantum effect and it can be chemically stabled. In addition, the phosphor element can be driven at the low voltage and the light can be emitted with high efficiency by the silicon fine particles.
BRIEF DESCRIPTION OF DRAWINGS
[0023] These objects and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings:
[0024] FIG. 1 is a sectional view showing a constitution of a phosphor element according to a first embodiment of the present invention;
[0025] FIG. 2 is a sectional view showing a constitution of a phosphor element according to an eighth embodiment of the present invention;
[0026] FIG. 3 is a perspective view showing an electrode constitution of a phosphor element according to a ninth embodiment of the present invention;
[0027] FIG. 4 is a schematic plain view showing a display device according to a tenth embodiment of the present invention;
[0028] FIG. 5 is a sectional view showing another constitution of a phosphor element according to a fourth embodiment of the present invention; and
[0029] FIG. 6 is a sectional view showing another constitution of a phosphor element according to an eighth embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Although a phosphor element according to embodiments of the present invention will be described in detail with reference to the accompanying drawings hereinafter, the present invention is not limited to the embodiments. In addition, the same reference numerals are allotted to substantially the same components in the drawings.
First Embodiment
[0031] A phosphor element according to a first embodiment of the present invention will be described with reference to FIG. 1 . FIG. 1 is a schematic view showing an element structure of the phosphor element 10 . The phosphor element 10 has a phosphor layer 3 sandwiched between two first and second electrodes 2 and 4 . According to a laminated relation of each layer, a transparent board 1 is provided as a substrate, and the first electrode 2 , the phosphor layer 3 and the second electrode 4 are laminated in this order thereon in the phosphor element 10 . In addition, light is emitted from the side of the transparent board 1 .
[0032] In addition, in the phosphor element 10 , although a luminescent color emitted from the phosphor element is determined by silicon fine particles which constitute the phosphor layer 3 , a color conversion layer may be provided ahead of the phosphor direction of the phosphor layer 3 or a color conversion material may be mixed in a transparent conductor matrix in order to display multiple colors, or white color or to adjust color purity of each color and the like. Since the color conversion layer and the color conversion material may only have to emit light as an excitation source, it may be an organic material or an inorganic material, so that a well-known fluorescent material, a pigment, a dye and the like can be used. For example, when the color conversion layer which emits light in complementary color to that of the light from the phosphor layer 3 is provided, a surface light source which emits white light can be provided.
[0033] The luminescent characteristics of the phosphor element 10 will be described. Extracting electrodes from the ITO transparent electrode (first electrode) 2 and the Ag electrode (second electrode) 4 , then, applying an external voltage between the ITO transparent electrode 2 and the Ag electrode 4 causes the phosphor element 10 to be emitted. In addition, according to the phosphor element in the first embodiment, a silicon fine particle surface having a particle diameter of 10 to 30 nm is covered with a titanium nitride film having a thickness of 10 to 30 nm. Next, a manufacturing method of the phosphor element 10 will be described. The phosphor element was manufactured according to the following procedures.
(a) A non-alkali glass substrate was used as the substrate 1 . A thickness of the substrate 1 was 1.7 mm. (b) The ITO transparent electrode 2 was formed on the substrate 1 using an ITO oxide target as the first electrode 2 by a RF magnetron sputtering method. (c) The phosphor layer 3 in which the silicon fine particle 5 was covered with a conductive material 6 was formed on the ITO transparent electrode 2 by an evaporation method. (d) The Ag electrode paste was screen-printed on the phosphor element 3 as the second electrode 4 and dried to form the second electrode 4 .
[0038] According to the above steps, the phosphor element 10 was formed.
[0039] When the first electrode 2 and the second electrode 4 of the phosphor element 10 were connected to a positive electrode and a negative electrode of a DC power supply 7 , respectively and a DC voltage was applied to them, bright emission at 4.5V was confirmed. Since the phosphor element 10 can be driven at a low voltage, a pixel can be controlled by the TFT
Second Embodiment
[0040] A phosphor element according to a second embodiment of the present invention will be described. This phosphor element is the same as the phosphor element 10 according to the first embodiment other than that a particle diameter of a silicon fine particle 5 is different. The particle diameter of the silicon fine particle 5 was 5 to 20 nm.
[0041] When a first electrode 2 and a second electrode 4 of the phosphor element according to the second embodiment were connected to a positive electrode and a negative electrode of a DC power supply 7 , respectively and a DC voltage was applied to them, bright emission at 3.6V was confirmed. Since the phosphor element according to the second embodiment can be driven at a low voltage, a pixel can be controlled by the TFT.
Third Embodiment
[0042] A phosphor element according to a third embodiment of the present invention will be described. This phosphor element is the same as the phosphor element 10 according to the first embodiment other than that a particle diameter of a silicon fine particle 5 is different. The particle diameter of the silicon fine particle 5 was 70 to 100 nm. When a first electrode 2 and a second electrode 4 of the phosphor element according to the third embodiment were connected to a positive electrode and a negative electrode of a DC power supply 7 , respectively and a DC voltage was applied to them, bright emission at 22V was confirmed. Since the phosphor element according to the third embodiment can be driven at a low voltage, a pixel can be controlled by the TFT
Fourth Embodiment
[0043] A phosphor element according to a fourth embodiment of the present invention will be described. This phosphor element is the same as the phosphor element 10 according to the first embodiment other than that a conductive material 6 is a magnesium silver alloy. A molecule ratio of magnesium and silver was 10:1 and a film thickness was 5 to 50 nm. When a first electrode 2 and a second electrode 4 of the phosphor element according to the fourth embodiment were connected to a positive electrode and a negative electrode of a DC power supply 7 , respectively and a DC voltage was applied to them, bright emission at 3.1V was confirmed. Since the phosphor element according to the fourth embodiment can be driven at a low voltage, a pixel can be controlled by the TFT.
[0044] In addition, when a metal material is used instead of a semiconductor material as the conductive material which covers the silicon fine particles, it is preferable that not entire surface of the silicon fine particle but only a part of thereof is covered with the conductive material. In this case, as shown in FIG. 5 , the phosphor layer 3 may be constituted by diffusing such silicon fine particles 15 in which a part of the surface is covered with a conductive material 16 formed of the metal material in a transparent conductor matrix 17 formed of a semiconductor material.
Fifth Embodiment
[0045] A phosphor element according to a fifth embodiment of the present invention will be described. This phosphor element is the same as the phosphor element according to the fourth embodiment other than that a particle diameter of a silicon fine particle 5 is different. The particle diameter of the silicon fine particle 5 was 70 to 100 nm. When a first electrode 2 and a second electrode 4 of the phosphor element according to the fifth embodiment were connected to a positive electrode and a negative electrode of a DC power supply 7 , respectively and a DC voltage was applied to them, bright emission at 19V was confirmed. Since the phosphor element according to the fifth embodiment can be driven at a low voltage, a pixel can be controlled by the TFT.
Sixth Embodiment
[0046] A phosphor element according to a sixth embodiment of the present invention will be described. This phosphor element is the same as the phosphor element according to the third embodiment other than that a conductive material 6 is mainly formed of Ga 2 0 3 . A particle diameter of a silicon fine particle 5 was 70 to 100 nm. When a first electrode 2 and a second electrode 4 of the phosphor element according to the sixth embodiment were connected to a positive electrode and a negative electrode of a DC power supply 7 , respectively and a DC voltage was applied to them, bright emission at 21V was confirmed. Since the phosphor element according to the sixth embodiment can be driven at a low voltage, a pixel can be controlled by the TFT
Seventh Embodiment
[0047] A phosphor element according to an seventh embodiment of the present invention will be described. This phosphor element is the same as the phosphor element according to the sixth embodiment other than that a conductive material 6 is mainly formed of In 4 Sn 3 O 12 . A particle diameter of a silicon fine particle 5 was 70 to 100 nm. When a first electrode 2 and a second electrode 4 of the phosphor element according to the seventh embodiment were connected to a positive electrode and a negative electrode of a DC power supply 7 , respectively and a DC voltage was applied to them, bright emission at 16V was confirmed. Since the phosphor element according to the seventh embodiment can be driven at a low voltage, a pixel can be controlled by the TFT.
[0048] In addition, in the phosphor element according to the second embodiment to seventh embodiment, although a luminescent color is determined by silicon fine particles 5 which constitute the phosphor layer 3 , a color conversion layer may be provided ahead of the phosphor direction of the phosphor layer 3 or a color conversion material may be mixed in the transparent conductor matrix in order to display multiple colors, or a white color or to adjust color purity of each color similar to the first embodiment.
Eighth Embodiment
[0049] A phosphor element according to an eighth embodiment of the present invention will be described with reference to FIG. 2 . FIG. 2 is a sectional view showing a constitution of a phosphor element 20 . The phosphor element 20 is different from that in the first embodiment to seventh embodiment in that a first electron transport layer 8 is provided between a phosphor layer 3 and a first electrode 2 , and a second electron transport layer 9 is provided between the phosphor layer 3 and a second electrode 4 . Electrons can flow into the phosphor layer 3 well because of these electron transport layers 8 and 9 . In addition, when the first electrode 2 and the second electrode 4 of the phosphor element according to the eighth embodiment are connected to a positive electrode and a negative electrode of a DC power supply 7 , respectively, the first electron transport layer 8 provided on the side of the first electrode 2 functions as an electron hole stopper layer. As a material constituting the electron transport layers 8 and 9 , there are two main types of an organic material such as a low-molecular material and a high-molecular material.
[0050] The low-molecular material including an electron transport property includes an oxadiazole derivative, a triazole derivative, a styrylbenzene derivative, a silole derivative, 1,10-phenanthroline derivative, a quinolinol series metal complex, a thiophene derivative, a fluorene derivative, a quinone derivative, and the like or their dimer or trimer. More preferably, although the following material may be used, the present invention is not limited to these, that is, 2-(4-biphenyl)-5-(4-tert-butylphenyl)-1,3,4-oxadiazole (PBD); 2,5-biss(1-naphtyl)-1,3,4-oxadiazole (BND); 2,5-bis[1-(3-methoxy)-phenyl]-1,3,4-oxadiazole (BMD); 1,3,5-tris[5-(4-tert-butylphenyl)-1,3,4-oxadiazole-2-yl]benzene (TPOB); 3-(4-biphenyl)-4-phenyl-5-(4-tert-butylphenyl)-1,2,4-triazole (TAZ); 3-(4-biphenyl)-4-(4-ethylphenyl)-5-(4-tert-butylphenyl)-1,2,4-triazole(p-EtTAZ); 4,7-diphenyl-1,10-phenanthroline (BPhen); 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (BCP); 3,5-dimethl-3′,5′-di-tert-butyl-4,4′-diphenoquinone (MBDQ); 2,5-bis[2-(5-tert-butylbenzoxazolyl)]-thiophene (BBOT); trynitrofluorenone (TNF); tris(8-quinolinolato) aluminum (Alq3); and 5,5′-bis(dimesitylboryl)-2,2′bithiophene (BMB-2T) and the like.
[0051] In addition, the high-molecular material including the electron transport property includes poly-[2-methoxy-5-(2-etyhlhexyloxy)-1,4-(1-cyanovinylene) phenylene] (CN-PPV), polyquinoxaline, and a low-molecule polymer and the like incorporating a molecular structure which shows the electron transport property, in a molecular chain. Furthermore, molecules of the above low-molecular material may be diffused in a conductive or non-conductive polymer. In addition, a single-crystalline body of an n-type semiconductor material in which electrons can be well injected and there is no absorption in a visible light range as represented by zinc oxide (ZnO), indium oxide (In 2 O 3 ), titanium oxide (TiO 2 ) and the like, its polycrystalline body, or a resin diffused layer of its particle powder and the like may be used.
[0052] In addition, when the metal material is used as the conductive material which covers the silicon fine particles instead of the semiconductor material, it is preferable that not entire surface of the silicon fine particle but only a part thereof is covered with the conductive material. In this case, as shown in FIG. 6 , the phosphor layer 3 may be constituted by diffusing such silicon fine particles 15 in which one part of the surface is covered with a conductive material 16 formed of a metal material, in a transparent conductor matrix 17 formed of a semiconductor material.
Ninth Embodiment
[0053] A phosphor element 30 according to a ninth embodiment of the present invention will be described with reference to FIG. 3 . FIG. 3 is a perspective view showing an electrode constitution of the phosphor element 30 . The phosphor element 30 further includes a thin film transistor 11 connected to the electrode 2 of the phosphor element according to the first embodiment to eighth embodiment. An x electrode 12 and a y electrode 13 are connected to the thin film transistor 11 . According to the phosphor element 30 , since at least a part of a surface of a silicon fine particle 5 is covered with a conductive material 6 , it can be driven at a low voltage and the thin film transistor 11 can be used. In addition, when the thin film transistor 11 is used, the phosphor element 30 has a memory function. As this thin film transistor 11 , low-temperature polysilicon or amorphous silicon thin film transistor and the like may be used. Furthermore, it may be an organic thin film transistor constituted by a thin film including an organic material, or may be a transparent thin film transistor formed of zinc oxide and the like.
Tenth Embodiment
[0054] A display device according to a tenth embodiment of the present invention will be described with reference to FIG. 4 . FIG. 4 is a schematic plain view showing an active matrix of the display device 40 which is constituted by x electrodes 12 and y electrodes 13 intersecting with each other. The display device 40 is an active matrix display device having a thin film transistor 11 . The active matrix display device 40 includes a two-dimensional phosphor element array in which a plurality of phosphor elements 30 including the thin film transistors 11 shown in FIG. 3 are arranged, the plurality of x electrodes extending parallel to each other in a first direction which is parallel to a surface of the phosphor element array, and the plurality of y electrodes 13 extending parallel to each other in a second direction which intersects with the first direction at right angles. The thin film transistor 11 in the phosphor element connects the x electrode 12 to the y electrode 13 . The phosphor element specified by the pair of x electrode 12 and y electrode 13 becomes a pixel. According to the active matrix display device 40 , as described above, a phosphor layer 3 constituting the phosphor element of each pixel includes silicon fine particles 5 in which at least a part of its surface is covered with a conductive material 6 . Thus, since it can be driven at a low voltage, the thin film transistor 11 can be used and a memory effect can be provided. In addition, since it can be driven at the low voltage, the display device has a long life. In addition, when the silicon fine particles 5 constituting the phosphor layer 3 are arranged in each pixel depending on its luminescent color (RGB), there can be provided a full-color display device using the three primary colors. In addition, a color filter may be provided ahead of the phosphor direction in order to adjust the color purity of each color of RGB. Furthermore, the phosphor layer 3 emitting one color to every pixel may be used, and a color conversion layer and the color filter may be further provided ahead of the phosphor direction. Thus, when the color conversion layer absorbs blue light generated from the phosphor layer 3 , green or red light is generated and when they are taken out respectively, there can be provided a full-color display device using the three primary colors according to another example.
COMPARATIVE EXAMPLE 1
[0055] A phosphor element according to a comparative example will be described. This phosphor element is the same as the phosphor element 10 according to the first embodiment other than that a particle diameter of a silicon fine particle is different and there is no conductive material on a surface. A particle diameter of a silicon fine particle in the comparative example 1 was 180 to 220 nm. When a first electrode 2 and a second electrode 4 of the phosphor element according to comparative example 1 were connected to a positive electrode and a negative electrode, respectively and a DC voltage was applied to them, bright emission at 103V was confirmed. Since the phosphor element according to the comparative example 1 is driven at a high voltage, it is difficult or impossible to control a pixel by the TFT
COMPARATIVE EXAMPLE 2
[0056] A phosphor element according to a comparative example 2 will be described. This phosphor element is the same as the phosphor element 10 according to the first embodiment other than that a particle diameter of a silicon fine particle is different. A particle diameter of a silicon fine particle in the comparative example 2 was 200 to 240 nm. Although a first electrode 2 and a second electrode 4 of the phosphor element according to the comparative example 2 were connected to a positive electrode and a negative electrode, respectively and a DC voltage was applied to them, emission could not be confirmed even at 200V
COMPARATIVE EXAMPLE 3
[0057] A phosphor element according to a comparative example 3 will be described. This phosphor element is the same as the phosphor element according to the fourth embodiment other than there is no conductive material. Although a first electrode 2 and a second electrode 4 of the phosphor element according to the comparative example 3 were connected to a positive electrode and a negative electrode, respectively and a DC voltage was applied to them, emission could not be confirmed even at 200V.
COMPARATIVE EXAMPLE 4
[0058] A phosphor element according to a comparative example 4 will be described. This phosphor element is the same as the phosphor element according to the fourth embodiment other than a film thickness of a magnesium silver alloy is different and the film thickness is 60 to 100 nm. Although a first electrode 2 and a second electrode 4 of the phosphor element according to the comparative example 4 were connected to a positive electrode and a negative electrode, respectively and a DC voltage was applied to them, emission could not be confirmed even at 200V
COMPARATIVE EXAMPLE 5
[0059] A phosphor element according to a comparative example 5 will be described. This phosphor element is the same as the phosphor element 10 according to the first embodiment other than a film thickness of titanium nitride which is the conductive material is different and the film thickness is 40 to 80 nm. Although a first electrode 2 and a second electrode 4 of the phosphor element according to the comparative example 5 were connected to a positive electrode and a negative electrode, respectively and a DC voltage was applied to them, emission could not be confirmed even at 200V.
[0060] As described above, although the present invention has been described in detail by the preferred embodiments, the present invention is not limited to the embodiments, and as will be understood by those skilled in the art, many preferred variations and modifications can be made in a technical scope of the present invention described in the following claims. | A phosphor element includes a pair of electrodes opposed to each other and a phosphor layer sandwiched between the pair of electrodes and having silicon fine particles whose average particle diameter is not more than 100 nm, and at least a part of a surface of the silicon fine particle is covered with a conductive material. In addition, the conductive material may include an oxide or a composite oxide containing at least one element selected from a group of indium, tin, zinc, and gallium. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 164,086, filed July 19, 1971, now U.S. Pat. No. 3,875,215.
BACKGROUND OF THE INVENTION
The compounds of the present invention are substituted phenoxyalkyl quaternary ammonium compounds. Various ether phenoxyalkyl quaternary ammonium compounds have been described by Hey, Brit. J. Pharmacol. 7, 117 (1952); Hey and Willey, Brit. J. Pharmacol. 9, 471 (1954) and U.S. Pat. No. 2,895,995; and by Jones et al., Biochem. J. 45, 143 (1949).
SUMMARY OF THE INVENTION
This invention is directed to quaternary ammonium salt compounds, and to a method and composition utilizing such compounds. More particularly, the invention is concerned with quaternary ammonium salt compounds corresponding to the formula: ##SPC1##
Wherein Y represents amino, loweralkylamino or diloweralkylamino; R 1 and R 2 represent lower alkyl; R 1 and R 2 independently taken together represent an aliphatic hydrocarbon moiety of from 4, to 5, to 6 carbon atoms, which can be substituted with zero, one, or two lower alkyl substituents, R 1 , R 2 and the quaternary nitrogen forming a 5, 6 or 7-membered ring; R 3 represents lower alkenyl, phenacyl, mono-, di or trihalophenacyl, lower alkynyl, substituted lower alkyl, substituted lower alkenyl or substituted lower alkynyl in which such moieties are substituted with one substituent selected from halogen, phenyl, halophenyl, dihalophenyl, trihalophenyl, nitrilo, hydroxy, carboxyalkyl and keto; or R 1 , R 2 and R 3 taken together represent a quinuclidine residue; X 1 and X 2 both represent halogen; A - represents a stoichiometric equivalent quantity of a pharmaceutically-acceptable anion; n represents one of the integers 2, 3 or 4; HX represents a stoichiometric equivalent quantity of a pharmaceutically-acceptable acid; and m represents one of the integers 0 and 1. The quaternary ammonium salt compounds are crystalline solids which are soluble in water, and of varying degrees of solubility in organic liquids such as dimethyl formamide, esters, halohydrocarbons, alcohols and the like.
In the present specification and claims, the term "halogen" is employed with respect to the moieties X 1 , X 2 and R 3 of the above formula to designate one of the halogens chlorine, bromine and iodine, and the term "lower alkyl" is employed to designate lower alkyl of from 1, to 2, to 3, to 4, to 5, to 6 carbon atoms, the term "carboxyalkyl" is employed to designate such moieties containing from 2, to 3, to 4, to 5 carbon atoms. The terms "lower alkenyl" and "lower alkynyl" are employed to designate such moieties containing from 2, to 3, to 4, to 5, to 6 carbon atoms. The terms "pharmaceutically-acceptable anion" and "pharmaceutically-acceptable acid" as herein employed, refer to non-toxic anions or acids employed in quaternary ammonium salt compounds or acid-addition salts thereof. The terms include the acidic or anionic moieties which have no substantial toxicity or detrimental pharmacological effect when a quaternary ammonium salt compound including such an anion is administered to animals at dosages consistent with good pharmacological activity and acids of such moieties. Such pharmaceutically-acceptable anions include non-toxic inorganic anions such as the chloride, bromide, iodide, sulfate, nitrate, bisulfate or phosphate, or organic anions such as the acetate, propionate, succinate, malate, fumarate, glutamate, salicylate, maleate, tartrate or citrate anions, organic sulfonate anions such as the camphorsulfonate, methanesulfonate, benzenesulfonate or toluenesulfonate anions. The methanesulfonate, benzenesulfonate, chloride and bromide anions are particularly useful in the preparation, purification and use of the quaternary ammonium salts of the invention and are preferred pharmaceutically-acceptable anions.
The compounds of the invention are useful in the study of drug effects upon cardiac activity in animals, and have been found to be particularly useful as antiarrhythmic agents. The compounds can be employed in combatting cardiac arrhythmias in animals by administering an antiarrhythmic amount of one or more of the quaternary ammonium salt compounds to an animal. In such use, the compounds are administered internally to the animal to introduce the compound into the animal's cardiovascular system. The compounds can be administered parenterally by intraperitoneal, subcutaneous or intravenous injection, for example, and typically by intravenous injection. In contrast to many known quaternary ammonium compounds, the quaternary ammonium salt compounds of the invention can also be administered to animals via the gastrointestinal tract, typically by oral administration. The compounds have excellent antiarrhythmic activity both therapeutically, in administration to an animal suffering from a cardiac arrhythmia, and prophylactically to protect an animal against the occurrence or recurrence of arrhythmias, typically in an animal subject to arrhythmias.
The terms "arrhythmic", "cardiac arrhythmia" and "arrhythmia" as employed herein refer to irregular cardiac activity characterized by irregular beating of the heart, that is, non-rhythmic heart beat. Such arrhythmias involve substantial departures from the regular, substantially sinus (sinusoidal) normal heart beat. Arrhythmias are generally beyond the normal increased, but still substantially regular, heart beat rate resulting from physical activity. The term is inclusive of the conditions described by terms such as ventricular fibrillation, ventricular tachycardia, atrioventricular nodal beats, auricular flutter, auricular fibrillation or premature ventricular contractions. The terms "arrhythmic animal" and "arrhythmic mammal", as employed in the present specification and claims, mean and refer to animals suffering cardiac arrhythmias. Such arrhythmias can be the result of physiological or pathological conditions. They can also be brought about by physical conditions such as electrical stimulation or physical injury or they can result from pharmacological effects such as the administration of compounds such as digitalis or similar compounds such as ouabain, acetyl strophanthidin, deslanoside C or digitoxin; epinephrine; ergot; chloroform; cyclopropane and the like having cardiac stimulant and arrhythmia-inducing activity or side effects.
In the practice of the method of the invention, a quaternary ammonium salt compound is normally incorporated in a pharmaceutical carrier and the resulting composition is administered internally to an animal. In the present specification and claims, "pharmaceutical carrier" refers to known pharmaceutical excipients which are substantially non-toxic and non-sensitizing at dosage levels consistent with good antiarrhythmic activity. The active ingredient is preferably administered parenterally in the form of liquid injectable solutions or suspensions, and orally in the form of solid compositions which can be prepared by known techniques such as tableting and encapsulation. Suitable pharmaceutical carriers which can be employed for formulating the solid compositions include starch, lactose, glucose, sucrose, gelatin, powdered licorice, malt, rice flour, chalk, silica gel, hydroxyethyl cellulose, hydroxypropyl cellulose, magnesium carbonate, magnesium stearate, carboxymethyl cellulose, and the like and compatible mixtures thereof. The quaternary ammonium compounds can also be formulated as liquid compositions including syrups, elixirs, suspensions and emulsions for oral administration. Among the liquid pharmaceutical carriers which can be employed for orally-administered compositions are ethanol, water, saline, glucose syrup, syrup of acacia, mucilage of tragacanth, propylene glycol, polyethylene glycols, peanut oil, wheat germ oil, sunflower seed oil or corn oil and the like and compatible mixtures thereof. Orally-ingestible compositions can include emulsifying agents such as lecithin, sorbitan trioleate, polyoxyethylene sorbitan monooleate and natural gums such as gum acacia and gum tragacanth, and suspending agents such as polyethylene oxide condensation products of alkylphenols or fatty acids or fatty alcohols, or cellulose derivatives such as carboxymethyl cellulose or hydroxypropylmethyl cellulose. The compositions can also contain sweetening agents such as sucrose, or saccharin, flavoring agents such as caramel, coloring materials, preservatives and the like.
Injectable compositions adapted for parenteral administration such as intramuscular, subcutaneous or, preferably, intravenous injection can be prepared with pharmaceutical carriers which are liquid parenterally-acceptable vehicles, i.e., liquid pharmaceutical carriers which are adapted for use in formulating parenteral preparations and which are substantially non-toxic and non-irritating when administered parenterally at dosages consistent with good antiarrhythmic activity. Representative liquid parenterally-acceptable vehicles include pyrogen-free water, normal saline solutions, Ringer's Injection, Lactated Ringer's Injection, dextrose solutions, ethanol, propylene glycol, liquid polyethylene glycols, fixed vegetable oils such as corn oil, peanut oil or cottonseed oil, ethyl oleate, isopropyl myristate and the like. The injectable compositions can also contain other materials such as preservatives, buffers and the like. Preferred injectable compositions comprise a sterile solution of the quaternary ammonium salt compound in the parenterally-acceptable vehicle. The compositions can be formulated by using conventional procedures such as are described in Remington's Pharmaceutical Sciences, 13th Ed., Chapter 36, Mack Publ. Co., Easton, Pa. (1965).
The selection of the exact pharmaceutical carrier to be employed in any given circumstance can be carried out by routine and conventional range finding operations to arrive at formulations having the desired characteristics of physical form, ease of administration in a desired route, storage stability, etc.
The antiarrhythmic amount of the quaternary ammonium salt compounds to be administered to an animal can vary depending upon such factors as whether or not the animal is suffering from an arrhythmia at the time of administration, the type and severity of arrhythmia exhibited, the method and frequency of administration, the exact anti-arrhythmic effect to be produced, the particular quaternary ammonium salt compounds employed and the species, size, weight, age and physical condition of the particular animal being treated. In general, when the animal is actively exhibiting arrhythmia, it is preferred to administer the compound at an antiarrhythmic dosage rate sufficient to bring about a complete conversion of the arrhythmia to normal sinus cardiac activity. In such operations, the active compound is preferably introduced directly into the cardiovascular system of the animal to provide an antiarrhythmic concentration of the quaternary ammonium salt compound in the cardiovascular system, particularly at the heart. In a convenient procedure, the compound is administered by intravenous injection at an initial antiarrhythmic dosage less than that required to fully convert the arrhythmia to normal rhythm, and the heartbeat of the animal is monitored as the amount of compound administered is gradually increased over a period of minutes until an antiarrhythmic amount sufficient to fully convert the arrhythmia to rhythmic cardiac activity has been administered. It is then preferred to supply the compound in periodic maintenance antiarrhythmic dosages, such administration being either by the same parenteral route, or by administration of larger antiarrhythmic dosages by another route such as orally. The maintenance antiarrhythmic dosage and mode of administration are selected to provide a more-or-less continuous antiarrhythmic concentration of the quaternary ammonium salt compound in the cardiovascular system, such concentration being sufficient to inhibit further arrhythmia. In general, the quaternary ammonium compound can be administered intravenously in initial dosages of from about 0.1 or less to about 15 or more milligrams per kilogram of animal body weight, providing initial antiarrhythmic concentrations in the cardiovascular system. Maintenance dosages can vary widely depending upon a variety of factors such as the time and frequency of administration, the exact compound or compounds employed, the condition, size, age and species of the animal, the route of administration selected, the type of dosage form employed, the type and cause of the arrhythmia, and the length of time during which a maintenance dose is desired. In cases in which there is little or no likelihood of recurrence of arrhythmia once conversion has been brought about, the maintenance dosage can comprise a continuation of the initial intravenous antiarrhythmic dosage for a relatively brief period. When recurrence of arrhythmia is likely, the maintenance dosage can comprise repeated oral administration of an antiarrhythmic amount of the compounds over extended periods. Maintenance dosages can be administered by single or multiple doses provided that the compounds are administered in an antiarrhythmic amount sufficient substantially to alleviate cardiac arrhythmia.
A preferred group of the quaternary ammonium salt compounds comprises the compounds corresponding to the above formula I wherein R 1 and R 2 are both methyl or both ethyl, wherein Y is amino and wherein X 1 and X 2 are both bromine or both chlorine. It is also generally preferable that the moieties R 1 and R 2 together contain from 2 to 6 carbon atoms; that the moiety R 3 contain from 3 to 7 carbon atoms and that R 1 , R 2 and R 3 together contain from 5 to 9 carbon atoms. Other preferred groups of compounds include those wherein Y is amino, R 3 is lower alkenyl or lower alkynyl of 3 to 4 carbon atoms or those wherein R 3 is substituted lower alkyl, lower alkenyl or lower alkynyl of from 2 to 4 carbon atoms substituted with a single bromo, chloro, keto or nitrilo substituent, and those wherein R 3 is benzyl, monohalobenzyl and dihalobenzyl. A further preferred group comprises the compounds corresponding to the above formula wherein n is 2, Y is amino, X 1 and X 2 are bromine, R 1 and R 2 are methyl, and R 3 is lower alkenyl or lower alkynyl of 3 or 4 carbon atoms, and A - is chloride or bromide anion. This latter group of quaternary ammonium salts thus corresponds to the formula ##SPC2##
wherein m, HX and A - have the significance set out above with respect to formula I and R 3 is lower alkenyl or lower alkynyl of 3 or 4 carbon atoms, preferably 2-propynyl, allyl or 2-methylallyl. The preferred compounds of Formula Ia provide excellent antiarrhythmic results of long duration when administered orally or parenterally in relatively low dosages and are particularly preferred for combatting cardiac arrhythmias.
PREPARATION OF THE COMPOUNDS
The quaternary ammonium salt compounds of the invention can be prepared by the reaction of a tertiary amine compound corresponding to formula II ##EQU1## with a substituted organic alkylating agent corresponding to formula III
R'''' -- B III
In the above formulae II and III, one of the substituent moieties R',R", R'", and R"" represents a substituted phenoxyalkyl moiety corresponding to formula IV ##SPC3##
wherein X 1 , X 2 , Y and n all have the significance set out above with respect to formula I; and each of the remaining substituent moieties R', R", R'" and R"" represents a different individual one of the moieties R 1 , R 2 and R 3 as set out above with respect to formula I and B represents a pharmaceutically-acceptable strongly anionic moiety such as halide, alkyl or aryl sulfonate, sulfate or phosphate. Thus the substituted phenoxyalkyl moiety of formula IV can be provided as a substituted phenoxyalkylamine or as a substituted phenoxyalkyl halide, and the R 1 , R 2 and R 3 moieties similarly can be provided by a tertiary amine compound of formula II or by a substituted organic compound of formula IV. Representative tertiary amines which can be employed as starting materials include N-methyl-N-ethyl-N(2-propynyl) amine; dimethyl phenethylamine; N,N-diethyl-N-4-chlorobutylamine; N-2-butenyl dimethylamine; N-allyl-pyrrolidine; picoline, lutidine; quinuclidine; 3,5-dibromo-β-dimethylamino-p-phenetidine; 3,5-diiodo-β-(N-3-nitrilopropyl-N-ethyl)amino-p-phenetidine; 3-chloro-5-bromo-4-[2-(N-2,4,5-trichlorobenzyl-N-methyl amino)propoxy]-N-butyl aniline; N,N-diethyl-N-(2-methylallyl) amine; N-butyl-N-[ 3-(2,5-diiodophenyl)propyl]-N-[3-(2,6-dichloro-4-aminophenoxy)propyl]amine; 3,5-dichloro-4-[3-(N-3-nitrilopropyl-N-methylamino)propoxy]-N,N-dimethylaniline; 3,5-dibromo-4-[β-N-(3-butynyl)-N-methyl amino ethoxy]-N-ethylaniline; N-[β(2-bromo-4-amino-6-iodophenoxy)-ethyl]-N-(2-methylallyl)-N-ethylamine; N-allylpiperidine; 3,5-dichloro-β-(N-isopropyl-N-methyl)amino-p-phenetidine; and 3,5-dibromo-β-(N-3-ketobutyl-N-methyl)amino-p-phenetidine. Representative substituted organic compounds can include propargyl bromide, propargyl chloride, 3,5-dibromo-4-(2-bromoethoxy)aniline; 3,5-dichloro-4-(3-bromopropoxy) N,N-dimethylaniline, β-cyanoethyl tosylate; 1-(2-bromo-6-chlorophenoxy)-(2-bromoethane); propenyl chloride, chlorohexane, methyl bromide, ethylene dibromide, benzyl bromide, 3,4,5-trichlorophenethyl bromide, chloroacetone, 1,4-dichloro-2-butene, butyl bromide, 1-chloro-2-methyl propane, 1-chloro-3-cyanopropane, 1,1,3-trichloropropane, 1-bromo-4-phenylbutane, and 3,4,5-trichlorophenacyl bromide.
The reaction proceeds when the reactants are contacted and mixed, preferably in the presence of an inert organic liquid such as acetonitrile or dimethyl formamide as a reaction medium. In preparing the quaternary ammonium compounds of the invention, the substituted halophenoxyalkyl amine compound of formula II and the organic compound of formula III are selected from such compounds in which the R', R", R'" and R"" moieties are such as to provide the R 1 , R 2 and R 3 moieties desired in the quaternary product. The reaction proceeds readily at temperatures of from about 10° to about 100°C., and is preferably carried out at a temperature from about 25° to about 70°C. The exact proportions of the reactants to be employed are not critical, however the formation of one molar proportion of the quaternary ammonium salt product requires one molar proportion of each of the tertiary amine and substituted organic reactants, and the reactants are preferably employed in such proportions. The reaction of the tertiary amine and organic compound proceeds with the evolution of heat and the production of a quaternary ammonium salt product wherein the anionic moiety is the anionic moiety B of the organic compound of formula III. In those cases in which the product separates as a precipitate in the reaction mixture, the product can be separated by conventional procedures such as filtration, decantation, centrifugation. In cases in which the product does not precipitate from the reaction mixture, the quaternary ammonium salt can be separated by other conventional procedures such as evaporation under reduced pressure, cooling of the reaction mixture and scratching or seeding to induce crystallization, dilution with organic liquids such as ethyl acetate, benzene or butyl acetate or the like. The product can be purified by conventional procedures such as recrystallization and washing.
The anionic moiety A - of the quaternary ammonium salts corresponding to formula I can be varied by conversion of one salt to another by conventional procedures for anion exchange. The exchange can be carried out, for example, by the methathetic reaction of one of the quaternary ammonium salts of the invention with the desired anion in the presence of a cation which forms a methathesis reaction product with the anionic moiety to be replaced, and methathesis reaction product being insoluble in the reaction medium employed for the metathetic reaction. In a convenient procedure a quaternary ammonium halide of the invention is prepared as described above using a reactant corresponding to formula III wherein A is halogen, such as chlorine or bromine. The quaternary ammonium halide is dissolved in aqueous ethanol at room temperature and the solution is mixed with an aqueous solution of an acid supplying the desired anion, e.g., sulfuric acid. The haldie is removed as hydrogen halide by fractional distillation and the methathesis quaternary ammonium salt product is separated and purified by conventional procedures. Alternatively, different anionic moieties can be introduced into the quaternary ammonium salt compounds of formula I by passing an aqueous solution of a compound of formula I through an anion-exchange resin saturated with the anion desired in the product.
In the preparation of the quaternary ammonium salts of the invention wherein R 1 , R 2 and R 3 represent a quinuclidine, pyridine, picoline or lutidine residue, the substituted phenoxyalkyl moiety is conveniently supplied as a substituted phenoxyalkyl halide. The tertiary amine reactant is a substituted nitrogen-containing heterocyclic amine such as quinuclidine, pyridine, α-picoline, 3,4-dimethyl pyridine or the like. The quaternization reaction is conveniently carried out under substantially the conditions described above.
The pharmaceutically-acceptable acid addition salt form of the quaternary ammonium compounds, that is, those quaternary ammonium salts of formula I wherein m is 1, are prepared according to conventional procedures for forming acid addition salts of primary, secondary or tertiary amines. In a convenient procedure, a quaternary ammonium salt corresponding to formula I wherein m is 0 is taken up in a minimal amount of a lower alkanol and the mixture is treated with an excess of the desired pharmaceutically-acceptable acid in ether or dioxane. The salt is separated and purified by conventional procedures.
In a convenient procedure for the preparation of the quaternary ammonium salts of the invention wherein R 1 and R 2 represent lower alkyl, the tertiary amine reactant employed is a substituted 3,5-dihalophenoxy alkylamine corresponding to the above formula II wherein R' and R" represent the R 1 and R 2 lower alkyl moieties as described above with respect to formula I and R'" represents a substituted phenoxyalkyl moiety corresponding to the above formula IV. Such tertiary amine starting materials can be prepared readily by the reaction of a substituted phenoxyalkyl halide with a dialkyl amine by the procedures described in U.S. Pat. No. 3,389,171 or by analogous procedures. The substituted organic compound reactant employed is a compound of formula III above wherein R"" represents R 3 as described with respect to formula I and B represnts halo, alkyl sulfonyl or aryl sulfonyl. In such procedure, the substituted halophenoxyalkylamine is dispersed in an inert organic liquid such as dimethylformamide or acetonitrile, and an equimolar proportion of the organic compound of formula III is added gradually and mixed therewith. The reaction mixture is maintained at a temperature within the reaction temperature range for a period of 1 to 36 hours. In those cases in which the product does not separate from the reaction mixture, the product can be conveniently separated by diluting the reaction mixture with several volumes of ethyl acetate. In those cases in which a crystalline product is not obtained upon dilution with ethyl acetate, the product can be crystallized by treating the ethyl acetate mixture with excess pharmaceutically-acceptable acid, trituration, or crystallization from other organic liquids such as methanol, ethanol, or isopropanol. The product can be purified by conventional procedures such as recrystallization and washing.
DESCRIPTION OF PREFERRED EMBODIMENTS
The following examples are illustrative of the invention.
EXAMPLE 1
3,5-Dibromo-β-dimethylamino-p-phenetidine (25.4 grams; 0.075 mole) is dissolved in 200 milliliters of acetonitrile at room temperature. 2-Methylallyl chloride (6.9 grams; 0.075 mole) is rapidly added dropwise to the solution with stirring, during which time a temperature rise of 3°-4° C. is observed. The reaction mixture is heated at a temperature of 55°-65°C. for 4 hours with continued stirring. Formation of a precipitate is observed in the mixture, beginning about 15 minutes after addition of the 2-methallyl chloride and continuing through the heating period. The reaction mixture is then cooled in an ice bath and filtered. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl-(2-methylally)ammonium chloride product is collected as a filter cake, dried in air and found to melt at 185°-186°C. The product is dissolved in hot isopropanol and the solution treated with activated carbon and filtered. The solution is cooled, whereupon a crystalline solid precipitate forms, and filtered. The purified [2-(4-amino-2,6-dibromophenoxy)ethyl]-dimethyl(2-methylallyl)ammonium chloride product is collected as a filter cake, dried under reduced pressure, and found to melt at 181°-182°C. The structure of the product, corresponding to the formula: ##SPC4##
is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 39.35, 4.98 and 6.64 percent, respectively, as compared with the theoretical contents of 39.2, 4.94 and 6.54 percent, respectively, calculated for the named structure.
EXAMPLE 2
3,5-Dibromo-β-dimethylamino-p-phenetidine (16.9 grams; 0.05 mole) is dissolved in 50 milliliters of dimethyl formamide at a temperature of about 25°C. To this solution is added dropwise with stirring ethyl bromoacetate (9.2 grams; 0.055 mole). During the addition the mixture warms spontaneously to a temperature of about 49°C., and the mixture is cooled to 27°C. prior to addition of the final 2 grams of ethyl bromoacetate. A precipitate forms in the reaction mixture after the addition is complete, and 50 milliliters of additional dimethyl formamide is added. The mixture is stirred for one hour, then held over night at room temperature. The crystalline solid product is collected as a filter cake by suction filtration of the mixture and the filter cake is recrystallized from boiling ethanol. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(ethyl carboxymethyl) ammonium bromide is obtained as a light tan crystalline solid, melting at 187°-188°C. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 33.5, 4.3 and 5.6 percent, respectively, as compared with the theoretical contents of 33.3, 4.2 and 5.6 percent, respectively, calculated for the named structure. The structure of the product is confirmed by infrared spectroscopy and nuclear magnetic resonance analysis.
A second crop of the product is obtained by diluting the dimethyl formamide reaction mixture filtrate with excess ethyl acetate, and collecting the resulting precipitate by filtration. This crop of the product is dried, crystallized from acetonitrile and found to have nuclear magnetic resonance and infrared spectra consistent with the assigned structure, and in excellent agreement with the spectra obtained with the first crop.
EXAMPLE 3
3,5-Dibromo-β-dimethylamino-p-phenetidine (20.3 grams; 0.06 mole) and 2-chlorobenzyl chloride (9.7 grams; 0.06 mole) are dissolved in 200 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 35° C. for about 1 hour and then at ambient temperature overnight with continued stirring. Formation of a precipitate is observed in the mixture, beginning about one hour after initial contacting of the reactants. The reaction mixture is filtered, and the [2-(4-amino-2,6-dibromophenoxy)-ethyl]dimethyl(2-chlorobenzyl)ammonium chloride product is collected as a filter cake, dried in air, and recrystallized from isopropanol. The purified [2-(4-amino-2,6-dibromophenoxy)-ethyl]dimethyl(2-chlorobenzyl)ammonium chloride product is found to melt at 172°-173°C. The structure of the product is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 41.3, 4.3 and 5.8 percent, respectively, as compared with the theoretical contents of 40.9, 4.0 and 5.6 percent, respectively, calculated for the named structure.
EXAMPLE 4
3,5-Dibromo-β-dimethylamino-p-phenetidine (16.9 grams; 0.05 mole) is dissolved in 35 milliliters of dimethyl formamide and the solution is cooled in an ice-bath to a temperature of about 10°C. To this solution is added dropwise with stirring propargyl bromide (6.5 grams; 0.055 mole). During the addition the mixture warms spontaneously to a temperature of about 18°C., and the mixture is cooled to 10°C. prior to addition of the final amounts of propargyl bromide. The mixture is allowed to warm to room temperature then heated at a temperature of 45°C. for 1 hour and diluted with ethyl acetate, whereupon the crystalline solid product separates. The product is separated by filtration of the mixture, recrystallized once from a mixture of isopropanol and ethanol and recrystallized a second time from a mixture of ethanol and ethyl acetate. The [2-(4-amino-2,6-dibromo-phenoxy)ethyl]dimethyl(2-propynyl)ammonium bromide product is obtained as a yellow crystalline solid melting at 166°-168°C. The product is found by combustion analysis to have carbon, hydrogen and bromide contents of 34.5, 3.8 and 52 percent, respectively, as compared with the theoretical contents of 34.2, 3.8 and 52.5 percent, respectively, calculated for the named structure. The structure of the product is confirmed by infrared spectroscopy and nuclear magnetic resonance analysis.
EXAMPLE 5
3,5-Dibromo-β-dimethylamino-p-phenetidine (25.4 grams; 0.075 mole) is dissolved in 200 milliliters of acetonitrile at room temperature. Chloroacetone (7.0 grams; 0.075 mole) is rapidly added dropwise to the solution with stirring, during which time a slight temperature rise is observed. The reaction mixture is heated at a temperature of 55°-65°C. for 4 hours with continued stirring, then cooled in an ice bath and filtered. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(acetonyl)ammonium chloride product is collected as a filter cake, dried in air, and recrystallized from isopropanol. The purified [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(acetonyl)ammonium chloride product is obtained as a tan crystalline solid melting at 181°-182°C. The structure of the product is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 36.1, 4.6 and 6.4 percent, respectively, as compared with the theoretical contents of 36.3, 4.5 and 6.5 percent, respectively, calculated for the named structure.
EXAMPLE 6
3,5-Dibromo-β-dimethylamino-p-phenetidine (16.9 grams; 0.05 mole) is dissolved in 35 milliliters of dimethyl formamide at a temperature of about 25°C. Allyl bromide (6.7 grams; 0.055 mole) is added dropwise to the solution with stirring. During the addition the mixture warms spontaneously to a temperature of about 32°C. The mixture is then held overnight at room temperature. The mixture is diluted with a large excess of ethyl acetate, whereupon a yellow amorphous solid separates. The solid product is separated by decantation, washed with ethyl acetate and crystallized by trituration with isopropanol. The product is recrystallized once from hot isopropanol and a second time from an ethanol-ethyl acetate mixture. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(allyl)ammonium bromide product is obtained as a yellow crystalline solid melting at 157.5°-159°C. The product is found by combustion analysis to have carbon, hydrogen and bromide contents of 33.8, 4.2 and 52.0 percent, respectively, as compared with the theoretical contents of 34.0, 4.2 and 52.2 percent, respectively, calculated for the named structure. The structure of the product is confirmed by infrared spectroscopy and nuclear magnetic resonance analysis.
EXAMPLES 7-14
In procedures similar to those employed in Examples 1-6 above, 2,6-dibromo-β-dimethylamino-p-phenetidine is quaternized with appropriate organic alkylating reactants to produce quaternary ammonium salt compounds of the invention. The compounds correspond to formula I above wherein m is zero, Y is amino, n is 2, X 1 and X 2 are both bromo and R 1 and R 2 are methyl. The compounds obtained, identified by the R 3 and A - moieties, and the organic reactants reacted with the said phenetidine compounds are set out in the following table.
__________________________________________________________________________Ex. R.sub.3 A.sup.- Melting Alkylating Point °C. Reactant__________________________________________________________________________7 2-hydroxyethyl bromide 228°-229° ethylenebromohydrin8 3,4-dichlorophenacyl bromide 212°-214° 3,4-dichlorophenacyl- bromide9 phenethyl bromide 209°-210° β-bromoethylbenzene10 3-chloropropen-2-yl chloride 168°-169° 1,3-dichloropropene11 benzyl bromide 198°-199° benzyl bromide12 4-chlorobenzyl chloride 187°-188° 4-chlorobenzyl chloride13 2,4-dichlorobenzyl chloride 172°-173° 2,4-dichlorobenzyl chloride14 3,4-dichlorobenzyl chloride 158.5°-160° 3,4-dichlorobenzyl chloride__________________________________________________________________________
EXAMPLE 15
3,5-Dichloro-β-dimethylamino-p-phenetidine (15 grams) and 2-methylallyl chloride (5.6 grams) are dissolved in 140 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 60°-65°C. for 32 hours and then cooled. The reaction mixture is filtered, and the [2-(4-amino-2,6-dichlorophenoxy)ethyl]dimethyl(2-methylallyl)-ammonium chloride product is collected as a filter cake, washed with acetonitrile and dried. The purified [2-(4-amino-2,6-dichlorophenoxy)ethyl]dimethyl(2-methylallyl)-ammonium chloride product is found to melt at 189°-191°C.
EXAMPLE 16
3,5-Dibromo-β-diethylamino-p-phenetidine (14 grams; 0.038 mole) and 4.85 grams of allyl bromide are dissolved in 140 milliliters of acetonitrile. The mixture is heated with stirring at a temperature of 60°-65°C. for 4 hours, stirred at room temperature overnight, then heated at 60°-65°C. for about 18 hours and cooled. The crystalline product is separated by filtration of the mixture and the [2-(4-amino-2,6-dibromophenoxy)ethyl]diethyl(allyl)ammonium bromide product is obtained as a crystalline solid melting at 205°-207°C.
EXAMPLE 17
3,5-Dibromo-4-(3-dimethylaminopropoxy)aniline (5 grams) and 1.8 grams of allyl bromide are mixed with 30 milliliters of acetonitrile. Crystal formation and a slight temperature rise is observed. The reaction mixture is heated at a temperature of 50°-60°C. for 4 hours with stirring, then held overnight and filtered. The [3-(4-amino-2,6-dibromophenoxy)propyl]dimethyl(allyl)ammonium bromide product is collected as a filter cake, dried in air, and obtained as a buff colored crystalline solid melting at 167°-169°C.
EXAMPLE 18
3,5-Dibromo-β-dimethylamino-p-phenetidine (13.5 grams; 0.04 mole) is dissolved in 150 milliliters of ethyl acetate at room temperature. Cyanomethyl benzenesulfonate (8 grams; 0.04 mole) is added dropwise to the solution with stirring. The reaction mixture is held overnight at room temperature. The reaction mixture is filtered. The [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-nitriloethyl)-ammonium benzenesulfonate product is collected as a filter cake. The product is taken up in hot acetonitrile and the solution is filtered. The hot filtrate is cooled, whereupon a crystalline solid precipitate forms, and filtered. The purified [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-nitriloethyl]ammonium benzenesulfonate product is collected as a filter cake, air dried, and found to melt at 173.5°-175°C. The structure of the product is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 40.6, 3.93 and 7.87 percent, respectively, as compared with the theoretical contents of 40.39, 3.96 and 7.85 percent, respectively, calculated for the named structure.
EXAMPLE 19
3,5-Dibromo-β-dimethylamino-p-phenetidine (25.4 grams; 0.075 mole) is dissolved in 300 milliliters of acetonitrile at room temperature. Allyl methanesulfonate (10.2 grams; 0.075 mole) is rapidly added to the solution with stirring. The reaction mixture is heated at a temperature of 35°-45°C. for 5 hours with continued stirring. Formation of a precipitate is observed in the mixture, beginning about 10 minutes after addition of the allyl methanesulfonate and continuing through the heating period. The reaction mixture is cooled and filtered. The [2-(4-amino-2,6-dibromophenoxy)-ethyl]dimethyl(allyl)ammonium methanesulfonate product is collected as a filter cake, dried, and recrystallized from n-propanol. The product is found to melt at 202°-203°C. The structure of the product is confirmed by infrared and nuclear magnetic resonance spectroscopy. The product is found by combustion analysis to have carbon, hydrogen and nitrogen contents of 35.35, 4.65 and 6.13 percent, respectively, as compared with the theoretical contents of 35.45, 4.68 and 5.91 percent, respectively, calculated for the named structure.
EXAMPLE 20
α,3,5-Tribromo-p-phenetidine (20.2 grams) is dissolved in 150 milliliters of acetonitrile, then mixed with a solution of 6 grams of quinuclidine in 100 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 50°C. for 4 hours and then cooled, and held for 48 hours at ambient temperature. The reaction mixture is filtered, and the [2-(4-amino-2,6-dibromophenoxy)-ethyl] quinuclidinium bromide product is collected as a filter cake, washed with acetonitrile and dried. The purified [2-(4-amino-2,6-dibromophenoxy)ethyl] quinuclidinium bromide product is found to melt at 239°-241°C. The product corresponds to the formula: ##SPC5##
EXAMPLE 21
3,5-Dibromo-β-pyrrolidino-p-phenetidine (15 grams) and allyl bromide (5.25 grams) are mixed in 50 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 60°-70°C. for 4 hours and then cooled. The reaction mixture is diluted with ethylacetate, and the [2-(4-amino-2,6-dibromophenoxy)ethyl] allyl pyrrolidinium bromide product is collected by decantation. The product is taken up in isopropanol, mixed with excess hydrogen bromide in isopropanol and the mixture is cooled and filtered. The 1-[2-(4-amino-2,6dibromophenoxy)ethyl]-1-allyl pyrrolidinium bromide hydrobromide product is found to melt at 211°-213°C.
EXAMPLE 22
In a procedure similar to that described in Example 21, 1-[2-(4-amino-2,6-dibromophenoxy)ethyl]-1-allyl piperidinium bromide hydrobromide, melting at 207°-209°C., is prepared by reacting 17 grams of 3,5-dibromo-β-piperidino-p-phenetidine and 5.75 grams of allyl bromide in 50 milliliters of acetonitrile.
EXAMPLE 23
3,5-Dibromo-β-hexamethyleneamino-p-phenetidine (16.8) grams) and allyl bromide (5.47 grams) are dissolved in 70 milliliters of acetonitrile. The reaction mixture is heated at a temperature of about 60°C. for 2 hours and then cooled. The reaction mixture is filtered, and the [2-(4-amino-2,6-dibromophenoxy)ethyl]-1-allylhexahydroazepinium bromide product, corresponding to the formula ##SPC6##
is collected as a filter cake, washed with acetonitrile and dried. The purified product is found to melt at 177°-179°C.
EXAMPLE 24
In a procedure similar to that described above in Example 20, β,3,5-tribromo-p-phenetidine and 3-picoline are reacted together to prepare 1-[2-(4-amino-2,6-dibromo-phenoxy)ethyl]-3-picolinium bromide, melting at 218°-220°C.
EXAMPLE 25
In a procedure similar to that of Example 17, 3,5-dibromo-4'-(4-dimethylaminobutoxy) aniline is reacted with allyl bromide to prepare [4-(4-amino-2,6-dibromophenoxy)-butyl]dimethyl(allyl) ammonium bromide as a pale yellow crystalline solid melting at 184°-186°C.
In procedures similar to those described above in Examples 1-25, the following quaternary ammonium salt compounds are prepared:
1-[3-(4-ethylamino-2,6-dibromophenoxy)propyl]-1-allyl-2-methyl pyrrolidinium bromide hydrobromide;
[4-(4-dimethylamino-2,6-dichlorophenoxy)butyl]-dibutyl(3-butynyl)ammonium methanesulfonate;
1-[2-(4-amino-2,6-diiodophenoxy)ethyl]-3,4-dimethyl pyridinium bromide hydrobromide;
[3-(4-hexylamino-2,6-dichlorophenoxy)propyl]dimethyl-(4-nitrilobutyl)ammonium chloride;
[2-(4-amino-2,6-dibromophenoxy)ethyl]diethyl(3-butenyl)ammonium p-toluenesulfonate;
[2-(4-amino-2,6-diiodophenxoy)ethyl]dimethyl[4-(3,4-dichlorophenyl)butyl]ammonium chloride;
1-[3-(4-ethylamino-2,6-dichlorophenoxy)propyl]-1-(2-propynyl)-hexahydroazepinium chloride hydrochloride; and
[2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(3-keto butyl)ammonium benzenesulfonate.
The following examples further illustrate the invention, particularly as to the use of the compounds in controlling cardiac arrhythmias.
EXAMPLE 26
Ventricular tachycardia is produced in dogs in a method similar to the method of Lucchesi and Hardman (J. Pharmacol. Exptl. Therap., 132, 372, 1961) by the administration of ouabain. In such operations, a dog is anesthetized by the intravenous administration of pentobarbital sodium at a dosage rate of 30 milligrams per kilogram. A femoral artery is cannulated with polyethylene tubing for measurements of blood pressure. A femoral vein is similarly cannulated for administration of ouabain and administration of the test compound. Hypodermic needle electrodes are employed for recording electrocardiograms. In such operations, ouabain is administered intravenously by infusion at a constant rate via the cannulated femoral vein. The infusion rate is 35 micrograms of ouabain per kilogram of animal body weight per hour. Within 1 to 1.5 hours following the start of the infusion, a ventricular tachycardia is seen to develop.
After ventricular tachycardia is observed, a test compound is administered intravenously by administration of varying amounts of a composition comprising 50 milligrams of the test compound as a sterile solution in 10 milliliters of water containing 0.9 percent sodium chloride. Each dose is administered slowly over a period of 15 to 30 seconds. The compound is administered at an initial dosage rate of 0.25 milligram of test compound per kilogram of animal body weight. Blood pressure and electrocardiogram are observed for 5 minutes after administration. When a complete conversion from the arrhythmic condition to normal sinus rhythm is not observed within the 5 minute period, a second dose of 0.50 milligram of the test compound per kilogram is administered by a similar procedure and blood pressure and heartbeat are similarly observed for 5 minutes. When complete conversion of the ventricular tachycardia to normal sinus rhythm is not observed, the dosage is increased two-fold every five minutes until complete conversion is obtained. The animal is then observed and the duration of the period of normal cardiac rhythm produced by administration of the test compound is recorded as the duration of antiarrhythmic activity. The termination of the period of normal activity is marked by the reappearance of ventricular tachycardia or fibrillation as indicated by the electrocardiogram observations. The antiarrhythmic dosage of test compound sufficient to bring about a complete conversion of the cuabain-induced tachycardia, and the duration of the period of normal cardiac activity are set out below.
______________________________________Cmpd. of Conversion Dose DurationEx. No. (Milligrams per Kilogram) in Minutes______________________________________1 0.5 152 1 2.6 2 3.53 1 12.54 0.5 245 1 116 1 67 1 258 16 109 2 3.510 1 311 1 8.512 1 9.513 0.5 414 2 1415 0.5 4.516 2 6.517 1 618 1 419 1 17.5 2 39.020 0.5 121 2 1.522 1 6.523 0.5 3.3 1 7.524 0.5 3825 2 26______________________________________
EXAMPLE 27
The procedure of Example 26 is repeated, employing the compound of Example 1, [ 2-(4-amino-2,6-dibromophenoxy)-ethyl]-dimethyl(2-methylallyl)ammonium chloride, as a test compound. In these operations two groups of three dogs each are administered the test compound intravenously at anti-arrhythmic dosage rates of 1 and 2 milligrams per kilogram after ectopic ventricular rhythms have been established by continuous infusion of cuabain. Complete conversion of the arrhythmias to sinus rhythm is observed in all the dogs, with mean durations of sinus rhythm of 12.7 and 26.5 minutes, respectively, being observed in the groups administered 1 and 2 milligrams of the test compound, respectively, per kilogram.
EXAMPLE 28
[2-(4-Amino-2,6-dibromophenoxy)ethyl]dimethyl-(2-methylallyl)ammonium chloride is employed to alleviate multifocal ventricular arrhythmias induced by administration of n-hexane and epinephrine. In these operations, dogs are anesthetized by intravenous administration of 30 milligrams of pentobarbital sodium per kilogram. Transient ventricular arrhythmias are induced by a modification of the method of Garb and Chenowith, J. Pharmacol. Exp. Ther. 94; 12 (1948) in which the heart is sensitized by intratracheal injection of 0.04 milliliter of n-hexane per kilogram, followed in 15 seconds by rapid intravenous administration of 1-epinephrine bitrate at a dosage rate of 10 micrograms per kilogram. Such procedure produces a transient arrhythmia lasting about 10 seconds. Duration of protection by a test compound is evaluated by repeating the n-hexane and epinephrine challenge periodically and monitoring electrocardiogram and arterial blood pressure. In such operations the above-named quaternary ammonium compound is found to give excellent protection against the arrhythmias when administered intravenously at a dosage rate of one milligram per kilogram, the duration of antiarrhythmic effect lasting about 1 hour. When the same compound is administered at a dosage rate of 2 milligrams per kilogram, the duration of protection is found to be greater than 2 hours.
In similar operations, dosages of 5 to 10 milligrams per kilogram are found to be required to obtain similar antiarrhythmic effects when the known antiarrhythmic agent, quinidine sulfate, is employed as a test compound.
In other operations carried out by procedures similar to that described by Bacaner, American Journal of Cardiology, 21, 504 (1968); the intravenous administration of [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-methylallyl) ammonium chloride to electrically paced dogs is found to provide substantial increases in the threshold for electrically induced ventricular fibrillation.
EXAMPLE 29
An experimental occlusion of the anterior descending coronary artery is produced in dogs according to the method of Harris, Circulation 1, 1318 (1950). Following surgery the animals are given a penicillin-streptomycin preparation and allowed to recover for 18-24 hours. The animals are given 3 milligrams per kilogram of morphine sulfate as an analgetic and sedative to allow handling. Electrocardiograms are recorded both before and after administration of [2-(2-amino-2,6-dibromophenoxy)ethyl]dimethyl-(2-methylallyl)ammonium chloride to the test animals. The incidence of abnormal complexes (premature ventricular contractions and atrioventricular nodal beats) per minute is recorded as a percentage of total beats per minute. In one such operation the test compound is administered by intravenous infusion at rates of 1, 2, 2 and 2 milligrams per kilogram at intervals of 10 to 15 minutes. A marked decrease in heart beat rate is observed with a concomitant decrease in percentage of abnormal beats per minute following the first infusion. Following the last infusion of test compound the heartbeat rate is observed to have decreased from a rate of over 160 beats per minute prior to the first infusion to about 90-100 beats per minute. The incidence of ectopic beats at this time has decreased from a pre-treatment level of 100 percent abnormal beats per minute to below 60 percent, reaching zero (100 percent normal beats) within about 10 minutes after the last infusion. The lower heartbeat rate and low incidence of abnormal beats (generally 0 to 20 percent of the total beats per minute are abnormal) is found to persist for 2 hours following the last infusion of test compound, at which time the experiment is terminated.
In similar operations, the same test compound is infused at dosages of 1, 2 and 4 milligrams per kilogram at intervals over a forty minute period. Prior to infusion the incidence of abnormal beats is 100 percent. Within about eight minutes following the last infusion, a substantially complete conversion to sinus rhythm is obtained. The incidence of abnormal beats is found to remain at zero with occasional brief periods of slight arrhythmia (2-5 percent abnormal beats) for 2.5 hours following the last dosage of the test compound, when recording is terminated. Resumption of recording 215 minutes later indicates that significant anti-arrhythmic effects are still exhibited.
In a similar operation the [2-(2-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-methylallyl)ammonium chloride is administered orally in gelatin capsules. The test compound is administered in multiple dosages of 30, 30 and 50 milligrams per kilogram over a period of 150 minutes. Periods of reduced frequency of abnormal heart beats are noted beginning 10 minutes after administration of the first dosage of test compound, the second and third doses providing further and more consistent antiarrhythmic effects. Beginning about 25 minutes after the last dose of the test compound is administered the electrocardiogram shows periods in which less than 10 percent of the beats are abnormal interspersed with occasional periods of arrhythmia. Antiarrhythmic effects continue to be observed until the recording is terminated 140 minutes after the last dose of test compound.
EXAMPLE 30
[2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl-(allyl)ammonium bromide is administered to mice intravenously and orally. The animals are thereafter sacrificed and blood and heart tissue analyses are carried out to ascertain the concentration of test compound present. In such operations mice intravenously administered the test compound at a rate of 6 milligrams per kilogram are found to have blood levels of 27 micrograms of test compound per milliliter 10 seconds after injection, 2.1 micrograms per milliliter 3 minutes after injection. Analysis of heart tissue indicates a concentration of 5.5 micrograms of test compound per gram of tissue 10 minutes after injection. Similar analyses are carried out with animals administered 6 milligrams of test compound per kilogram orally. Thirty minutes after oral administration, blood and heart levels of 1.1 and 5.1 micrograms, respectively, of test compound per milliliter of blood or gram of heart tissue, respectively, are found.
Similar operations carried out by administration of [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-methylallyl)-ammonium chloride to rabbits similarly indicate oral absorption of the test compound. Significant blood and heart levels of test compound are detected with both oral and intravenous administration.
EXAMPLE 31
An aqueous solution of [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl (2-methylallyl)ammonium chloride is administered orally to several groups of male and female Sprague-Dawley derived rats and male and female Swiss mice (Cox strain). The compound is administered as single oral dosages in varying amounts, and the animals are held to assess toxicity twenty-four hours after administration of the compound. In such operations, the quaternary ammonium compound is found to have an LD 50 of 758 milligrams per kilogram (mg/kg) in the male rats; 725 mg/kg in the female rats, 560 mg/kg in the male mice, and 550 mg/kg in the female mice.
EXAMPLE 32
35 Grams of [2-(4-amino-2,6-dibromophenoxy)ethyl]-dimethyl (2-methylallyl)ammonium bromide is dissolved in 2 liters of sterile normal physiological saline solution. The solution is filtered and filled into 10 cubic centimeter (cc) syringes calibrated to permit injection of the parenteral preparation in 0.5 cc increments. The syringes are individually packaged in containers adapted to maintain sterility and sterilized. The parenteral dosage units are each adapted for parenteral administration of the active compound in increments of about 8.75 milligrams each to a total of 175 milligrams.
Similar parenteral preparations are prepared using 25 grams of [2-(4-amino-2,6-dibromophenoxy)ethyl](ethyl)methyl-(allyl) ammonium methane sulfonate in 1.5 liters of Lactated Ringer's Injection; 40 grams of 1-[2-(4-amino-2,6-diiodophenoxy)ethyl) (2-methylallyl)3,4-dimethylpyrrolidinium bromide hydrobromide in sterile distilled water containing 0.4 percent chlorobutanol preservative; and 10 grams of [3-(4-diethylamino-2,6-dichlorophenoxy)propyl]dimethyl(2-propynyl)-ammonium chloride in 1 liter of Dextrose Injection.
EXAMPLE 33
100 Parts of [3-(4-amino-2,6-dichlorophenoxy)-propyl]dibutyl(3-butynyl)ammonium methanesulfonate and 35 parts of lactose are mixed well with 751 parts of starch. The mixture is filled into gelatin capsules in the amount of 0.4 grams per capsules are suitable for oral administration.
EXAMPLE 34
Tablets are prepared from a granulation comprising 50 parts by weight of [2-(4-amino-2,6-dibromophenoxy)ethyl]dimethyl(2-methylallyl)ammonium chloride, 100 parts lactose, 3.5 parts magnesium stearate, 170 parts starch, 50 parts microcrystalline cellulose, one part of a polyoxyethylene sorbitan monooleate surface active dispersing agent and 0.4 part of F.D.&C. approved color. The granulation is screened and compressed into tablets weighing about 0.287 gram each to prepare a composition in dosage unit form adapted for oral administration to animals. The dosage units are adapted to be employed in maintenance antiarrhythmic therapy to inhibit recurrence of arrhythmias in animals subject thereto, and prophylactically to animals in preparation for exposure to physical or chemical conditions creating a risk of cardiac arrhythmia. The tablets are administered to animals at the rate of one or two tablets (containing 50 milligrams of active antiarrhythmic agent) per day. | Quaternary ammonium compounds such as [2-(4-amino-2,6-dibromophenoxy)ethyl[dimethyl (allyl) ammonium bromide are prepared by the reaction of a tertiary amine such as 3,5-dibromo-β-dimethylamino-p-phenetidine with a substituted organic compound such as allyl bromide. The quaternary ammonium compounds are useful in alleviating or inhibiting cardiac arrhythmias when the quaternary ammonium compounds, or compositions comprising the same are administered to animals. | 2 |
This invention relates to a polyvinyl chloride plastisol sealer composition, more particularly a cross-linking polyvinyl chloride plastisol sealer composition which can prevent undesirable cracking of the coating film(s) of intercoat-paint and/or topcoat-paint formed on the layer of the sealer composition, which occurs during the baking and/or cooling steps of the coating films. Said sealer composition is useful as a body-sealer of automobiles in an automobile assembly line.
PRIOR ART
In the automobile assembly line, a sealer is usually used for sealing the automobile body, for example, a certain polyvinyl chloride plastisol composition comprising a polyvinyl chloride resin, a plasticizer, a filler and optionally an adhesive promoter. The sealer is usually used for effecting a watertight and hermetic seal at the joint of panels of the automobile body and exhibits the sealing effects by gelling at the time of baking of the paint in the steps of intercoating and/or topcoating after the application of the sealer. However, during the steps of baking at 140° to 160° C. for 20 to 30 minutes and subsequent cooling thereof, the sealer expands with heating and then shrinks, which causes undesirable cracking of the formed paint-coating films on the sealer and can not give good appearance of the coated paints and further can not exhibit sufficiently the desired sealing effects.
BRIEF DESCRIPTION OF THE INVENTION
The present inventors have intensively studied to find an improved sealer composition which can prevent such undesirable cracking of the coating films on the sealer, and have found that a crosslinking sealer can prevent movement of sealer during the baking and cooling steps and thereby can achieve the desired prevention of cracking of the coating film on the sealer.
An object of the invention is to provide an improved polyvinyl chloride plastisol sealer composition which can prevent undesirable cracking of the coating films on the sealer during =he baking and cooling steps of the intercoat-paint and/or topcoat-paint. Another object of the invention is to provide a crosslinking sealer composition which can inhibit the movement of the the sealer composition and thereby can prevent the undesirable cracking of the paint coating films such as the intercoat and/or topcoat on the sealer. These and other objects and advantages of the invention will be apparent to those skilled in the art from the following description.
DETAILED DESCRIPTION OF THE INVENTION
The polyvinyl chloride plastisol sealer composition of the invention comprises (A) a polyvinyl chloride resin containing a hydroxy group (OH) or a carboxy group (COOH) in the molecule (hereinafter, referred to as "crosslinkable PVC"), (B) a blocked polyisocyanate compound, and (C) an isocyanuric acid compound containing two or more groups selected from epoxy group, hydroxy group (OH) and carboxy group (COOH) in the molecule.
The crosslinkable PVC (component A) includes a copolymer of vinyl chloride with a monomer containing OH or COOH in the molecule (e.g. 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, hydroxybutyl vinyl ether, maleic acid, maleic anhydride, acrylic acid, methacrylic acid, etc.). The component A may optionally be incorporated by a-conventional polymer resin for plastisol, such as a conventional polyvinyl chloride resin or vinyl chloride/vinyl acetate copolymer resin.
The blocked polyisocyanate compound (component B) is prepared by blocking a polyisocyanate compound such as aliphatic polyisocyanates (e.g. hexamethylene diisocyanate, lysine diisocyanate, etc.), alicyclic polyisocyanates (e.g. hydrogenated diphenylmethane diisocyanate, isophorone diisocyanate, hydrogenated tolylene diisocyanate, etc.), aromatic polyisocyanates (e.g. tolylene diisocyanate, diphenylmethane diisocyanate, naphthylene diisocyanate, xylylene diisocyanate, etc.), trimere or dimers of these polyisocyanates, or propolymers which are produced by reacting one of the above polyisocyanates with a compound containing an active hydrogen such as a polyol, with a blocking agent, i.e. a compound containing an active hydrogen, such as alcohols (methanol, ethanol, propanol, butanol, benzyl alcohol, phenyl cellosolve, furfuryl alcohol, cyclohexanol, etc.), phenols (phenol, cresol, xylenol, p-ethylphenol, o-isopropylphenol, p-tert-butylphenol, p-tert-octylphenol, thymol, p-naphthol, p-nitrophenol, p-chlorophenol, etc.), oximes (e.g. formamide oxime, acetamide oxime, methyl ethyl ketone oxime, cyclohexanone oxime, etc.), acid amides (e.g. acetanilide, acetanisidide, acetamide, benzamide, ε-caprolactam, etc.), active methylene-containing acid esters (e.g. dimethyl malonate, diethyl malonate, ethyl acetoacetate, etc.), mercaptanes (e.g. methylmercaptane, thiophenol, tertdodecylmercaptane, etc.), amines (e.g. diphenylamine, phenylnaphthylamine, aniline, carbazole, etc.), imidazoles (e.g. imidazole, 2-ethylimidamole, etc.), carbamates (e.g. phenyl N-phenylcarbamate, 2-oxamolidone, etc.), imines (ethyleneimine, etc.), aulfites (e.g. sodium bisulfite, potassium bisulfite, etc.), and the like. The blocked polyisocyanate compound is de-blocked by heating at the step of baking and gelling, in which there is produced an active isocyanate group (NCO) which participates in the crosslinking reaction with the OH or COOH group of the crosslinkable PVC. The blocked polyisocyanate compound (B) is usually used in an amount of 20 to 60 parts by weight to 100 parts by weight of the crosslinkable PVC.
The isocyanuric acid compound (component C) contains two or more groups selected from epoxy, OH and COOH which participate in the crosslinking reaction with the OH or COOH of the above crosslinkable PVC together with the active NCO of the blocked polyisocyanate compound. The isocyanuric acid compound includes, for example, 1,3,5-triglycidyl isocyanurate, tris-1,3,5-(2-carboxyethyl) isocyanurate, tris-1,3,5-(2-hydroxyethyl) isocyanuate, and the like. The isocyanuric acid compound (C) is usually used in an amount of 5 to 35 parts by weight, preferably 10 to 20 parts by weight, to 100 parts by weight of the crosslinkable PVC. When the amount of the isocyanurlc acid compound is ever 35 parts by weight, the final sealer composition has inferior physical properties (particularly less elongation), and when the amount is less than 5 parts by weight, the composition does not exhibit sufficient crosslinking properties and hence can not show the desired effect for the prevention of cracking of the coating film.
The polyvinyl chloride plastisol sealer composition of the present invention comprises the above mentioned crosslinkable PVC (component A), blocked polyisocyanate compound (component B) and isocyanuric acid compound (component C), and may optionally incorporate any conventional additives, such as plasticizerm (e.g. phthalates such as di(n-butyl) phthalate, octyl decyl phthalate, diisodecyl phthalate, di(2-ethylhexyl) phthalate, butyl benzyl phthalate, dioctyl phthalate (DOP), dinonyl phthalate, diisononyl phthalate (DINP), diheptyl phthalate, dodecyl benzyl phthalate, butylphthalyl-butylglycol, etc.; aliphatic dibasic acid esters such as dioctyl adipate, didecyl adipate, dioctyl sebacate, di(2-ethylnexyl) adipate, diisodecyl adipate, di(2-ethylhexyl) azelate, dibutyl sebacate, di(2-ethylhexyl) sebacate, etc.; phosphates such as tricresyl phosphate, trioctyl phosphate, tributyl phosphate, tri(2-ethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate, etc.; epoxy plasticizers such as epoxidized soybean oil, epoxidized tall oil fatty acid 2-ethylhexyl esters, etc.; and other conventional polyester plasticizers); fillers (e.g. precipitated calcium carbonate or a product thereof surface-treated with an aliphatic acid or resin acid, ground calcium carbonate, calcium oxide, clay, talc, silica, glass powder, etc.); stabilizers for inhibiting dehydrochloric acid reaction (e.g. metal soap, organic tin compounds, etc.); heat stabilizers (e.g. dibutyl tin laurate, epoxidized soybean oil, Ba or Zn compounds, etc.), pigments (e.g. titanium white, etc.); fire retardants, and the like, which are used in an appropriate amount usually used in the conventional sealer composition.
The sealer Composition of the present invention can mainly be used as a body-sealer of automobiles, but may also be used for other utilities, for example, as an under-body coating material which is used for prevention of injuries to body due to stone chipping on the road during running of automobiles.
EXAMPLES
The present invention is illustrated by the following Examples and Reference Examples but should not be construed to be limited thereto.
EXAMPLES 1 AND 2 AND REFERENCE EXAMPLES 1 TO 3
The materials as shown in the following Table 1 are mixed and the mixture is degassed under reduced pressure to give polyvinyl chloride plastisol sealer compositions.
The evaluation of cracking of the coating film and other properties as shown in Table 1 were carried out in the following manner.
(1) Viscosity: using BH viscometer, with rotor #7, at number of revolution 20 r.p.m., and 20° C.
(2) Adhesion:
The sealer compositions of Examples 1 and 2 and Reference Examples 1 to 3 were each applied in the bead form onto a surface of a steel panel coated by a cationic electrodeposition and subjected to baking and gelling at 120° C. or 140° C. for 30 minutes. After cooling, the sealer layer thus formed was peeled and the adhesion was evaluated by the criteria of CF: cohesive failure, i.e. failure of the sealer, and AP: adhesive failure, i.e. the interfacial failure between the electrodeposited coating layer and the sealer.
(3) Cracking Of the coating films:
The sealer compositions of Examples 1 and 2 and Reference Examples 1 to 3 were each coated in the bead form (10 mmφ half round shape×100 mm) on a surface of a steel panel coated by an electrodeposition and subjected to baking and gelling at 120° C. for 10 minutes. On the sealer composition layer was further coated an intercoat-paint (melamine alkyd resin paint) by spray coating (thickness, about 30 μm), followed by baking and curing by heating at 140° C. for 30 minutes, and further thereon was coated a topcoat-paint (melamine alkyd resin paint) by spray coating (thickness, about 30 μm), followed by baking and curing by heating at 160° C. and 170° C. for 30 minutes respectively, and then, the cracking of the surface of the cured topcoat on the sealer was observed and evaluated by the following criteria:
◯: No cracking, good properties
Δ: Cracking of less than 1 mm width
x: Cracking of more than 1 mm width
(4) Elongation:
The sealer compositions of Examples 1 and 2 and Reference Examples 1 to 3 were each applied in a thickness of 2 nun onto a surface of a release paper and subjected to baking and gelling at 140° C. for 60 minutes. After gelling, the elongation of the sealer composition with #2 Dumbbell in accordance with the method as described in Japanese Industrial Standard (JIB) K6830.
(5) Storage stability:
The sealer compositions of Examples I and 2 and Reference Examples 1 to 3 were each entered in a 250 cc Glass-made vessel and sealed. After keeping the vessel at 40° C. for 5 days, the change of viscosity of the composition was measured. The storage stability of the composition was evaluated by the percentage of the viscosity after being kept at 40° C. for 5 days of the initial viscosity of the sealer composition. When the number of the percentage of viscosity is smaller, and hence, the increase of the viscosity is smaller, it is evaluated that the storage stability is better.
These results are shown in Table 1.
TABLE 1______________________________________ Examples Ref. Examples 1 2 1 2 3______________________________________PVC for plastisol (*1) 200 200 200 300 200Crosslinker PVC (*2) 100 100 100 -- 100Plasticizer (*3) 400 400 400 400 400Surface treated 270 270 270 270 270calcium carbonateCalcium carbonate 300 300 315 300 355Blocked 85 85 85 85 --polyisocyanate (*4)Polyamide resin -- -- -- -- 30(adhesive promoter)(*5)1,3,5-Triglycidyl 15 -- -- 15 15iso-cyanurateTris-1,3,5-(2-hydroxy- -- 15 -- -- --ethyl) isocyanurateOther additives 60 60 60 60 60Total 1430 1430 1430 1430 1430(parts by weight)(1) Viscosity (poise) 900 950 1200 920 750(2) Adhesion120° C. × 30 min. CF CF CF CF AF140° C. × 30 min. CF CF CF CF CF(3) Cracking of the coating film160° C. × 30 min. ∘ ∘ Δ x x170° C. × 30 min. ∘ Δ x x x(4) Elongation (%) 180 180 210 230 150(5) Storage 125 120 120 115 140stability (%)______________________________________ Notes in Table 1: *1: Zeone 121, manufactured by Nippon Zeone K.K. *2: Vinica P100, manufactured by Mitsubishi Kasei Vinyl K.K. *3: Diisononyl phthalate *4: Trimer of hexamethylene diisocyanate blocked with nonylphenol *5: Barsamide 115, manufactured by Henkel Hakusui K.K. | A polyvinyl chloride plastisol sealer composition comprising (A) a polyvinyl chloride resin containing hydroxy group or carboxy group in the molecule, (B) a blocked polyisocyanate compound, and (C) an isocyanuric acid compound containing two or more groups selected from epoxy group, hydroxy group and carboxy group in the molecule, which is particularly useful for sealing the panels of automobile body without undesirable cracking of the coating films of the intercoat-paint and/or topcoat-paint applied on the sealer. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of domestic appliances, particularly the field of blenders, juice extractors or the like.
BACKGROUND OF THE INVENTION
[0002] Juice extractors have become increasingly popular over the years. These devices extract juice from fresh fruits and/or vegetables and provide people with fresh, healthy, and all natural beverages.
[0003] While numerous health benefits are associated with juicing, the extraction process is often known to be time-intensive, difficult, and messy. Typically, a user must: gather necessary fruit and/or vegetables, wash and cut the food to proper size, insert all food into the extractor, dispose of the organic waste, disassemble and clean the extractor parts, and lastly reassemble the extractor. Thus, many users are left frustrated and demanding a better option. Moreover, a correct portion size is not easily enforced due to no standard amount of fruit and/or vegetables allowed to be juiced during a single session. It is also known that devices have been made that simply blend fruit and/or vegetables into a pulp and provide both the pulp and juice mixed together for consumption. However, many people prefer a pulp-free beverage.
[0004] In a fast-paced world, there is an increasing demand for healthy beverages that can be prepared easily, quickly, and most importantly with minimal cleanup. Furthermore, people would greatly benefit from a properly portioned, fresh beverage from the comfort of their own home. For the foregoing reasons, there is a need for a machine that can produce personal juice beverages from fresh fruit and/or vegetables.
BRIEF SUMMARY
[0005] The present invention is directed to a personal blender and juicer system that meets these needs.
[0006] Specifically, it is an aspect of the invention to provide a food blending and pressing apparatus. The food blending and pressing apparatus includes a housing that covers moving machinery used for blending and pressing food and/or beverage in a removable container located in a container chamber. The upper face of the bottom of the container chamber preferably includes an anti-rotational surface so that when the container with a preferably complimentary anti-rotational bottom surface is inserted into the container chamber, the container is secured. A start button is preferably pressed by a user to initiate the automatic blending and pressing process. A blending tool is rotated by a driving source which blends food and/or beverage in the container to a desired consistency while a cover hermetically seals the container during the blending process. A primary elevator assembly is used to raise and lower a shaft attached to the blending tool during the blending process. The primary elevator is preferably driven by a spring-loaded lever. A secondary elevator assembly is used to raise and lower the cover during the blending and pressing. The secondary elevator is preferably driven by an inflatable and deflatable airbag. Once the blending process is complete, the cover is used to press the food and/or beverage towards the bottom of the container causing liquid to flow through an outlet in the container. The shaft is preferably connected to the driving source as well as to the secondary elevator by quick release connectors for quick removal and cleaning. The cover is preferably connected to the secondary elevator by a quick release connector for quick removal and cleaning.
[0007] Furthermore, it is another aspect of the invention to provide a container. The preferably cylindrical container has an upper opening to afford food and/or beverage, a blending tool and a cover. The top diameter of the container is preferably larger than that of the bottom diameter to allow for efficient stacking and a funnel is preferably connected to the top of the container to allow the cover to properly seal upon entering the upper opening of the container. The sides of the container preferably have vertical concave grooves extending half-way down to allow pressure to escape when the cover is inserted into the container. A spacer may be mounted at the center of the upper face of the bottom of the container to prevent the blending tool from contacting the bottom of the container during operation. The container preferably includes an anti-rotational surface on the bottom so that when inserted into a food blending and pressing apparatus with a complementary anti-rotational surface, the container is properly secured. The container is removably inserted into a food blending and pressing apparatus. Food and/or beverage is first blended and then pressed in the container, forcing liquid to flow through an outlet fitted with a filter in the bottom of the container into an external cup. The outlet is preferably connected to a secondary outlet extending out to a spout, thereby allowing liquid to be received in the external cup placed adjacent to the container. The outlet is preferably covered by a valve that prevents liquid from passing out of the container due to gravity. Furthermore the outlet and open top are preferably covered with a plastic film to prevent contamination prior to use.
[0008] It is another aspect of the invention to provide a method of blending and pressing food and/or beverage in a container wherein food and/or beverage is placed on a container, the container is secured in a container chamber, a shaft with a blending tool is lowered into the container while a cover is also lowered into the container to seal the container, the shaft and the blending tool are rotated by a driving source thereby blending the food and/or beverage, the shaft and the blending tool are moved up and down as necessary until a desire consistency is met, the cover is lowered further into the container thereby forcing liquid through an outlet in the container and into an external cup, followed by the cover, shaft, and blending tool being retracted, and then removing the container from the chamber. The cover and blending tool may be removed for cleaning.
[0009] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention is generally shown by way of reference to the accompanying drawings in which:
[0011] FIG. 1 is a perspective view of one embodiment of a food blending and pressing apparatus with both primary and secondary doors open, the container chamber empty, and the blending tool and cover removed;
[0012] FIG. 2 is a perspective view similar to FIG. 1 with the blending tool and cover inserted;
[0013] FIG. 3 is a perspective view similar to FIG. 2 with the container inserted in the container chamber;
[0014] FIG. 4 is a perspective view similar to FIG. 3 with both primary and secondary doors closed and an external cup placed next to the food blending and pressing apparatus;
[0015] FIG. 5 is a frontal cross sectional view of the food blending and pressing apparatus of FIG. 3 showing the blending tool and cover fully refracted;
[0016] FIG. 6 is a frontal cross sectional view similar to FIG. 5 showing the blending tool and cover are partially extended downward wherein the cover contacts the container;
[0017] FIG. 7 is a frontal cross sectional view similar to FIG. 6 showing the blending tool and cover extended downward wherein the blending tool contacts the spacer;
[0018] FIG. 8 is a side cross sectional view of the food blending and pressing apparatus of FIG. 5 showing the airbag apparatus deflated;
[0019] FIG. 9 is a side cross sectional view of the food blending and pressing apparatus of FIG. 7 showing the airbag inflated;
[0020] FIG. 10 is a perspective view of the blending tool and cover assembly of the blending and pressing apparatus shown in FIG. 2 ;
[0021] FIG. 11 is a perspective view of one embodiment of a container in accordance with the present invention;
[0022] FIG. 12A is a side cross sectional view of the container shown in FIG. 11 ;
[0023] FIG. 12B is an enlarged side cross sectional view of the spout shown in FIG. 12A with liquid exiting the spout;
[0024] FIG. 13 is an exploded view of the container shown in FIG. 11 ;
[0025] FIG. 14 is a perspective view of another embodiment of a container in accordance with the present invention, a plastic film is shown covering the open top;
[0026] FIG. 15 is a perspective view of the bottom of the container shown in FIG. 14 ;
[0027] FIG. 16 is a cross sectional view of the container shown in FIG. 14 ; and
[0028] FIG. 17 is a perspective view of another embodiment of a container in accordance with the present invention, the sides are angled such that the containers are stackable.
DETAILED DESCRIPTION
[0029] Referring to the drawings, FIGS. 1-4 generally depict a food blending and pressing apparatus 100 comprising a removable container 200 with an open top 201 received in a container chamber 101 , a cover 111 used for both sealing open top 201 and pressing the contents in container 200 , and a blending tool 112 used for chopping, mixing, or liquefying food in container 200 .
[0030] FIG. 11 provides a view of one embodiment of container 200 . Container 200 further comprises sides 202 which may be generally cylindrical and a bottom 203 . For example, container 200 is constructed to hold food and/or beverage before, during, and after the blending and pressing process. An outlet 204 is mounted through bottom 203 to allow liquid to flow out of container 200 when pressurized. Outlet 204 has a filter 207 which provides a sieve-like configuration to prevent solids from flowing out of container 200 during the blending and pressing process. A spacer 205 may be mounted on the upper surface of bottom 203 . As shown in FIG. 7 , spacer 205 prevents blending tool 112 from hitting and thus damaging bottom 203 during operation. The upper face of spacer 205 is a bearing surface 206 and therefore allows blending tool 112 to spin freely while contacting bearing surface 206 .
[0031] In one example of container 200 , all parts of container 200 are manufactured with non-hazardous materials conforming to international food safety standards. The materials used to construct it may be such that container 200 is discarded after a single use. Likewise, in another example, the materials used to construct container 200 may be such that it is reusable after cleaning by increasing the thickness and strength of such materials.
[0032] FIG. 10 illustrates one embodiment of cover 111 . Cover 111 is used to hermetically seal open top 201 of container 200 and also to press food and/or beverage toward bottom 203 forcing liquid to flow out through outlet 204 . For example, a secondary elevator assembly 109 is attached to cover 111 ( FIGS. 5-7 ) to provide the means to vertically reciprocate cover 111 up and down as needed during the blending and pressing process. The reciprocating motion of secondary elevator assembly 109 may be driven by deflating and inflating an airbag apparatus 116 . A releasable connector 118 may be integrated into cover 111 to allow cover 111 to be removed for cleaning ( FIG. 10 ).
[0033] FIG. 10 also illustrates one embodiment of blending tool 112 . Blending tool 112 is attached to the bottom end of a shaft 110 . Shaft 110 is extended through the center of cover 111 and includes a connector 117 on the top end of shaft 110 that is connected to a driving source 114 using a belt 113 to rotate blending tool 112 . In the preferred embodiment, connector 117 has a hex shaped cross-section and is integrated into shaft 110 . A sanitary seal 121 is attached to cover 111 , hermetically sealing cover 111 about shaft 110 thereby preventing air, liquid, or solids escaping from container 200 ( FIG. 7 ). A primary elevator assembly 108 is attached to shaft 110 to provide the means to vertically reciprocate blending tool 112 up and down as needed during the blending and pressing process ( FIGS. 5-7 ). The reciprocating motion of primary elevator assembly 108 may be driven by a spring-load lever 115 ( FIGS. 8-9 ). Connectors 117 and 119 may be releasable to allow blending tool 112 and shaft 110 to be removed for cleaning. Blending tool 112 may include radially extended cutting blades 120 with sharpened edges, pointed tips, and one or more bends along the surface of the cutting elements.
[0034] FIGS. 1-4 generally illustrate the process of installing components into food blending and pressing apparatus 100 . FIG. 1 shows a housing 107 used to protect the components. A primary door 103 and latch 104 may be opened to provide access to blending tool 112 and cover 111 ( FIG. 2 ). A secondary door 102 and latch 105 may be opened to provide access to container chamber 101 . Blending tool 112 and cover 111 are inserted into food blending and pressing apparatus 100 as shown in FIG. 2 . Container 200 is charged with food and inserted into food blending and pressing apparatus 100 as shown in FIG. 3 . FIG. 4 shows one embodiment where primary door 103 and secondary door 102 are closed and an external cup 300 next to food blending and pressing apparatus 100 . During the food blending and pressing process, juice may be extracted out through spout 213 into external cup 300 for consumption ( FIGS. 12A-12B ). Spout 213 may be connected to a secondary outlet 212 which may be connected to outlet 204 .
[0035] Sides 202 of container 200 may be constructed in an inverted frustaconical shape such that the diameter of open top 201 is larger than the diameter of bottom 203 ( FIG. 17 ). This allows container 200 to be stacked in another container 200 efficiently when empty. Container 200 may include a funnel 208 attached to open top 201 thereby correcting small misalignments when cover 111 is lowered into container 200 . Container 200 may include one or more vertical pressure relief grooves 209 ( FIG. 11 ) which allows pressure to escape container 200 until cover 111 is lowered below the bottom of pressure relief grooves 209 . This allows cover 111 and blending tool 112 to be lowered into container 200 without forcing liquid through outlet 204 . Also, a valve 211 may cover outlet 204 to prevent liquid from flowing out of container 200 until pressure is applied inside container 200 , forcing liquid through outlet 204 ( FIG. 15 ).
[0036] Bottom 203 may include an anti-rotational surface 210 in the shape of a downwardly protruding triangular-shaped vane ( FIG. 15 ). Anti-rotational surface 210 is complementary to a concavely shaped anti-rotational surface 122 located in the bottom of container chamber 101 ( FIG. 1 ) and such that when container 200 is inserted in container chamber 101 , container 200 is unable to rotate. A plastic film 214 may be fixed to both open top 201 ( FIG. 14 ) and outlet 204 ( FIG. 15 ) of container 200 to prevent contamination prior to use.
[0037] FIGS. 14-16 generally illustrate an alternative configuration to container 200 . No spout 213 or secondary outlet 212 are used. Outlet 204 may allow liquid to flow out of container 200 into an external cup (not shown) directly below container 200 .
[0038] In the preferred embodiment, container 200 is filled with food and/or beverage and then placed in container chamber 101 . A start button 106 is pressed by the user to initiate the blending and pressing process. The blending and pressing process begins by lowering shaft 110 along with attached blending tool 112 into container 200 while also lowering cover 111 into container 200 until cover 111 contacts container 200 , thereby sealing open top 201 . The food and/or beverage is blended by rotating shaft 110 and blending tool 112 using driving source 114 . Shaft 110 and blending tool 112 are lowered and raised as necessary while rotating in order to properly blend the contents and then rotation is halted once a preferred consistency is met. Cover 111 is then lowered further into container 200 , pressing food and/or beverage towards bottom 203 and forcing liquid through outlet 204 . After the desired liquid has been extracted from the food and/or beverage, cover 111 , shaft 110 , and blending tool 112 are fully retracted and container 200 is removed from container chamber 101 . Cover 111 and blending tool 112 may be removed from food blending and pressing apparatus 100 for cleaning.
[0039] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained therein. Any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specified function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. §112, ¶6. In particular, the use of “step of” in the claims is not intended to invoke the provisions of 35 U.S.C. §112, ¶6.
[0040] The reader's attention is directed to all papers and documents which are filed concurrently with his specification and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. All features disclosed in this specification (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. | The invention concerns a personal juice extractor system including a blending and pressing apparatus where a user places a container charged with food or beverage or any combination thereof in a container chamber. After the start button is pressed, a blending tool attached to a shaft along with a cover are lowered into the container until the cover seals the open top of the container. The blending tool is axially rotated until a desired consistency is achieved. The cover then presses down on the blended contents, forcing liquid to flow out an outlet in the bottom of the container and into an external cup for consumption. The cover, shaft, and blending tool are retracted and then the container is removed from the container chamber and discarded or cleaned for reuse. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/756,847, filed Jan. 6, 2006, which is incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a rotary latch.
[0004] 2. Description of Related Art
[0005] Rotary latches are well known in the art, providing a strong, compact latching mechanism for many applications. A rotary latch generally includes a housing portion fixed to a first structure having a U-shaped slot configured to receive a post fixed to an opposing structure. A C-shaped latch is pivotally attached within the housing and arranged to rotate from a latched position within and perpendicular to the U-shaped slot to an unlatched position. In the latched position, the C-shaped latch and the U-shaped notch overlap to define a central opening configured to hold the post. In the unlatched position, the C-shaped latch is rotated toward the opening of the U-shaped slot, allowing the post to move into or out of the U-shaped slot. The C-shaped latch usually includes a catch on its body in an opposing position to the opening of the “C” relative to the pivot point of the latch. The catch is configured to act in concert with a trip lever pivotally mounted within the housing. The C-shaped latch and the trip lever are generally spring-biased. The C-shaped latch is biased in an open position and the trip lever is biased in a locked position. When the C-shaped latch is moved into the closed position, the trip lever is biased to engage the catch, holding the C-shaped latch in the closed position. The C-shaped latch is released by rotating the trip lever until it disengages from the catch. A stud is usually mounted to the trip lever for attachment of a release cable. Because of the configuration of the trip lever having a fixed pivot axle, it is necessary to arrange the release cable in a very narrow approach angle to the stud, in order to be able to pivot the trip lever with a minimal force exerted on and by the release cable. In the known arrangement, the release cable is generally aligned parallel to the housing of the rotary latch. Deviations from the optimal attachment of the release cable to the stud, with a tangential positioning of the cable relative to the pivot axis of the trip lever, unnecessarily increase the force required to release the rotary latch. The mechanical advantage available in the trip lever can therefore be lost by suboptimal positioning of the cable. Also, in different applications, it becomes necessary to modify the configuration of the trip lever and the stud so that the release cable can even access the stud. This necessitates the manufacture and stocking of multiple configurations of rotary latch assemblies, dependent upon the variety of applications used in a particular assembly.
[0006] It would be advantageous to provide a rotary latch system that provides the maximum available mechanical advantage regardless of the exact alignment of the release cable relative to the pivot axis of the trip lever. It would further be advantageous to provide a rotary latch system that improves the accessibility of a release mechanism in different applications without requiring the physical modification of the rotary latch.
BRIEF SUMMARY OF THE INVENTION
[0007] A rotary latch for selectively locking a closure, such as a tonneau cover on a pickup truck bed or the swing-up window on a pickup truck cap, is provided with a spring loaded toggle release lever, or joystick. The joystick enables the rotary latch to be installed in any position with respect to a remote actuating handle because the joystick can be pushed or pulled in almost any direction to release the rotary latch.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] The present invention will become more fully understood from the following detailed description and the accompanying drawings, wherein:
[0009] FIG. 1 is a side view of a pickup truck with a tonneau cover and a rotary latch with joystick according to the invention.
[0010] FIG. 2 is a partially broken sectional view of the rotary latch according to the invention, mounted on FIG. 1 pickup truck tailgate and tonneau cover, and substantially as taken on the line 2 - 2 of FIG. 3 .
[0011] FIG. 3 is a front view of the rotary latch of FIG. 2 .
[0012] FIG. 3A shows various means for actuating connection to the joystick of FIG. 3 and schematically illustrates the possibility of linking two (or more) latch mechanisms by means of their joysticks.
[0013] FIG. 3B shows a power actuator to joystick connector according to FIG. 3 .
[0014] FIG. 3C shows an unlatched position of parts of the FIG. 3 apparatus.
[0015] FIG. 4 is a pictorial view of the rotary latch of FIG. 3 .
[0016] FIG. 5 is a bottom view of the rotary latch of FIG. 3 .
[0017] FIG. 6 is a rear view of the rotary latch of FIG. 3 .
[0018] FIG. 6A is a fragment of FIG. 3 showing the joystick in central cross section.
[0019] FIG. 6B is a sectional view substantially taken on the line 6 B- 6 B of FIG. 6 .
[0020] FIG. 7 is an end view of the rotary latch of FIG. 3 .
[0021] FIG. 8 is an opposite end view of the rotary latch of FIG. 3 .
[0022] FIG. 8A is an exploded pictorial of a bracket for mounting the latch mechanism of FIGS. 1-8 .
[0023] FIG. 9 is an exploded pictorial view of the housing of the rotary latch of FIG. 3 .
[0024] FIG. 9A is a pictorial view of the latch member and latch release member of the rotary latch of FIG. 3 .
[0025] FIG. 10 is a side view similar to FIG. 6 , but with the rear housing portion mostly removed.
[0026] FIGS. 11A-11H depict the release sequence the main parts (only) of the rotary latch of FIG. 3 .
[0027] FIG. 12 is an end view of the free end of the joystick of the rotary latch of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0028] Certain terminology will be used in the following description for convenience in reference only and will not be limiting. The words “up”, “down”, “right” and left” will designate directions in the drawings to which reference is made. The words “in” and “out” will refer to directions toward and away from, respectively, the geometric center of the device and designated parts thereof. The words “proximal” and “distal” will refer to the orientation of an element with respect to the device. Such terminology will include derivatives and words of similar import.
[0029] FIG. 1 shows an application by way of example and not limitation, for the present invention. The invention is applicable in any enclosure requiring selective latching, and wherein the release of said latching can be accomplished by powered or manual actuation, electronically or mechanically, or by direct or remote control. In a motor vehicle 50 , e.g. a pickup truck, the present invention is applied for latching a door on a pickup truck cap or, as here shown, a tonneau cover 55 over a pickup truck bed cargo area 60 having a tailgate 65 . The tonneau cover 55 is movable between an open position (shown) and a closed position (shown in phantom). In the closed position, the tonneau cover 55 can be secured by a latch mechanism 100 releasably engaging a pin, or strike, 110 ( FIG. 2 ). The latch mechanism 100 is here indicated as being mounted on the tonneau cover 55 and the pin 110 on the tailgate 65 , respectively, but could on the tailgate 65 and tonneau cover 55 , respectively instead.
[0030] The latch mechanism 100 is attached to the inside of the tonneau cover 55 by a bracket 105 . A cooperating pin 110 is mounted to the tailgate 65 .
[0031] Referring further to FIGS. 3A-3C , the latch mechanism 100 includes a joystick 130 . The joystick 130 is spring biased into a rest position (vertical as shown in the drawings), and as will be further disclosed, displacement of the joystick 130 from such vertical position triggers unlatching of the latch mechanism 100 .
[0032] Referring now to FIGS. 5-10 , the latch mechanism 100 has a housing 140 formed of a left (in FIGS. 7-9 ) housing portion 145 and a right housing portion 150 .
[0033] The left ( FIG. 9 ) housing portion 145 comprises an elongate longitudinally extending sidewall 145 A having a laterally and endwardly facing notch 145 B, an elongate longitudinal flange 145 C extending widthwise perpendicularly from and following one length edge of the sidewall, a perpendicular first end flange 145 D at the notched end of the sidewall and adjacent one end of the elongate flange 145 C, a narrow step-like end wall 145 E extending widthwise perpendicularly from the other end of the sidewall to about half the width of the adjacent end of the elongate flange 145 C, an extension wall 145 F extending longitudinally from the free edge of the end wall 145 E in a plane parallel to the sidewall 145 A, and a narrow end flange 145 G extending from the free end of the extension wall generally parallel to and spaced from the step-like end wall 145 E.
[0034] The housing portion 150 is preferably substantially a mirror image of the housing portion 145 except as follows. The housing portion 150 comprises a longitudinally and widthwise extending flange 150 H at the longitudinally extending edge 150 J of its notch 150 B, but omits parts comparable to the longitudinal flange 145 C, first end flange 145 D and narrow end flange 145 G of the housing portion 145 .
[0035] The left and right housing portions are joined by a pair of swaged bushings 175 , 180 whose ends are fixedly received in respective apertures 155 , 165 and 160 , 170 in recessed portions of the sidewalls 145 A and 150 A. The swaged bushings 175 , 180 each have a threaded interior passage 185 for receiving a threaded fastener (e.g. screw) 190 , for securing the latch mechanism 100 to the bracket 105 and to an alignment plate 195 . In FIG. 3 , the bracket 105 is fixed to the tonneau cover 55 by bolt and nut units 194 . The left (in FIGS. 5 , 6 and 10 - 11 ) end 196 of housing 140 defines a U-shaped channel, or notch, 198 for receiving the pin 110 .
[0036] The housing narrow end walls 145 E and 150 E space the housing extension walls 145 F and 150 F laterally inboard of the housing sidewalls 145 A and 150 A, at the width of the end flange 145 G. The extension walls 145 F and 150 F and end flange 145 G define the left (in FIGS. 5 and 6 ) end portion 196 of the housing as a narrow (compared to the width of the housing at the sidewalls 145 and 150 ) nose 196 . The narrowed nose 196 allows mounting of the housing very close (e.g. almost abutting as in FIG. 5 ) the structure 65 (e.g. the truck tailgate) carrying the cooperating conventional pin 110 , even if the latter incorporates a radially projecting mounting flange, or the like, as indicated in the dotted line at 111 in FIG. 5 . Moreover, and as will be noted in FIG. 5 , since the narrowed nose 196 is spaced laterally inboard from both sidewalls 145 A and 150 A of the housing 140 , the housing 140 can be placed close to the pin supporting structure 65 , even with its orientation reversed, e.g. with its sidewall 150 A adjacent the pin supporting structure 65 , rather than its sidewall 145 A as in FIG. 5 . Thus, not only can the latch mechanism 100 be mounted in any desired orientation (e.g. joystick up, joystick down, joystick left, joystick right, housing length axis vertical or horizontal or sloped, but in any of those orientations, the housing 140 can be placed close to or spaced from the pin support structure 65 with which the latch mechanism 100 latchingly cooperates.
[0037] The mounting bracket 105 here includes a main body and a mounting flange 106 perpendicular thereto. Slots 107 and 108 in the main of the bracket 105 and in the flange 106 , respectively, allow adjustment of the location of the bracket 105 with respect to the adjacent side of the housing 140 and structure (e.g. the tonneau cover 55 of FIG. 1 ) on which the bracket is fixed.
[0038] To allow mounting of the housing 140 , in its contents, in any desired orientation, the bracket 105 may be fixed on either side of the housing 140 , e.g. either adjacent to the sidewall 150 A as seen in FIG. 8 , or to the opposite side wall 145 A. Moreover, with the mounting bracket 105 fixed to supporting structure (e.g. the FIG. 1 tonneau cover 55 ) by means of its mounting flange 106 ( FIG. 8 ), the housing 140 can be fixed in its joystick down orientation of FIG. 8 or reoriented with the joystick 130 up.
[0039] The alignment plate 195 ( FIG. 8A ) has through holes 195 A spaced from each other widthwise of the plate 195 at the same spacing as the slots 107 and the bracket and bushing holes 155 and 160 in the housing portion 145 and holes 165 and 170 in the housing portion 150 so as to coaxially align therewith. Aligned with the holes 195 A are a pair of upper lugs 195 B and a pair of lower lugs 195 C adjacent the top and bottom (in FIG. 8A ) edges of the alignment plate 195 . The lugs 195 B and 195 C protrude toward and are of width be snuggly received in the bracket slots 107 , as indicated in FIG. 8 . With the screws 190 loosened to adjust the position of the housing 140 along the length of the slots 107 , the adjustment plate 195 positively prevents one of the screws 195 from rising above the other and so prevents tilting of the housing 140 in a plane parallel to the adjustment plate 195 and main portion of the bracket 105 , i.e. maintains the top and bottom plates of the housing 140 perpendicular to the length axis of the slots 107 of the bracket 105 .
[0040] The latch mechanism 100 ( FIGS. 9A and 10 ) includes a rotating latch member 200 and a rotating latch release member 205 .
[0041] As shown in FIG. 10 , the latch member 200 and latch release member 205 are plate-like and pivotally mounted on the bushings 180 and 175 , respectively, which extend through corresponding holes 201 and 206 ( FIG. 9A ) therein.
[0042] The latch member 200 includes a C-shaped portion 235 to the left (in FIG. 10 ) of the bushing 180 and a tail portion 255 on the opposite side of the bushing 180 . The C-shaped portion 235 includes an inner arm 240 and an outer arm 245 . The inner arm 240 and the outer arm 245 define a U-shaped channel, or notch, 250 therebetween. The tail portion 255 has a shallow notch 215 in its lower ( FIG. 10 ) edge.
[0043] The close flanking of the C-shaped portion 235 ( FIG. 10 ) of the latch member 200 by the extension walls 145 F and 150 F of the housing portions 145 and 150 helps prevent the C-shaped portion 235 from bending or cocking out of its intended operating plane. Further, the bearing of the end flange 145 G on the extension wall 150 F (as seen in FIG. 5 ) helps rigidify the housing nose 196 .
[0044] The latch release member 205 includes a catch portion 260 . The catch portion 260 includes a step-like catch 265 and a shallow notch 230 . The catch 265 , as shown in FIGS. 9A-11 , is configured to engage the tail portion 255 of the latch member 200 . The latch release member 205 further includes a lever portion 270 . The lever portion 270 and catch portion 260 are on opposite sides of the bushing 180 . The lever portion 270 is formed as a flange perpendicular to the remainder of the latch release member 205 and comprises a leg 271 extending substantially tangentially beyond the bushing and terminating in a foot 272 extending parallel to the axis of the bushing hole 206 . The foot 272 here includes an aperture 275 .
[0045] A torsion-type latch spring 210 is also concentrically mounted on the bushing 180 , and at one end engages the notch 215 in the latch member 200 . The spring 210 at its other end bears against the end wall 220 of the housing 140 , thereby biasing the latch member 200 in a counterclockwise direction (as seen in FIG. 10 ). A second torsion-type spring 225 is mounted concentrically on the bushing 175 . The second spring 225 at one end engages the notch 230 in the latch release member 205 . The second spring 225 has its other end trapped behind the bushing 180 to bias the latch release 205 in a clockwise direction.
[0046] As shown in FIG. 6A , a rivet 280 protrudes through the longitudinal flange 145 C in alignment with the aperture 275 and thus secures a first end 285 of a coil compression spring 290 . The compression spring 290 passes through the aperture 275 and is received within a cavity 295 in the joystick 130 .
[0047] The joystick 130 includes a flat circular base portion, or annular flange, 300 ( FIG. 10 ), a necked-down (here convex or substantially frusto-conical) central portion 305 , and an elongate cylindrical arm portion 310 . The joystick 130 ( FIGS. 6A , 9 and 10 ) passes through a round aperture 315 in the flange 150 H of the right housing portion 150 . The flat circular base portion 300 of the joystick 130 is larger than the aperture 315 , so that the joystick 130 is retained within the housing 140 , with the base portion 300 bearing against an inner surface 316 of the flange 150 H of the housing 140 . The joystick 130 is biased into the aperture 315 by the compression spring 290 bearing between the base portion 300 of the joystick 130 and the longitudinal flange 145 C of the left housing portion 145 . The joystick central portion 305 tapers, from a diameter closely conforming to the aperture 315 , to the diameter of the cylindrical arm portion 310 . The profile of the outer wall 317 of the tapered central portion 305 can be linear or arcuate.
[0048] The compression spring 290 is partially compressed between the longitudinal flange 145 C ( FIG. 6A ) and the inboard end of the recess, or cavity, 295 in the inboard end of the joystick 130 , even in the relaxed (unactuated) position of the joystick shown. The rivet 280 is received in the first end 285 of the spring 290 to prevent the spring 290 from sliding sideways along the flange 145 C. The function of the rivet 280 can also be provided by forcible upsetting of the material of the flange 145 C in a position to retain the first end 285 of the spring 290 .
[0049] The joystick cylindrical arm portion 310 is hollow, having a threaded internal recess 320 . A pair of openings 322 , 325 pass transversely through the cylindrical arm portion 310 and the internal recess 320 . The threaded internal recess 320 is configured for receiving a connecting screw 330 ( FIG. 6A ). The cylindrical arm portion 310 further includes a pair of longitudinally spaced annular flanges 335 , 340 adjacent at its distal end 345 .
[0050] A given latch mechanism 100 may be used with one or more devices for unlatching same. As shown for example in FIG. 3 , the latch mechanism 100 is operable by a conventional power actuator 115 . As shown, the power actuator 115 is mounted in line with the latch mechanism 100 by a bracket 116 fixed to the tonneau cover 55 by nut and bolt units 117 (or by a bracket not shown carried by the latch mechanism 100 ). The power actuator 115 conventionally is electrically connected to a power source 120 (e.g. the vehicle battery not shown) and operated by a switch 125 . The switch 125 is conventionally capable of direct manual actuation or actuation by a conventional wireless remote control (not shown). The joystick 130 is connected to the power actuator 115 by a substantially rigid spring wire, push/pull connector, or “spring pull”, 135 ( FIG. 4 ). Due to the construction of the joystick 130 , displacement of the joystick 130 in any direction will actuate the latch mechanism 100 . Therefore, the actuator 130 need not be aligned with the latch mechanism 100 as shown. The power actuator 115 can be any type of mechanical or electrical actuator, or a hydraulic, magnetic, or pneumatic actuator. Furthermore, the actuator 115 need not be fixedly attached to the joystick 130 , but need only be positioned so as to displace the joystick 130 upon activation.
[0051] As shown in FIG. 3A , the spring pull 135 grips the cylindrical arm portion 310 of the joystick 130 between the flanges 335 , 340 . As a further example one or more conventional pullable release cables 350 , 355 ( FIG. 3A ) can be received through the openings 322 , 325 , and maintained therein by distal end plugs 360 , 365 fixed thereon. As a further example, a similar release cable, or a push rod 370 , having an eye 371 ( FIG. 6A ) can be fixed to the joystick 130 by a screw 330 .
[0052] In some instances, it may be desirable to provide more than one latch mechanism in a single installation of (e.g. tonneau cover pickup truck bed as in FIG. 1 ). For example, two could be located and spaced apart along the tailgate, or one might be provided on each side of the pickup truck bed. In such a dual installation, it may be desired to use a single powered or manual actuator to unlatch both latch mechanisms 100 . This can be done without any modification to the joysticks 130 of the dual latch mechanisms 100 . As seen for example in FIG. 3A , two joysticks 130 are spaced apart and linked by the cable 350 ,) the left (in FIG. 3A ) joystick 130 being connected through the wire member 135 to the power actuator 115 ( FIG. 3 ), and the other joystick being connected by a further cable 355 to another (e.g. manual) actuator of conventional type, not shown. In this way, actuation of one joystick 130 actuates the other so that both of the corresponding latch mechanisms 100 unlatch simultaneously.
[0053] Since axial pushing on the exposed end of the at rest joystick will also pivot the latch release member 205 and open the latch mechanism 100 , it is contemplated that screw 330 ( FIG. 6A ) may in some instances be substituted by a manually engageable push button, not shown, with the latch mechanism 100 being located so that such push button is reachable by a user either inside or outside the protected cavity (e.g. truck bed in FIG. 1 ).
Operation
[0054] The latch mechanism 100 has a latched position ( FIGS. 3 and 10 ), e.g. for latching the tonneau cover 55 in its closed, dotted line position on the pickup truck 50 .
[0055] As shown in FIG. 10 , the latch member 200 is held in a latched position against the bias of the spring 210 by the interference of the latch release member 205 , wherein the tail portion 255 of the latch member 200 is received within the catch 265 of the latch release member 205 .
[0056] Referring sequentially to FIGS. 11A-11H , the latched latch mechanism 100 is unlatched by axially depressing or pivotally deflecting the joystick 130 from its rest (here vertical) position shown in FIG. 11A . In this position, the latch member 200 is positioned such that the outer arm 245 of the C-shaped portion 235 appears perpendicular to the left end 196 of the housing 140 . The latch member 200 and the housing 140 thereby close the channel 198 and trap the pin 110 therein, such that the tonneaus cover (for example) is closed and latched.
[0057] The joystick 130 is then pivotally deflected e.g. by the power actuator 115 drawing on the spring pull 135 , by a manual actuator (not shown) pulling on a cable 350 , 355 , or in any other convenient way.
[0058] In FIG. 11B , the joystick 130 has been slightly pivotally deflected (to the right in FIG. 11B , though to the left or into or out of the page, or even axial deflection upward into the housing 140 would serve as well), forceably rotating the latch release member 205 slightly counterclockwise without yet releasing the latch member 200 . The joystick flat circular base portion 300 is slightly tilted away from the inner surface 316 of the housing 140 , while the frusto-conical portion 305 of the joystick 130 rides in the aperture 315 in the housing 140 .
[0059] In FIGS. 11C-11D , the joystick 130 is further deflected. The latch release member 205 is rotated further counterclockwise still without releasing the latch member 200 .
[0060] In FIG. 11E , the joystick 130 is fully deflected so that the latch release member 205 has been rotated sufficiently counterclockwise to clear the tail portion 255 of the latch member 200 . The latch member 200 is now free to rotate counterclockwise under the biasing force of the spring 210 .
[0061] In FIGS. 11F-11H , the latch member 200 , freed from latch release member 205 , sequentially rotates counterclockwise towards its unlatched position. In FIG. 11H , the latch member 200 has rotated to its fully counterclockwise, fully open position. At any time in the FIG. 11F-11H sequence the joystick 130 can be released, so that the latch release member 205 is allowed to rotate clockwise under the bias of the spring 225 , to return both to their FIG. 11A rest position. As the latch member 200 rotates counterclockwise under the bias of its spring 210 , the inner arm 240 of latch member 200 effectively pushes the latch mechanism 100 and pin 110 away from each other. The user is thus free to open the tonneau cover 55 to its FIG. 1 solid line position.
[0062] In the preferred embodiment shown, and as seen for example in FIG. 10 , during actuation the joystick base portion 300 bears at diametrically opposed points on the housing flange 150 H and on the foot 272 of the latch release member 205 to define a driven lever arm. On the other hand, the free end of the joystick, as at a point between the flanges 335 and 340 , may be connected to an actuator (for example the power actuator 115 or one of the release cables 350 , 355 , or the like). The distance, between that connection point on the free end of the joystick and the mentioned point on the joystick base 300 bearing on the housing flange 150 H, defines a driving lever arm. The ratio of these two lever arms (e.g. 2 to 1) defines the mechanical advantage provided by the joystick.
[0063] Similarly, the distances from the rotative center of the latch release lever 205 (the axis of swaged bushing 175 ) to the point of contact of the foot 272 with the joystick base 300 above mentioned and to the point of engagement of the step-like catch 265 with the portion 255 of the latch member 200 , define corresponding driving and driven lever arms of the latch release member 205 . For example in the embodiment shown, the ratio of such lever arms is approximately 2 to 1, the latch release member 205 thus providing a mechanical advantage of approximately 2 to 1.
[0064] Thus, the joystick and catch release member, taken together would, in this example, thus provide a combined mechanical advantage of approximately 4 to 1.
[0065] Moreover, the distances from the pivot axis of the latch member 200 (the central axis of its swaged bushing 180 ) to the point of contact of its tail portion 255 with the step-like catch 265 of the latch release member 205 and to the point of contact of the spring 210 with the shallow notch 215 , again defines driving and driven lever arms, which in the embodiment shown are the length ratio of about 3 / 2 .
[0066] Thus, in this particular example, there is a total mechanical advantage of about 6 to 1 from the joystick free end to pin 110 . The FIG. 1 tonneau cover 55 may have substantial weight. To release the latch mechanism 100 requires the tonneau cover mounted inner arm 240 to push downward on the pin 110 with sufficient force to cause the bushing 180 and housing 140 and bracket 105 to lift the tonneau cover 55 out of its normally closed, latched position shown in dotted line in FIG. 1 . Thus, the latch member spring 210 has to be strong enough to forcibly pivot the latch lever 200 , from its FIG. 11F position through its FIG. 11G position and into its fully opened FIG. 11H position, to lift the heavy tonneau cover 55 . However, that same strong spring 210 , in the latch mechanism closed position of FIGS. 10 and 11 A strongly holds the tail portion 255 against the step-like catch 265 , so as to strongly resist the opening rotation of the latch release lever 205 above discussed as to FIGS. 11B-11D . Again, the distance, from the point of contact of the tail portion 255 of the latch member 200 with the step-like catch 265 of the latch release member 205 , ( FIGS. 10 and 11A ) to the point of contact of the spring 210 with the edge of the spring 210 with the edge of the notch 215 in the latch member 200 , is here in the approximate ratio of 1 to 1. Accordingly, the combined mechanical advantage available to overcome the force of the spring 210 by actuation of the joystick 130 is hereabout 6 to 1. Accordingly, if a 40 pound force is required to lift the tonneau cover 55 to complete the laterally sequence from FIG. 11F through 11H , only about ⅙ that force (e.g. 7 pounds) need be applied to the end of the free end of the joystick 130 to open the latch mechanism 100 . Accordingly, it becomes possible to actuate the joystick 130 by relatively low force means, for example a conventional low cost power actuator 115 , even with a relatively heavy tonneau cover, and without need for the user to attempt to assist the unlatching process by manually lifting the tonneau cover. In short, even a relatively heavy tonneau cover 55 will pop open as the end result of the unlatching process shown in the FIG. 11A-11H sequence.
[0067] Vehicle users will occasionally load their pickup beds high enough that the user must exert downward pressure on the tonneau cover 55 to enable the pin 110 and latch lever 200 to assume their FIG. 10 latched positions. In that instance, after latching, the user stops pressing downward on the tonneau cover 55 and moves away to other activity, but the overweight load in the pickup bed is still pressing the tonneau cover upward away from the pickup truck bed, and hence urges the latch mechanism 100 upward with respect to the pin 110 , i.e. adding to the counterclockwise (in FIG. 10 ) force of the spring 210 and hence pushing the tail portion 255 even harder against the step-like catch 265 to further resist counterclockwise, unlatching rotation of the latch release member 205 . Thus, the substantial mechanical advantage provided by the inventive joystick 130 and latch release 205 allows this added resistance to latching to be overcome with a relatively light force applied to the joystick 130 manually, by cables, or by the power actuator 115 .
[0068] The power actuator 115 and other means (e.g. cables 350 / 365 of FIG. 3B actuate the joystick independently of each other, i.e. the power actuator actuates the joystick when the cables are slack and the cables actuate the joystick when the actuator is not powered. The latch mechanism 100 can be initially installed without the power actuator and, at some later time, the user can add a power actuator.
[0069] Should a person accidentally become trapped in the FIG. 1 pickup truck bed with the tonneau cover 55 latch closed, the inventive latch mechanism 100 provides a safety advantage in that it enables relatively easy escape. More particularly, the joystick 130 stands proud from the housing 140 to a substantial extent and so is relatively easy to find, even in the dark. Also, the joystick 130 requires only a very low activating force (in view of the substantial mechanical advantage of the latch mechanism 100 ), and pushing or pulling the joystick in a wide range of directions causes the latch mechanism 100 to unlatch.
[0070] The joystick 130 is free to rotate about its length (vertical in FIGS. 6 and 6A ) axis to orient the diametral through holes 322 and 325 in any desired direction on a plane perpendicular to the longitudinal axis of the joystick, so as to accommodate the actuators (e.g. cables 350 and/or 355 ( FIG. 3B )) approaching the joystick from virtually any direction.
[0071] While the invention has been described in the specification and illustrated in the drawings with reference to preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to particular embodiments illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the scope of the appended claims. | A rotary latch for selectively locking a closure, such as a tonneau cover, is provided with a joystick or toggle release lever. The joystick release lever enables the rotary latch to be installed in any position with respect to a remote handle because the joystick can be pulled in any direction, 360 degrees, to release the rotary latch. The joystick includes a trapped base supporting a spherical portion that is nested in a circular opening in the housing of the latch. The joystick is spring loaded, and is movable about its central axis in any direction, causing the base to pivot against the inside of the housing. The base of the joystick is positioned over a spring-loaded catch locking the rotary latch. As the base of the joystick rotates against the inside of the housing, it depresses the spring-loaded catch, releasing the rotary latch. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority to International Patent Application PCT/DE2014/100155, filed on May 2, 2014, and thereby to German Patent Application 10 2013 210 365.4, filed on Jun. 4, 2013.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] No federal government funds were used in researching or developing this invention.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
SEQUENCE LISTING INCLUDED AND INCORPORATED BY REFERENCE HEREIN
[0004] Not applicable.
BACKGROUND
[0005] 1. Field of the Invention
[0006] The invention relates to a sealing inner sleeve having a deformable intermediate section.
[0007] 2. Background of the Invention
[0008] Sealing inner sleeves are widely known and described for example in DE 44 01 318 C2. With the help of such sealing inner sleeves leakages can be repaired, e.g., in underground pipes made from concrete or another material, without digging being necessary. For this purpose, the sealing inner sleeve is inserted into the leaking pipe to be repaired until it reaches the place of the leak. Here, initially the sealing inner sleeve is spirally contracted so that it shows a smaller diameter than the pipe to be sealed. Once the sealing inner sleeve has been moved to the place of the leak of the pipe to be repaired, using a mechanical assembly unit said sealing inner sleeve is expanded until, under compression of the sealing rings, it has tightly contacted the interior wall of the pipe. Using a locking device, which comprises a clamping sprocket combing a row of teeth and an elastic blocking latch engaging these teeth, the sealing inner sleeve is kept in its expanded position.
[0009] A locking device, improved in reference thereto, is suggested in EP 0 805 932 B1. Here, a sealing inner sleeve is disclosed with a locking device that allows very small latching steps and thus, upon the expansion being concluded, ensures a tight, lasting contacting of the interior wall of the pipe with a high pressure upon the sealing organs. For this purpose, the improved locking device is provided with a slot arranged in the circumferential direction at the interior end of the band, with a row of teeth being arranged respectively at its two opposite longitudinal edges. Two clamping sprockets are provided in the slot, each of which combing one of the two rows of teeth and simultaneously being impinged by a common blocking sprocket as the latching organ. The blocking sprocket is pressed via a clamping spring into the space between the two clamping sprockets.
[0010] These sealing inner sleeves are best suited to be inserted into straight pipelines, in order to seal here cracked walls, for example. For this purpose, the sealing inner sleeves are provided at their external circumference with a sealing means, particularly an elastic coating, such as a rubber hose for example, which may show one or more circumferential sealing lips, and then it is moved with a so-called packer to the damaged point of the pipeline to be repaired. The packer with the sealing inner sleeve is brought into position and then inflated via the entrained air hose; here the sealing inner sleeve also potentially expands until it seals the pipe section to be repaired. The locking device ensures that the sealing inner sleeve maintains this position even when the packer is removed again.
[0011] However, in practice, pipelines are frequently damaged, in which two adjacent pipe sections show a radial offset. This may be caused particularly by an offset pipe coupling. Additionally, in pipelines it may occur that pipes with different diameters are connected to each other. Damages in such pipes showing a radial offset or different diameters cannot be repaired with the above-described sealing inner sleeves, because the sealing inner sleeves in the locked and exterior-supported state show a high deformation resistance, similar to that of a circumferentially closed pipe and thus they cannot be deformed.
[0012] This problem can be solved with a sealing inner sleeve as described in EP 0 795 714 A1. This sealing inner sleeve is characterized by an intermediate section arranged between two end sections of the sealing inner sleeve, which shows a lesser resistance to deformation when bent about the longitudinal axis compared to the end sections of the sealing inner sleeve. The reduced resistance to deformation is here possible by material weakening and/or a bellow-like embodiment. Here, among other things, a punctual or corrugated punching of the sealing inner sleeve is suggested in the intermediate section as the material weakening. The plurality of slots distributed here in a circumferential direction in the intermediate section of the sealing inner sleeve is arranged in the idle state of the sealing inner sleeve, i.e. in the still non-deformed state of the sealing inner sleeve, axially parallel in reference to each other and the center axis of the sealing inner sleeve.
[0013] This is the foundation for the present invention.
[0014] The objective of the invention is to further develop these sealing inner sleeves of prior art such that on the one hand, good deformation of the sealing inner sleeve in the intermediate section is ensured, but sufficient stability still remains of the sealing inner sleeve when used in pipes to be repaired that show radial offsets and/or different diameters. In particular, with the sealing inner sleeve it should also be possible to repair pipes that are arranged at a slight angle in reference to each other.
[0015] This objective is attained by a sealing inner sleeve showing the features as claimed herein.
BRIEF SUMMARY OF THE INVENTION
[0016] In a preferred embodiment, a sealing inner sleeve ( 10 ) to be inserted into pipe in order to seal leakages there, comprising an annularly contracted and expandable band ( 12 ), preferably made from sheet steel, with its band parts overlapping in the circumferential direction at least partially, and with a locking device ( 20 ) allowing an increase in diameter of the sealing inner sleeve ( 10 ), however blocking any deformation in the opposite direction, whereby the sealing inner sleeve ( 10 ) comprises two end sections ( 14 , 15 ) and an intermediate section ( 16 ) connecting them to a contiguous component, and whereby a plurality of longitudinal slots ( 30 ) is arranged in the intermediate section ( 16 ), separated from each other and distanced by a plurality of longitudinal webs ( 40 ) arranged in the circumferential direction, wherein the longitudinal slots ( 30 , 130 ) and the longitudinal webs ( 40 , 140 ) are arranged with a predetermined angular offset aslant in reference to the center axis (X) of the sealing inner sleeve ( 10 ) on the circumference of said sealing inner sleeve ( 10 ).
[0017] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, wherein a first group of longitudinal slots ( 30 ) and longitudinal webs ( 40 ) is provided, showing an angular offset ranging from approximately 5 degrees to approximately 20 degrees, preferably from approximately 8 degrees to 12 degrees, and furthermore, preferably amounting to approximately 10 degrees, and/or that at least one second group of longitudinal slots ( 130 ) and longitudinal webs ( 140 ) is provided, showing an angular offset in reference to the center axis (X) at a range from approximately more than 45° and less than 90°, preferably amounting to at least approximately 75°.
[0018] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that all longitudinal slots ( 30 ) and longitudinal webs ( 40 ) of the first group are arranged parallel in reference to each other.
[0019] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that the longitudinal slots ( 30 ) of the first group are at least approximately one to five times wider than the longitudinal webs ( 40 ) in the circumferential direction of the sealing inner sleeve ( 10 ).
[0020] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that the longitudinal slots ( 30 ) of the first group are rounded or angular at their end sections ( 41 ), ( 42 ).
[0021] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that the longitudinal webs ( 40 ) are enlarged in a bulging fashion, seen in the circumferential direction of the sealing inner sleeve ( 10 ) at a middle section ( 43 ).
[0022] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that the intermediate section ( 16 ) of the sealing inner sleeve ( 10 ) amounts to approximately 0.2 to 0.5 of the total length Z, seen in the direction of the center axis (X) of the sealing inner sleeve ( 10 ).
[0023] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that the sealing inner sleeve ( 10 ) shows in the first group approximately 10 to 120 longitudinal slots ( 30 ).
[0024] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that at least the intermediate section ( 16 ) of the sealing inner sleeve ( 10 ), provided with the longitudinal slots ( 30 , 10 , 130 ), is covered by a cover, particularly a metallic film.
[0025] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that the longitudinal slots ( 30 ) of the first group are arranged between the longitudinal slots ( 130 ) of two second groups of longitudinal slots ( 130 ).
[0026] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that the longitudinal slots ( 130 ) of the second group are narrower than the longitudinal slots ( 130 ) of the first group.
[0027] In a preferred embodiment, a sealing inner sleeve ( 10 ) according to one of Claims 1 to 11 , characterized in that the longitudinal slots ( 130 ) of the second group show a width of approximately 3 to 7 mm and a length of approximately 10 to 15 cm, and are limited by longitudinal webs ( 140 ), which are approximately 1 to 5 mm wide.
[0028] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that the two additional groups of longitudinal slots ( 130 ) are arranged symmetrically in reference to a perpendicular of the center axis (X) and aslant with a predetermined angular offset.
[0029] In another preferred embodiment, the sealing inner sleeve ( 10 ) as described herein, characterized in that the area of the second group of longitudinal slots ( 130 ) is smaller than the area of the first group of longitudinal slots ( 130 ) in reference to the length of the sealing inner sleeve in the direction of the center axis (X).
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a line drawing evidencing an exemplary embodiment of the sealing inner sleeve in the wound state seen diagonally from the front.
[0031] FIG. 2 is a line drawing evidencing the sealing inner sleeve of FIG. 1 in a side view.
[0032] FIG. 3 is a line drawing evidencing an enlarged detail of the sealing inner sleeve shown in FIG. 2 in the area of the longitudinal slots.
[0033] FIG. 4 is a line drawing evidencing a focused view upon a detail inside the sealing inner sleeve in the stressed state in a pipe with a constant diameter.
[0034] FIG. 5 is a line drawing evidencing a focused view upon a detail inside a pipe with different diameters equipped with a stressed sealing inner sleeve according to FIGS. 1 to 4 .
[0035] FIG. 6 is a line drawing evidencing an illustration similar to FIG. 1 , however now additional longitudinal slots are arranged at the exterior circumference of the sealing inner sleeve, in order to allow sealing pipe sections aligned angularly offset in reference to each other.
[0036] FIG. 7 is a line drawing evidencing the sealing inner sleeve of FIG. 6 in a side view.
[0037] FIG. 8 is a line drawing evidencing another exemplary embodiment of a sealing inner sleeve with various longitudinal slots in a side view.
[0038] FIG. 9 is a line drawing evidencing a detailed view of the sealing inner sleeve shown in FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0039] The invention is essentially based on the fact that a plurality of longitudinal slots at the exterior circumference of the sealing inner sleeve is arranged, which in reference to the center axis of the sealing inner sleeve show an angular offset. This means that a plurality of longitudinal slots is aligned diagonally in reference to the center axis of the sealing inner sleeve.
[0040] Experiments have shown that a plurality of longitudinal slots at the circumference of the sealing inner sleeve must be distributed ranging from approximately greater than 45° and less than 90° in reference to the center axis X of the sealing inner sleeve, if the sealing inner sleeve shall also be used for leaks of pipes arranged at a slight offset in reference to each other. An angular offset by more than 45° and less than 90° of these longitudinal slots also means that the longitudinal slots show an angle of less than 45° and more than 0° in reference to a perpendicular in reference to the center axis of the sealing inner sleeve.
[0041] In a preferred embodiment of the longitudinal slots, they are preferably placed from 55° to 85° and further preferred at an angle of approximately 75° in reference to the center axis X of the sealing inner sleeve.
[0042] In one embodiment of the invention, the longitudinal slots may be approximately 3 to 7 mm wide and approximately 10 to 15 cm long and limited by longitudinal webs, which are approximately 1 to 5 mm wide. Such an arrangement of longitudinal slots is best suited for sealing leaks in pipes arranged at an angle in reference to each other.
[0043] The pipes to be sealed are generally made from a plurality of abutting pipe sections. Here, it frequently occurs that individual pipe sections are not precisely aligned to each other axially. In addition to a slight angular alignment of abutting pipes, which can be sealed with the above-mentioned longitudinal slots when leaks appear, there are also constellations in which the abutting pipe sections are offset axially in reference to each other, thus showing a radial offset or showing different diameters. In order to allow effective sealing of such pipes as well, the invention provides, in addition to the above-mentioned group of longitudinal slots or instead thereof, another group of longitudinal slots, which are aligned less aslant in reference to the center axis of the sealing inner sleeve. Experiments have shown that the angular offset of this group of longitudinal slots ideally ranges from approximately 5 degrees to 20 degrees and should amount preferably to approximately 10 degrees. With such an angular offset of the longitudinal slots in reference to the center axis of the sealing inner sleeve, good deformation of the sealing inner sleeve is possible here and high stability is ensured as well, even when the sealing inner sleeve is inserted in pipelines showing a radial offset and/or different diameters.
[0044] In the following the group of longitudinal slots with the lesser angular offset, i.e. the longitudinal slots provided to repair pipelines with radial offset and/or different diameters, is called the first group of longitudinal slots, while the other longitudinal slots, aligned more aslant in reference to the center axis than the first group of longitudinal slots, are called the second group of longitudinal slots.
[0045] Preferably, all longitudinal slots are aligned in groups parallel to their diagonal alignment. Here, the individual longitudinal slots are separated from each other by longitudinal webs.
[0046] In a further development of the invention, it is provided that the longitudinal slots of the first group are embodied, in reference to the circumferential direction of the sealing inner sleeve, approximately one to five times wider than the longitudinal webs.
[0047] The longitudinal webs of the first group may be shaped rounded or angular at their ends. Here it is also possible, or in a further development independent there from, that the longitudinal webs in their middle, seen in the circumferential direction, are embodied bulging, i.e. in their central area they are wider than in their two end sections.
[0048] Additionally, it has proven advantageous to size the intermediate section of the sealing inner sleeve such that it is equivalent to approximately 0.2 to 0.5 of the total length of the sealing inner sleeve. Preferably, the intermediate section of the sealing inner sleeve is placed centrally in reference to the two end sections embodied with an equal length. The two end sections of the sealing inner sleeve can here for example each show a length from 0.25 to 0.4 in reference to the total length of the sealing inner sleeve.
[0049] In one embodiment of the invention, it is provided that the sealing inner sleeve in its intermediate section shows a first group of longitudinal slots, with this first group of longitudinal slots at their two sides being framed respectively by a second group of longitudinal slots. The two second groups of longitudinal slots may here show their longitudinal slots at an alignment parallel to each other, or be aligned to one side of the first group of longitudinal slots diagonal in one direction, and at the other end of the first group of longitudinal slot aligned diagonally in the opposite direction in reference to the perpendicular of the center axis of the sealing inner sleeve. In a further development of the invention it is provided that the sealing inner sleeve at its exterior circumference is covered, at least in the area of the intermediate section, i.e. where the longitudinal slots of the first and/or the second group are provided, with a cover, particularly a film or a metal sheet. This may for example involve a metallic film, particularly a stainless steel film or a stainless steel sheet, which shows for example a thickness from approximately 0.3 mm to 0.7 mm. This film and/or sheet is wound about the exterior circumference of the sealing inner sleeve, at least in the area of the longitudinal slots about the sealing inner sleeve. However, it is also possible to wrap up the entire sealing inner sleeve at the exterior with such a film or such a sheet. The sense and purpose of such a cover is to cover the longitudinal slots. The sealing inner sleeve provided with such a cover shall then preferably be provided with a suitable sealing material on the outside. This sealing material may be a rubber-like hose, which is pulled at the outside over the sealing inner sleeve and preferably shows at the exterior circumference one or more circumferential sealing lips. The sealing inner sleeve prepared with such a pulled-on rubber-like hose and cover can then be moved by the packer mentioned at the outset to the point of the pipeline to be repaired and placed there.
[0050] In one embodiment of the invention, the longitudinal slots of the second group are embodied narrower than the longitudinal slots of the first group. Here, the longitudinal slots of the second group may show a width from approximately 3 to 7 mm and a length from approximately 10 to 15 cm, with the longitudinal slots here being limited by longitudinal webs, which show a width from approximately 1 to 5 mm.
DETAILED DESCRIPTION OF THE FIGURES
[0051] FIG. 1 shows a sealing inner sleeve with a perspective view from the front. The sealing inner sleeve is provided with the reference character 10 and shows a coiled, metallic band 12 , with its band parts overlapping at the ends. In this coiled state, the sealing inner sleeve 10 is held by a locking device located in the interior, not discernible in FIG. 1 . The locking device is here embodied such it allows a widening with regard to the diameter of the sealing inner sleeve 10 , however blocks any deformation in the opposite direction. Suitable locking mechanisms and locking devices are widely known, for example from DE 44 01 318 C2 and EP 0 805 932 B1 mentioned at the outset.
[0052] In the state shown, the sealing inner sleeve 10 is a cylindrical body with a center axis X. The sealing inner sleeve 10 shows two end sections 14 , 15 with an intermediate section 16 located between these. Here, the end sections 14 , 15 are massive metal sections, while the intermediate section 16 comprises a plurality of longitudinal slots 30 extending in the circumferential direction of the sealing inner sleeve 10 , which are distanced by the longitudinal webs 40 .
[0053] The longitudinal slots 30 and the longitudinal webs 40 of the sealing inner sleeve 10 are aligned towards the center axis X at an angular offset a and thus placed diagonally in reference to the center axis X. This angular offset a may range from approximately 5 to 20 degrees, preferably amounting at least approximately to 10 degrees. The longitudinal slots 30 and the longitudinal webs 40 are explained in greater detail in the context with FIG. 3 . Overall, for example 10 to 120, preferably 25 to 35 longitudinal slots 30 may be implemented in the sealing inner sleeve 10 by way of punching or cutting out.
[0054] The sealing inner sleeve 10 shows a total length Z, for example from 40 cm to 80 cm. The above-mentioned central section 16 may here range from 0.2 to approximately 0.5 of this total length Z. The two end sections 14 , 15 are preferably each embodied with identical length in reference to the center axis X and show a length from approximately 0.25 to 0.4 of Z. The diameter D of the sealing inner sleeve 10 may for example range from 20 to 80 cm in the stressed state. Nevertheless, other dimensional ratios are also possible.
[0055] FIG. 3 shows the detail of the metallic band 12 in the area of the longitudinal slot 30 and the longitudinal webs 40 in an enlarged view. Once more, the angular offset a from the center axis X is discernible. The longitudinal slot 30 is embodied like a spoon, with respectively rounded sections at its longitudinal ends. The longitudinal slots 30 show a maximum width of B 2 at their ends. The width is reduced in the middle of the longitudinal slots 30 and amounts to B 1 . B 1 may for example be 2 cm, while B 2 is 2.5 cm. The longitudinal webs 40 are designed appropriately and show therefore in the center a maximum width C 1 and at their ends a minimum width C 2 . C 1 may for example be 1 cm and C 2 0.5 cm. Other size ratios are also possible. In the concrete exemplary embodiment of FIG. 3 the slots show a total length of approximately 10 cm. Such an arrangement of the longitudinal slots 30 and the longitudinal webs 40 is optimal with regard to the connection possibilities, on the one hand, and the stability of the sealing inner sleeve 10 , on the other hand.
[0056] This is shown based on the views of the interior of sealing inner sleeve of FIGS. 4 and 5 .
[0057] FIG. 4 shows a view of a detail inside the sealing inner sleeve 10 in the stressed state in a pipeline 50 with a constant diameter and without any radial offset. Two locking devices 20 are discernible from FIG. 4 , which respectively extend to a toothed rod 21 . Both locking devices 20 are located approximately at the same distance from the stop 23 of the toothed rod 21 and are therefore equally stressed. The longitudinal slots 30 and the longitudinal webs 40 are all aligned parallel in reference to each other, because neither any radial offset nor a change in diameter of the pipeline affects the sealing inner sleeve 10 in FIG. 4 .
[0058] FIG. 5 shows the sealing inner sleeve 10 of FIG. 4 stressed in a sealing fashion in a pipeline 50 with a change in diameter and/or radial offset. It is clearly discernible that the rear locking device 20 facing away from the viewer is placed much closer to the stop 23 of the locking device 20 than the frontal locking device 20 facing the viewer. This means that the locking devices 20 have stressed the end sections 14 , 15 to a different extent due to the given radial offset and/or the given change in diameter of the pipeline 50 . Here, the sealing inner sleeve 10 is deformed in the intermediate section with the longitudinal slots 30 and the longitudinal webs 40 , distorted in particular, which is particularly discernible in FIG. 5 in the area marked with the reference character A. Here, the longitudinal slots 30 and/or longitudinal webs 40 intersect between the exterior and interior band section of the band 12 of the sealing inner sleeve 10 .
[0059] The longitudinal slots 30 and the longitudinal webs 40 used in the exemplary embodiments discussed thus far are best suited to seal those sections of pipes that show a radial offset or a change in diameter. The above-mentioned longitudinal slots 30 and the longitudinal webs 40 may well compensate such a radial offset or such a change in diameter based on the particular diagonal position of the longitudinal slots 30 , when the sealing inner sleeve 10 is stressed inside the pipe section to be repaired. These previously discussed longitudinal slots 30 form a first group. When repairing pipes however, pipe sections also appear that may be aligned at a slight angle in reference to each other. This means that the pipe sections abutting each other show center axes extending diagonally in reference to each other. Such diagonal alignments may show a few degrees, for example ranging from 0° to 10 or 20°. In order to allow sealing even such diagonally extending pipeline sections when necessary, the above-mentioned first group of longitudinal slots is not suitable.
[0060] In the following exemplary embodiments of FIGS. 6 to 9 therefore sealing inner sleeves are introduced, in which a second group of longitudinal slots are also provided, which are placed considerably more aslant in reference to the center axis X of the sealing inner sleeve 10 than the above-discussed longitudinal slots 30 . The longitudinal slots discussed in the following are called hereinafter the second group of longitudinal slots and indicated with the reference character 130 . These longitudinal slots 130 of the second group are distanced by the longitudinal webs 140 .
[0061] At this point, it shall once more be pointed out that, depending on the application, it is sufficient to arrange in the sealing inner sleeve 10 longitudinal slots 30 of the first group or longitudinal slots 130 of the second group. However, in order to provide a universally suitable sealing inner sleeve 10 , it is recommended to provide at the circumference of the sealing inner sleeve 10 both the longitudinal slots 30 of the first group, as well as the longitudinal slots 130 of the second group.
[0062] FIGS. 6 to 9 show sealing inner sleeves 10 , in which both the longitudinal slots 30 of the first group as well as the longitudinal slots 130 of the second group are implemented. In this way, FIG. 6 now shows a sealing inner sleeve 10 , as already presented in the context of FIG. 1 , whereby now however a second group of longitudinal slots 130 is also provided, which are considerably more aslant than the longitudinal slots 30 of the first group, distributed at the circumference of the sealing inner sleeve 10 . These longitudinal slots 130 of the second group are placed at both sides of the longitudinal slots 130 of the first group. All of these longitudinal slots 30 of the second group are aligned parallel in reference to each other and placed at an angle β in reference to the center axis X, which is greater than 45° and less than 90°.
[0063] Most preferably, the angle β ranges from 55° to 85°, whereby it has proven beneficial with the concrete exemplary embodiment to adjust the angle to approximately 75°. In FIGS. 6 and 7 the angle β amounts to 75°.
[0064] As shown in FIGS. 6 and 7 the longitudinal slots 130 of the second group are designed considerably narrower than the longitudinal slots 30 of the first group. The longitudinal slots 130 of the second group are separated by longitudinal webs 140 , which are also relatively narrow. This way the longitudinal slots 130 of the second group may show a width from approximately 3 to 7 mm, and a length from approximately 10 to 15 cm. The longitudinal webs 140 are approximately 1 to 5 mm wide, assuming that the sealing inner sleeve 10 shows, for example, an interior diameter of 25 cm to 40 cm.
[0065] The illustration of FIG. 7 shows particularly clearly that the length of the longitudinal slots 130 of the second group is selected such that a virtual parallel P in reference to the center axis X intersects several longitudinal slots 130 on the circumferential surface of the sealing inner sleeve 10 . In the exemplary embodiment of FIG. 7 such a parallel P intersects e.g. three longitudinal slots 130 .
[0066] FIGS. 8 and 9 show another exemplary embodiment of a sealing inner sleeve 10 . This exemplary embodiment is very similar to the sealing inner sleeve of FIGS. 6 and 7 . However, the longitudinal slots 130 of the second group are divided into a first sub-group, which is placed in FIG. 8 at the left of the longitudinal slots 30 and into a second subgroup, which in FIG. 8 is placed at the right of the longitudinal slots 30 . All longitudinal slots 130 of this second sub-group placed at the left of the longitudinal slots 40 [sic: 30] are arranged with an angular offset in reference to the center axis X diagonally towards the left and the longitudinal slots 130 , which are arranged at the right of the longitudinal slots 30 , show an offset towards the center axis X, which points diagonally towards the right. In reference to a virtual level, which is positioned precisely in the center of the sealing inner sleeve 10 and orthogonal to the center axis X, a symmetric arrangement of the longitudinal slot 140 develops here of both subgroups. When once more considering a parallel P on the circumferential surface of the sealing inner sleeve 10 , which extends parallel to the center axis X, it is discernible that this parallel P intersects four longitudinal slots 130 at the left of the longitudinal slots 30 as well as four longitudinal slots 130 at the right of the longitudinal slots 30 of the first group.
[0067] FIG. 9 shows an enlarged detail of the longitudinal slots 130 and the corresponding longitudinal webs 140 of the second group of FIG. 8 .
LIST OF REFERENCE NUMBERS
[0000]
10 Sealing inner sleeve
12 Band
14 End section
15 End section
16 Intermediate section
20 Locking device
21 Toothed rod
23 Stop
30 Longitudinal slot of the first group
31 End section
32 End section
33 Middle section
40 Longitudinal web of the first group
41 End section
42 End section
43 Middle section
50 Pipeline
130 Longitudinal slot of the second group
140 Longitudinal web of the second group
A Section
B 1 Minimum width of 30
B 2 Maximum width of 30
C 1 Maximum width of 40
C 2 Minimum width of 40
D Diameter
X Center axis
α Angular offset of the longitudinal slots of the first group
β Angular offset of the longitudinal slots of the second group
Z Total length
P Parallel
[0098] The references recited herein are incorporated herein in their entirety, particularly as they relate to teaching the level of ordinary skill in this art and for any disclosure necessary for the commoner understanding of the subject matter of the claimed invention. It will be clear to a person of ordinary skill in the art that the above embodiments may be altered or that insubstantial changes may be made without departing from the scope of the invention. Accordingly, the scope of the invention is determined by the scope of the following claims and their equitable equivalents. | The invention is a sealing inner sleeve for insertion into pipes in order to seal leaks therein. Said sealing inner sleeve has a locking device allowing an increase in the diameter of the sealing inner sleeve, but blocking same in the opposite direction, the sealing inner sleeve having two end sections and an intermediate section connecting said end sections to form a contiguous component. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/103,536, filed Mar. 20, 2002, which application is a continuation of International Application No. PCT/US00/25886 filed Sep. 20, 2000 and published in English on Mar. 29, 2001 as Publication No. WO 01/22292, which is a continuation of U.S. Provisional Application 60/154,885 filed on Sep. 20, 1999. All applications are incorporated herein by reference.
COPYRIGHT NOTICE AND PERMISSION
[0002] A portion of this patent document contains material 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 the Patent and Trademark Office patent files or records, but otherwise reserves all copyright whatsoever. The following notice applies to this document: Copyright© 1999, Bodyl, Inc. (formerly known as MedBeat, Inc.)
BACKGROUND
[0003] Computers have enjoyed, in recent years, an enormous growth in utility. Early computers allowed users to perform tasks such as word processing and bookkeeping. Today, however, computers have become everyday communication tools, fast approaching the commonness of telephones and televisions.
[0004] Much of this growth in the communications realm stems from the fantastic, compounded growth of computer networks, such as the much-heralded Internet—a worldwide network of computers interconnected through public and private wiring and telephone systems. The Internet functions as a planetary communications system, enabling users to communicate with each other, to transmit data to each other, and to search for data of particular interest.
[0005] One problem stemming from the rapid growth of the Internet concerns the time and effort often necessary to find data of particular interest. There are numerous publicly accessible search engines that continually work to index the data on the Internet and thus facilitate locating it. However, with the vast amounts of available data, these search engines often answer user queries with large amounts of irrelevant data, leaving users to spend significant time and effort sifting through it for the data, the knowledge, they actually want. Although combination search engines have been developed to allow users to simultaneously use two or more search engines, in many instances these have only presented users with even more data to sift, thus compounding the data-finding problem.
[0006] Another related problem is that the planetary scope of the Internet makes it difficult for users to find and communicate with other users who share interests in similar kinds of information. Websites, chat rooms, and forums devoted to particular topics, such as health, have emerged in recent years. However, the information shared through these websites, chat rooms, and forums is too often sparse and of poor quality, since many participants behave as spectators and do not actively contribute information. Moreover, direct competition between the websites, chat rooms, and discussion forums for users generally leads to smaller, fragmented communities of users, thwarting development of larger aggregate communities.
[0007] Accordingly, there is a need not only to reduce the time necessary to find particular types of data on the Internet, but also to facilitate development of communities of active users around specific topics and conversion of information into real knowledge.
SUMMARY
[0008] To address this and other problems, the present inventor devised systems, methods, and related software for encouraging and managing growth of databases, particularly theme-oriented databases, such as health-information databases. One exemplary method entails establishing a theme-oriented database and granting users access rights to the database based on their contributions or submissions to the database. One specific embodiment scores the contributions based on quantity, quality, and/or relevance, granting access rights based on the scores. Other embodiments record the queries of users of the database and facilitate communications between users having similar queries as well as users making similar contributions.
[0009] Notably, various embodiments of the invention facilitate the incorporation of user experiential data into the context of thematic databases that make it relevant and useful, in essence converting it to knowledge.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a block diagram of an exemplary theme-oriented database-management-and-community-building system 100 incorporating teachings of the present invention.
[0011] FIG. 2 is a flow chart illustrating exemplary operation of system 100 in FIG. 1 .
[0012] FIG. 3 is a block diagram of an exemplary home page 300 for use in system 100 .
[0013] FIG. 4 is a diagram of a list of categories linked to home page 300 .
[0014] FIG. 5 is a facsimile of another exemplary home page 400 for use in system 100 .
[0015] FIG. 6 is a block diagram of an exemplary intelligent medical information system which can be integrated into a medical- or health-oriented version of system 100 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0016] The following detailed description, which references and incorporates the Figures, describes and illustrates one or more specific embodiments of the invention. These embodiments, offered not to limit but only to exemplify and teach, are shown and described in sufficient detail to enable those skilled in the art to implement or practice the invention. Thus, where appropriate to avoid obscuring the invention, the description may omit certain information known to those of skill in the art.
DEFINITIONS
[0017] This description includes many terms with meanings derived from their usage in the art or from their use within the context of the description. As a further aid, the following exemplary definitions are presented.
[0018] The term “document” refers to any logical collection or arrangement of machine-readable data having a filename.
[0019] The term “database” includes any logical collection or arrangement of machine-readable documents.
[0020] The term “hyperlink” or “link” includes any token conforming literally or functionally to any past, present, or future Uniform Resource Locator (URL) standard. It also includes any token including information identifying a specific computer system or networked device.
Exemplary System Architecture
[0021] FIG. 1 shows an exemplary theme-oriented database-management-and-community-building system 100 . The broken lines in the figure indicate that various components of the system are interconnected permanently or temporarily via a wired or wireless wide-area-network, such as the Internet, or a secure wired or wireless local-area networks, such as a corporate Intranet. The exemplary embodiment uses Secure Transaction Technology to ensure secure connections. System 100 includes user access stations 110 , a web server system 120 , a membership database 130 , and a theme-oriented database 140 .
[0022] More particularly, user access stations 110 includes one or more access stations, of which stations 110 a , 110 b , and 110 c are representative. The term “access station,” as used herein, encompasses browser-equipped personal computers, network appliances, personal digital assistants, telephones, cell phones, web phones, televisions, web television, etc. Thus, the present invention is not limited to any particular class or form of access device.
[0023] Selectively coupled to access stations 110 is web server system 120 . Web server system 120 includes one or more software modules 122 and one or more memory modules 124 which cooperate to serve data to and from databases 130 and 140 and the access stations 100 , and to define and generate related webpages and graphical-user interfaces. (See, for example, exemplary home pages 300 and 500 in FIGS. 3 and 5 , respectively.)
[0024] Membership database 130 includes information regarding members or potential members (users) of system 100 . Figure shows this information as representative records 132 and 134 , which are substantially identical in structure. In the exemplary embodiment, record 132 includes member-identification data 132 a , member-profile data 132 b , member-contact or -linking data 132 c , and member-participation data 132 d . Member-identification data 132 a includes data for identifying or authenticating the identity of a user. Member-profile data 132 b includes data describing the professional biographies and credentials of the member. Member-contact data 132 c includes data, such as one or more postal addresses, telephone numbers, e-mail addresses, or URLs for facilitating contact or communications with the associated user. And, member-system-participation data 132 d includes quantitative and qualitative information regarding actual and permitted use of the system by each user. For instance, the exemplary embodiment maintains one or more access scores for each member, indicating levels of access to respective portions of theme-oriented database 140 .
[0025] Theme-oriented database 140 includes theme data 142 , site data 144 , query data 146 , and user data 146 . Theme data 142 includes one or more keywords, terms, concept, or website address which define one or more aspects of the thematic or topical content of database 140 . Exemplary themes or topics includes general healthcare and wellness information for humans or other animals, such as dogs, cats, or fish; specific healthcare information for various parts of the human body, such as joints (knees, hips, elbows, spine, etc.) or organs (heart, lungs, stomach, kidney, liver, eyes, ears, skin, etc.); specific medical conditions, such as allergies (food, plant, etc.), cancer, arthritis, obesity, mental illness; auto-immune deficiency (HIV). Other exemplary topics include technology breakthroughs, health-technology breakthroughs, children, cooking, sports, entertainment, celebrities, politics, law, restaurants, consumer products, motion pictures, videos, music recordings, corporations, government officials, criminal activity, schools, science, wines, beers, foods, professional service providers (lawyers, doctors, contractors, artisans, etc.) colleges, alumni of educational institutions, genealogy, gossip, or sex. One exemplary health-oriented database includes user-generated health content, medical-journal content, and an archive of health-oriented feature stories. Thus, the present invention is not limited to any particular theme or class of themes.
[0026] Site data 144 includes feature articles, journal articles and other content added to database 144 manually by its creators, sponsors, or other parties governing or maintaining the database or automatically by the system itself. Query data 146 includes a listing of one or more queries (or query summaries) made by registered users or members of the community, against the database, with each query associated with one or more portions of the membership data for its submitting member. User data 146 includes user contributions to the database, with each contribution logically associated with or appended to one or more portions of the membership data for its submitting member.
[0027] In its exemplary operation, system 100 generally enables users not only to access, that is, query theme-oriented data in database 110 , but also to contribute data to the database. Users earn access rights to various portions of the database. Access rights are granted based on quality and/or relevance of database contributions and referrals of new members to the system.
Exemplary System Operation
[0028] More specifically, FIG. 2 , which shows an exemplary flowchart 200 , illustrates an exemplary method of operating system 100 . Flow chart 200 includes blocks 202 - 230 , which are executed serially in the exemplary embodiment. However, other embodiments of the invention may change the order of execution and/or execute two or more blocks in parallel using multiple processors or a single processor organized as two or more virtual machines or subprocessors. Moreover, still other embodiments implement the blocks as two or more specific interconnected hardware modules with related control and data signals communicated between and through the modules. Thus, the exemplary process flow is applicable to software, firmware, and hardware implementations.
[0029] The exemplary method begins at block 202 , with automatically or manually establishing an initial version of theme-oriented database 140 . To this end, the exemplary method entails determining a theme or topic and conducting one or more Internet searches to identify a set of one or more candidate members. Exemplary candidate members include existing websites or portions of websites related to the theme and persons or firms with expertise or indicated interest in the theme. The publishers of identified publications and websites are then invited to register as members of the system. An exemplary electronic invitation includes an explanation of the system and a URL to the system. Execution of the exemplary method then proceeds to block 204 .
[0030] In block 204 , one or more of the candidate members establish a communications link with the system through webserver 120 . This entails each of the candidate members using an access station, such as access station 110 , to invoke the URL to the system. For example, the user at access station 110 would invoke “www.domain-name.com” to connect her computer system (or other network appliance) to webserver system 120 . After establishing the link to webserver 120 execution proceeds to block 204 .
[0031] Block 206 entails receiving registration information from the candidate member. The registration information includes member-identification data, member-profile data, member-contact or -linking data, and member-system-participation data. Member-identification data includes data for identifying or authenticating the identity of a user, such as a username and password. Member-profile information includes professional biographical information, such as present employment, professional achievements, educational or other promotional type material indicating or suggesting the authority or credibility of the registering member in the topic. Member-contact data includes data, such as one or more postal addresses, telephone numbers, e-mail addresses, or URLs for facilitating contact or communications with the associated user. Member-system-participation data includes an access score that governs the level of access that the associated member has over theme-oriented database 140 . The exemplary system determines an initial access score based on whether the user was referred by an existing member, or whether the user was given a special invitation based on his or her expertise in the theme. If an existing member referred the user, the access score for the existing member is increased upon registration of the new user. After all registration information has been received for a particular member, execution proceeds to block 208
[0032] In block 208 , the system records the received registration information in membership database 130 . Although the exemplary embodiment maintains membership database 130 separate from theme-oriented database 140 for heightened security, some embodiments combine the databases. With recording of the registration information, the exemplary method advances to block 210 .
[0033] Block 210 entails the new member logging into the system to access theme-oriented database 140 . Specifically, this entails the new (or an existing) member manually or automatically entering a username and password. (Existing members bypass blocks 202 - 208 to reach block 210 ) The username and password are then verified against those in membership database 130 . Affirmative verification advances the exemplary method to block 212 .
[0034] In block 212 , the system presents the member a home page for theme-oriented database 140 . (See FIG. 3 and related description of exemplary home page.) From the home page, the member decides to query database 140 or to contribute data to database 140 as indicated by decision block 214 .
[0035] A member decision to make a contribution to the database branches execution to block 216 , which entails receiving a contribution from the member. Execution then continues to block 218 .
[0036] In block 218 , the system evaluates or scores the contribution based on its quality and/or relevance to the theme-oriented content of database 140 . To evaluate the contribution, the exemplary embodiment converts the contribution to a natural-language query and executes this query against all or part of database 140 . The natural-language searching algorithm produces quantitative measures of the relevance of the contribution. Other embodiments produce the measures using inverse-document-frequencies factors that favor rare terms and/or frequency factors which favor terms that in the document to be scored. In some embodiments, the contribution is summarized using specialized software, such as that described in U.S. Pat. No. 5,708,825, entitled Automatic Summary Page Creation and Hyperlink Generation, which is incorporated herein by reference. Other embodiments score the contribution based on additional factors, including for example, length (number of words), number of citations to leading journals, inclusion of hyperlinks to predetermined cites (such as sponsors of the system) and/or grammar. Still other embodiments score the contributions manually using an editorial board of experts in the theme.
[0037] Execution then continues at decision block 220 , where the system determines if the evaluation was good or not. That is, is the contribution of sufficient relevance and quality to be added to database 140 . If the contribution has a good evaluation, based for example on its score exceeding some threshold value, the system proceeds to block 222 .
[0038] In block 222 , the system adds the contribution to database 140 . In the exemplary embodiment, this entails appending the username along with one or more portions of the member's member-profile information and/or member-contact information to the beginning and/or end of the contribution. (Some embodiments use a side by side presentation approach for the contribution and its attribution.) Thus, other members accessing this information can identify its contributing member and assess credibility and authority of the contribution. Moreover, if a contributing member has elected to allow publication of its contact information, such as its e-mail address, future users of the information may establish communications with the contributor. Publication of a hyperlink or URL associated with the contributor will offer opportunities for reciprocal web traffic from webserver 120 to a webserver associated with the contributing member, creating an incentive for further contributions to the theme-oriented database.
[0039] In block 224 , after adding the contribution to database 140 , the system updates the access score portion of the participation data for the member based on the score of the contribution. In the exemplary embodiment, this entails adding the score of the contribution to the initial or previous access score in membership database 130 . However, other embodiments adopt other forms of update.
[0040] In block 226 , the system offers the contributing member an opportunity to connect with one or more other members who have made similar contributions to database 140 . In the exemplary embodiment, this entails defining a query based on the contribution and executing this query against the user data portion of database 140 , more precisely user data 149 . Based on the results of this query, the exemplary embodiment presents one or more usernames and related contact or biographical information for other members who have made similar contributions to the database, thereby facilitating communications between the contributing member and other contributing members.
[0041] On the other hand, if the contribution had a poor evaluation based on the threshold, execution proceeds to block 228 which outputs a message to the member indicating that the contribution was rejected. Some embodiments may offer an explanation for the rejection, and others refer the member to an alternate system with an appropriate theme for receiving the information. Still others reroute the contribution to the alternate system, automatically enrolling the member in the alternate system by transferring a copy of the associated membership information. After rejecting the data, execution returns to decision block 214 , where the member can choose to add new data or to submit a query for database 140 .
[0042] From block 214 , a decision to query database 140 branches execution to block 230 , which entails receiving a query from the member. Although the scope of the invention encompasses queries of any number of forms, the exemplary embodiment accepts queries as a textual string with boolean connectors or as a natural-language query. (Moreover, the exemplary embodiment permits the member to restrict the query to specific portions of theme-oriented database 140 , such as to site data or user data.) Execution of the exemplary method then proceeds to block 232 .
[0043] In block 232 , the system executes the query against database 140 . In the exemplary embodiment, this entails running the query against the entirety of database 140 . However, some embodiments restrict the query to one or more portions of database 140 .
[0044] In block 234 , the system presents query results to webserver 120 for viewing by the member through an access station. The exemplary embodiment presents the query results based not only on the query and the contents of database 140 , but also on the access score for the member. Thus, for example, a low access score may result in all or a portion of the results being withheld from the member. Some embodiments advise the member quantitatively regarding the withheld portion of the results. For example, the system presents a message that a certain percentage of the results is withheld. Other embodiments present citations for the portions being withheld to assist the member in determining the desirability of this withheld information. Variations of this approach may present the profile of the contributors of the withheld results.
[0045] In presenting the results to the requesting member, the exemplary system arranges or organizes the results based not only on relevance to the query presented but also on factors, such as the access rights of the respective contributors of data to the system. Thus, for example, data contributions from contributors that have accrued relatively high access rights are generally presented before data contributions from contributors with relatively lower access rights, assuming the contribution are of approximately equal relevance to the query. This presentation mechanism further encourages members, particularly those with related websites, to contribute content to the database.
[0046] Some embodiments present the results in a predetermined order based on the portions of the database that contain them. For example, one embodiment presents found data in the order of feature articles, user contributions, and journal articles, with the items in each category arranged based on relevance and/or access rights of respective contributors.
[0047] In block 236 , the system stores the query and associated member-profile and/or member-contact information to the query portion of database 140 . Once stored in database 140 , the query is searched like any other content within the database. When query results include one or more queries the queries are presented along with the usernames associated with the queries.
[0048] In block 238 , after storing the query, the system offers the contributing member an opportunity to connect with one or more other members who have made similar queries of database 140 . In the exemplary embodiment, this entails defining a query based on the query and executing this query against the query data portion of database 140 , more precisely user data 146 . Based on the results of this query, the exemplary embodiment presents one or more usernames and related contact or biographical information for other members who have made similar contributions to the database, thereby facilitating communications between the member and other members with similar queries. Of course, the member then has the option to contact one or more of the other members. Other embodiments also presents the member options to connect with members who have published information relating to the query or to allow other members with similar questions to contact her in the future.
Exemplary Home Pages
[0049] FIG. 3 shows an exemplary home (or start) page 300 generated by webserver system 120 for display in response to authorized access to health-oriented version of database 140 . Home page 300 includes banner advertising regions 310 and 312 , a site logo region 314 , information region 316 , a search region 318 , a feature-content region 320 , a sponsorship or partnership region 322 , and link region 324 .
[0050] Information region 316 includes a link 316 a to a list 120 of links to categories of medical conditions and health areas. This list of links is shown in FIG. 4 as table 400 . Each category link takes the user to archived content, user-contributed content, relevant site-generated top-ten lists, and links or phone number for groups, hospitals and doctors that specialize in the condition. (Some embodiments allow users to restrict the information based on geography.) Information region 316 also includes a donor or contribution subregion 316 b where users have the opportunity to publish useful health and medical information, and a site top-ten region 316 c where users cast votes on their favorite products, services, and advice.
[0051] Search region 318 accepts entry of keyword or natural-language style queries. Submitted queries are executed against user-generated content, medical journal content, and site-created editorial content in database 140 . In embodiments that associate, health-oriented database 140 with other theme-oriented databases, such as a knee database, a veins database, and a medical-technology database, search region 318 enables users to search across all or a subset of the related databases.
[0052] Feature-content region 320 , in the exemplary embodiment, changes daily and includes health-related stories, of for example 600 words. This region presents users an opportunity to add comments and/or contribute information at the end of the story in a user subregion 320 a , below the story. User subregion 320 a includes prompts (not shown) urging users to submit story-relevant information about local support groups and hospitals in their areas.
[0053] Sponsorship or partnership region 322 includes links to one or more nationally-recognized e-commerce or pharmaceutical companies. Exemplary commerce partners include an on-line drugstore, a baby-and-children products store, an online book retailer, and a vitamins-nutraceutical store.
[0054] Link region 324 includes one or more links to other general health or medical sites. Exemplary sites include a site for first-aid information and government health sites.
[0055] FIG. 5 shows another exemplary home page 500 . Home page 500 includes many features analogous to those in home page 300 .
Exemplary Medical-Information System
[0056] FIG. 6 shows an exemplary medical-information system 600 which can be integrated into system 100 of FIG. 1 , as software, hardware, or firmware modules. System 600 includes a user-registration-and-tracking module 602 , an initial-symptom-and-medical-history-dialog module 604 , a condition-inference engine 606 , a condition-hyperlink generator 608 , a followup-dialog module 610 , a knowledge-base-feedback module 612 , and a user-comments module 614 .
[0057] User-registration-and-tracking module 602 receives user or member registration or membership information and assigns the username and password. Alternatively, the user can define her own username and password. Exemplary registration or membership information includes the gender and date of birth of the user. The registration information is stored in a database such as database 130 in system 100 . The registration data is available for retrieval during subsequent user visits and for other operations of system 600 , such as knowledge base enhancement.
[0058] Initial-symptom-and-medical-history-dialog module 604 assigns a case number, specific to the username as it begins receiving an initial description of symptoms through a natural-language interface. A parser (not shown) attempts to extract one or more symptoms from the initial description. The user is then asked to confirm the one or more parsed symptoms. If a symptom cannot be parsed, a form-based interface is presented to the user, with a prompt to select a symptom from a pick list. Pick lists are subdivided, based on symptom categories. Based on the one or more extracted symptoms, the user is lead through a series of yes-no dialogs to aid in determining one or more conditions that may be causing the symptom.
[0059] Condition-inference engine 606 receives the yes-no answers from initial-symptom module 604 and develops a list of one or more potential conditions, ranked by probability or frequency. In the exemplary embodiment, the condition-inference engine uses rules stored in a database, rather than hard-coded rules, to facilitate maintenance and automatic modification based on experience with users.
[0060] Condition-hyperlink generator 608 accepts output from the condition-inference engine, in the form of a list of medical conditions. For each condition, generator 608 produces a short description of the condition and an HTML page of hyperlinks appropriate to the condition, including articles about the condition, potential treatments, effectiveness of treatments, side effects of treatments, prognosis, survival rates, specialists, support groups.
[0061] Followup dialog module 610 asks the user questions based on the username and case number. Questions are also based on data from the initial symptoms dialog and results from the condition-inference engine. Exemplary questions include whether the user visited a doctor, and if so, what diagnosis was given. In the exemplary embodiment, the followup dialog module includes a natural-language interface. However, in other embodiments, the followup dialog module includes a dynamically generated HTML form, with appropriate use of pick lists, radio buttons, check boxes, and text-entry fields.
[0062] Knowledge-base feedback module 612 uses information gained in the followup dialog to enhance the knowledge base used in the condition-inference engine. In particular, diagnosis by doctors shall be used to enhance the probability ranking of conditions.
[0063] User-comment module 614 accepts comments from users about conditions, treatments, and side effects noted from followup dialog. These comments are extracted from the followup dialog, stored in a database, and made accessible to other users.
[0064] An exemplary operational scenario for system 600 proceeds as follows. A user logs into the system and registers as a first time user, filling out a form identifying her gender and date of birth. The system asks the users, “How can I help you today?” The user types, in natural language, “My wife and I are having trouble getting pregnant.” The system replies, “I understand that you and your wife are having trouble conceiving. Is that correct?” The user replies, “Yes.” The system asks, “Have you seen a doctor about your condition?” The user replies, “No.” The system asks, “Have you been trying to get pregnant for more than one year?” Users says, “Yes,” and the system “Did you suffer from mumps after the age of 12?” User says, “No,” and system asks “Are you physically unfit or on a weight reducing diet?” User says, “No.” IMIS asks, “Do you have sex less than 3 times a week, on average?” User says, “Yes.” System says, “Infrequent sex may be the cause of your condition,” and adding “Here are other leading causes of infertility for people your age: 1) Low-sperm count in the male; 2) Blocked fallopian tubes in the female; and 3) Chronic pelvic infection in female. Further, the system communicates that “it cannot perform a physical exam and cannot diagnose your condition. Only a doctor can diagnose your condition. Would you like more information about these conditions?” User replies, “Yes.”
[0065] In response, the system outputs or presents a hyperlinked page of condition descriptions, treatments for each condition, success rates for each treatment, specialists in infertility, and infertility support groups. At the top of the page, the system communicates: “If you visit a doctor and are diagnosed, please come back for another visit.”
[0066] Six months later, the user logs on to the system. The system recognizing the username and its associated case number, communicates: “Welcome back. Can I ask the status of your situation with infertility?” User replies, “Yes, my wife and I are now pregnant.” System says, “Congratulations! Did you visit a doctor to be diagnosed? User says, “Yes, the doctor performed tests on both me and my wife. No obvious problem was found; he recommended that we buy a basal thermometer and use it. After two months, we got pregnant.” System says “Where did you buy your basal thermometer?” User says, “On the web, from drugstore.com.”
[0067] The system says, “Thank you for your input. I'll add your comments about basal thermometers to my database. Your input may help other couples that are having problems with fertility. Is there anything else I can help you with today?” User says, “No, that's all for now.” The system says, “Thanks again for your help. I'm going to e-mail you free coupons for baby formula and diapers. Visit me again if you need info about child care.”
CONCLUSION
[0068] In furtherance of the art, the inventor has presented systems, methods, and related software for encouraging and managing growth of databases, particularly theme-oriented databases. One exemplary method entails establishing a health-oriented database and granting users access rights to the database based on their contributions or submissions to the database. The exemplary method scores the contributions for quality and/or relevance, granting access rights based on the scores to contributors. Other embodiments record the queries of users of the database and facilitate communications between users having similar queries. Thus, the exemplary method and related systems and software facilitate not only organized growth of a theme-oriented database, but also developing relationships between users of the database.
[0069] The embodiments described above are intended only to illustrate and teach one or more ways of practicing or implementing the present invention, not to restrict its breadth or scope. The actual scope of the invention, which embraces all ways of practicing or implementing the concepts of the invention, is defined only by the following claims and their equivalents. | In recent years, computers have become everyday communication tools, fast approaching the commonness of telephones and televisions. Driving this approach is the ever-expanding Internet, which enables users not only to communicate with each other, but also to search for information of particular interest. Two problems for Internet users are the time and effort necessary to find information they want and to connect with other users who share interest in similar information. Accordingly, the present inventor devised systems, methods, and related software that spurs growth of databases and/or fosters connections between users of those databases. One exemplary method entails receiving user contributions to a theme-oriented database, such as a health-information website and granting users access rights to the database based on quantity, quality, and/or relevance of their contributions. The exemplary method also shares contact information with users making similar queries of the database, ultimately promoting development of intelligent on-line communities. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a cushion, and method for producing the same, with at least one soft elastic region. More specifically, the invention relates to a felt cushion with a silicone pad, for use with orthopedic devices.
2. The Prior Art
It is known that such cushions may be used in orthopedic devices, e.g., in epicondylitis braces. Therefore, a felt cushion is adapted to the shape of the epicondylitis brace. Silicone spots are applied to the skin of the user of the orthopedic devices to prevent the cushion from slipping. Recesses are usually cut into the felt cushion and soft elastic regions or silicone castings are glued into these recesses.
Such orthopedic devices are known for example from WO 97/24085 and WO 99/09917.
SUMMARY OF THE INVENTION
An object of the present invention is to create a cushion which can be used for an especially long period of time. In addition, the object of this invention is also to provide a method of producing such a cushion.
According to the invention, the soft elastic region is detachably attached to the cushion. This permits a reduction of material because the component of the cushion, namely either the cushion itself or the soft elastic region which is subject to less wear, can be reused. Therefore, if the soft elastic region, in particular a silicone pad, has become worn due to frequent use it can be removed from the cushion and replaced by a new one. Furthermore, the cushion area can be replaced if it is subject to greater wear. Numerous fastening options are available for arranging the cushion on the soft elastic region. The soft elastic region preferably has a retaining element with which the soft elastic region is attached to the cushion. It is also possible for the soft elastic region to be designed such that it is inserted into a recess in the cushion and remains there merely by friction. In this case, the soft elastic region would have to be designed to be exactly the same size or slightly larger than the corresponding recess.
However, it is preferable to design the soft elastic region in the form of a silicone casting, so that the retaining element projects beyond the dimensions of the other soft elastic region. The retaining element is designed as a retaining flange which is provided in at least two locations on the soft elastic region and is disposed on the upper edge of the soft elastic region. This allows the soft elastic region to be inserted into a corresponding recess in the cushion and the retaining flanges provided on the upper edge are in contact with the cushion. Therefore, the soft elastic region is designed thicker than the cushion by the thickness of the retaining flange. In a preferred embodiment, the retaining flange is designed peripherally and with a through-passage, so that a retaining effect is achieved in the entire soft elastic region. The retaining flange is arranged on the side facing away from the user's body, so that a flush seal is on the side facing away from the user's body.
In another preferred embodiment, a VELCRO®-type hook and loop element is provided as the retaining element. If VELCRO® hook and loop tape is provided on the soft elastic region, then a fleece is preferably arranged on the cushion. The VELCRO®-type hook and loop clement is preferably designed to project above the soft elastic region so that the VELCRO®-type hook and loop element can be engaged with a corresponding strip on the back side of the cushion. The soft elastic region can be inserted into a recess in the cushion and detachably attached to the cushion with the VELCRO®-type hook and loop element. The soft elastic region can then be detached as needed and replaced by a new soft elastic region. As an alternative, it is also possible to provide the VELCRO®-type hook and loop element on the back of the soft elastic region. The VELCRO®-type hook and loop closure is then established with the orthopedic device used with the cushion.
The VELCRO®-type hook and loop element can be attached to the soft elastic region in various ways. The VELCRO®-type hook and loop element is preferably bonded to the soft elastic region. This means that the VELCRO®-type hook and loop element forms with the soft elastic region a bordering layer or a boundary layer approximately 1 mm thick in which the soft elastic region is drawn into the VELCRO®-type hook and loop element.
To produce such a cushion, the, soft elastic region is designed from a cast. To form the casting, a free flowing material is poured into a mold, the VELCRO®-type hook and loop element is brought in contact with the material while it is still free-flowing, and the free-flowing material is then vulcanizec and bonder to the VELCRO®-type element. Therefore, the VELCRO®-type hook and loop clement is brought in contact with the material while still liquid before it undergoes vulcanization. The viscosity of the material and the vulcanization time must be selected so that the free-flowing material fuses with the VELCRO®-type hook and loop element, but does hot completely permeate it. As an alternative, the VELCRO®-type hook and loop element can be glued to the soft elastic region. Suitable adhesives include mixed adhesives, reactive adhesives, solvent adhesives or hot-melt adhesive, e.g., hot-melt adhesive films.
The VELCRO®-type element can be attached to the soft elastic region in various ways. The VELCRO®-type element is preferably bonded to the soft elastic region. This means that the VELCRO®-type element forms with the soft elastic region a bordering layer or a boundary layer approximately 1 mm thick in which the soft elastic region is drawn into the VELCRO®-type element.
To produce such a cushion, the soft elastic region is designed from a cast. To form the casting, a free-flowing material is poured into a mold, the VELCRO®-type element is brought in contact with the material while it is still free-flowing, and the free-flowing material is then vulcanized and bonded to the VELCRO®-type element. Therefore, the VELCRO®-type element is brought in contact with the material while still liquid before it undergoes vulcanization. The viscosity of the material and the vulcanization time must be selected so that the free-flowing material fuses with the VELCRO®-type element, but does not completely permeate it. As an alternative, the VELCRO®-type element can be glued to the soft elastic region. Suitable adhesives include mixed adhesives, reactive adhesives, solvent adhesives or hot-melt adhesives, e.g., hot-melt adhesive films.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
In the drawings, wherein similar reference characters denote similar elements throughout the several views:
FIG. 1 shows a top view of a cushion with a soft elastic region;
FIG. 2 shows a side view of a cushion with a soft elastic region according to FIG. 1;
FIG. 3 shows a cross-sectional view of the soft elastic region during the production process;
FIG. 4 shows a cross section through a cushion with a soft elastic region produced according to FIG. 3;
FIG. 5 shows a cross section through,an alternative embodiment of a soft elastic region according to the invention during the production process;
FIG. 6 shows a diagram according to FIG. 5 in an advanced stage of the process; and
FIG. 7 shows a cross section through a cushion with another embodiment of the soft elastic region.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now in detail to the drawings and, in particular, in FIG. 1 there is shown a cushion 1 intended for use in a epicondylitis brace. The shape of the cushion is adapted to the shape of the epicondylitis brace, and soft elastic regions 2 are arranged on the enlarged end areas so that they come in contact with the skin and prevent cushion 1 from slipping.
FIG. 2 shows a side view of cushion 1 . In its lower area, cushion 1 contains a felt cushion 3 on which fleece 4 is arranged. Fleece 4 is designed to engage with a hook strip to form a VELCRO®-type closure. Soft elastic regions 2 may be designed so that they have a retaining element 5 which projects above cushion 1 . Retaining element 5 is arranged on the side of cushion 1 facing away from the user's body.
FIG. 3 shows a cross sectional view through soft elastic region 2 during the production process. A mold 6 rests on a heating plate 7 . A liquid material, in particular liquid silicone, is introduced into this mold 6 and then vulcanizes in the mold to assume the shape indicated. The vulcanization time depends on the temperature, which is controlled by heating plate 7 , the catalyst content, and the original consistency or viscosity of the material cast in the mold. The soft elastic region is produced as one piece with peripheral retaining flange 8 formed in a corresponding recess in mold. Retaining flange 8 runs along the upper edge area of soft elastic region 2 .
FIG. 4 shows a cross section through soft elastic region 2 detachably arranged in felt cushion 3 . Thus, soft elastic region 2 can be inserted and removed through retaining flange 8 on felt cushion 3 . Secure handling is ensured when the side of felt cushion 3 on which retaining flange 8 is located is facing the user. This prevents unintentional detachment of soft elastic region 2 . If a continuous closure of felt cushion 3 and soft elastic region 2 is desired, the bottom side should face the user. This almost completely rules out unintentional slippage of soft elastic region 2 from felt cushion 3 because the cushion is usually used together with an orthopedic device, such as an epicondylitis brace with the back of soft elastic region 2 in contact with in. The back of soft elastic region 2 may be attached to the epicondylitis brace, e.g., by a VELCRO®-type hook and loop closure.
FIGS. 5 and 6 show cross sections through a cushion with a soft elastic region during two different steps of the method for production of the cushion. FIG. 5 shows a mold 6 which is resting on a heating plate 7 and in which a soft elastic region 2 is produced by filling it with liquid silicone. A plurality of molds 6 are preferably arranged on heating plate 7 so that a plurality of soft elastic regions 2 can be produced at the same time. This is also true of the embodiment of the method according to FIG. 3 .
FIG. 6 shows a retaining element 5 , formed by a VELCRO®-type element 9 , applied to the casting according to FIG. 5 while still molten. VELCRO®-type hook and loop element 9 is either a fleece or a VELCRO® hook and loop tape, so that it can be brought into VELCRO®-type hook and loop closure with a corresponding VELCRO® hook and loop strip or fleece. VELCRO®-type hook and loop element 9 is applied to the casting while still hot so that the liquid material is absorbed into the VELCRO®-type hook and loop element 9 about 1 mm, and is fused thereto. Soft elastic region 2 is then vulcanized by heating plate 7 , and then soft elastic region 2 can be removed from mold 6 and used in a cushion. VELCRO®-type hook and loop element 9 is attached to the orthopedic device according to the embodiment shown. Soft elastic region 2 can also be used with cushions which do not have any recesses but instead have a section corresponding to VELCRO®-type hook and loop element 9 . The soft elastic region is then applied directly to the cushion by a VELCRO®-type connection and projects slightly above it. As an alternative, it is also possible to use a VELCRO®-type hook and loop element 9 which projects beyond the edges of soft elastic region 2 in its outside dimensions.
A cross section through soft elastic region 2 is felt cushion 3 is shown in FIG. 7, VELCRO®-type hook and loop element 9 projects above soft elastic region 2 with a projection 10 . By using a VELCRO®-type hook and loop closure, this projection 10 can be attached with its VELCRO®-type hook and loop element facing downward to the felt cushion 3 or a corresponding fleece or VELCRO® strip hook and loop which is arranged on felt element 3 . Therefore, soft elastic region 2 can be detachable from the cushion.
Accordingly, while only a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made there unto without departing from the spirit and scope of the invention. | A cushion having at least one soft elastic region for use with orthopedic devices. The soft elastic region is detachably arranged on the cushion so that the cushion or the soft elastic region can be replaced when it is worn out while still using the other part. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to door operators for doors on transit vehicles such as buses and trains. Some vehicle doors have a single panel mounted at an outside edge of the door opening. Many vehicle doors have two panels, each mounted at an outside edge of the door opening. The panels usually swing outward to permit entrance or exit of passengers. Often, the doors are caused to open or close with a pneumatic cylinder or electric motor and a well known teeter assembly mounted over the top of the door opening. The space available for mounting the door operator over the door opening is often limited. Automatic opening and closing of the doors is controlled by the vehicle driver at stops for picking up and discharging passengers. It is an essential feature of door operators that the doors cannot be pushed open by passengers leaning against the doors, for example, while the vehicle is moving. However, in an emergency there must be a manual release that can be operated by a passenger. Generally, passengers must be able to operate the manual release with no more than 20 pounds pull force.
[0003] 2. Description of Related Art
[0004] U.S. Pat. No. 5,332,279 entitled “Power Door Operator for Multi-Passenger Mass Transit Vehicles” discloses an electric door operator and illustrates the manner in which the spaced doors are rotated open and closed by the action of the teeter assembly connected to drive rods and pivot levers fixed to the vertical door shafts on which the doors are mounted. FIG. 1 of the '279 patent is incorporated herein by reference. This application is directed to an improved system for driving the teeter assembly with an electric motor.
SUMMARY OF THE INVENTION
[0005] An electric door operator for opening and closing one or a spaced pair of transit vehicle passenger doors comprises a structure for being mounted adjacent an opening for the doors. A rotatable input shaft is mounted to the structure with an electric motor secured to the input shaft for driving the input shaft, a first stage pinion positioned on the input shaft, and an electric brake mounted to the input shaft. An output shaft is rotatable relative to the structure and has a teeter mounted thereon with journal bearings at at least one end thereof for engagement with drive bars for opening and closing the doors. An output gear is fixed to the output shaft for driving the output shaft.
[0006] A first stage shaft is rotatable relative to the structure and has a first stage gear fixed to the shaft in a position to engage the first stage pinion on the input shaft. A second stage pinion with a sliding connection to the first stage gear shaft enables axial movement of the second stage pinion between engaged and disengaged positions with the first stage gear.
[0007] A second shaft is rotatable relative to the structure. A second stage gear is fixed to the second shaft and arranged for engagement with the second stage pinion. A third stage pinion is fixed to the second shaft for directly or indirectly transferring torque to the output gear fixed to the output shaft.
[0008] A drum cam shaft is rotatable relative to the structure. A drum cam is axially movable relative to the drum cam shaft. A pin extending from the drum cam shaft engages a cam slot in the drum cam. A lifting plate is fixed to the drum cam and extends to engage a slot in the first stage pinion to move the first stage pinion between engaged and disengaged positions. A disengagement lever and an engagement/disengagement cam are fixed to the drum cam shaft. A pin extends from the disengagement lever.
[0009] A mechanical release is fixed to a slotted end piece. The aperture in the slotted end piece receives the pin extending from the disengagement lever. When the mechanical release is actuated, the drum cam shaft rotates the pin extending from the drum shaft and the drum cam moves to lift the lifting plate and first stage pinion to the disengaged position.
[0010] Briefly, according to a specific embodiment of this invention, there is provided an electric transit door operator for opening and closing a spaced pair of transit vehicle passenger doors. A housing is provided with a base plate for being mounted over an opening for the doors. A rotatable input shaft is mounted over the base plate and parallel thereto. An electric motor is secured to the input shaft for driving the input shaft; a worm is centrally positioned on the input shaft; and an electric brake is mounted to the input shaft at an end opposite the electric motor.
[0011] An output shaft is rotatable relative to the housing and has a teeter mounted thereon with journal bearings at opposite ends thereof for engagement with drive bars for opening and closing the doors. A gear is fixed to the output shaft for driving the output shaft.
[0012] The input shaft is rotatable perpendicular to the output shaft and has a worm fixed to the input shaft in a position to engage a worm gear. A second stage pinion with a sliding connection to the gear shaft enables axial movement of the second stage pinion between engaged and disengaged positions,
[0013] A second shaft is rotatable parallel to the output shaft. A second stage gear is fixed to the second shaft and arranged for engagement with the second stage pinion. A third stage pinion is fixed to the second shaft. The third stage pinion directly or indirectly transfers torque to the output gear fixed to the output shaft.
[0014] A drum cam shaft is rotatable on a drum cam shaft parallel to the output shaft. The drum cam is rotatably and axially movable relative to the drum cam shaft. A pin extends from the drum cam shaft engaging a cam slot in the drum cam. A lifting plate is fixed to the drum cam and extends to engage a slot in the second stage pinion to move the second stage pinion between engaged and disengaged positions. A disengagement lever and a disengagement cam are fixed to the drum cam shaft.
[0015] A cable sheath bracket fixes the sheath of a release cable to the base plate. A release cable is fixed to a slotted end piece. The aperture in the slotted end piece receives the pin extending from the disengagement lever. A return spring urges the slotted end piece away from the cable sheath bracket. When the release cable is pulled, the drum cam shaft rotates the pin extending from the drum cam shaft and the drum cam moves to lift the lifting plate and second stage pinion to the disengaged position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Further features and other objects and advantages will become apparent from the following detailed description made with reference to the drawings in which:
[0017] FIG. 1 is a front view in partial perspective of an electric door operator according to this invention;
[0018] FIG. 2 is a side view in partial perspective of an electric door operator according to this invention in which the housing has been removed to better observe the moving parts; and
[0019] FIG. 3 is an end view in perspective of an electric door operator according to this invention with the housing and brake removed to better observe certain of the moving parts.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring now to FIG. 1 , a structure or housing 12 supports or encloses most of the moving elements of the door operator. A housing has a base portion to which the moving elements are indirectly or directly mounted. The teeter 14 is mounted on an output shaft 16 . The teeter 14 has a drive arm 15 mounted to the output shaft 16 with journals 18 , 20 at one or both ends for receiving drive rods (not shown). The teeter can rotate both clockwise and counterclockwise to operate the drive rods. Mounted on opposite sides of the housing 12 are electric motor 22 and electric brake 24 connected to each end of an input shaft 26 . The electric motor can be controlled to rotate either clockwise or counterclockwise.
[0021] Referring now to FIGS. 2 and 3 , the electric motor 22 is coupled to the input shaft 26 at one end and to the electric brake 24 mounted to the input shaft, for example, at the other end. The electric brake is spring biased in the braking position with an electric release. An electromagnetic coil (not shown) inside electric brake 24 releases a spring actuation such that when no electric power is available the motor shaft is locked in position. Thus, a passenger leaning on a door will not force it open. Electric power is only required to open or close the doors and not to maintain the doors closed. Other fail safe braking systems can be used.
[0022] When the electric brake 24 is released, the electric motor 22 can turn the input shaft 26 either clockwise or counterclockwise. The motor may be brushless in one embodiment.
[0023] Mounted on the input shaft 26 is worm 28 . A gear shaft 30 is mounted rotatable, and preferably, perpendicular to the input shaft 26 . A worm gear 32 is fixed to the gear shaft 30 in a position to engage the worm 28 . A second stage pinion 34 has a sliding connection on the gear shaft 30 enabling axial movement of the second stage pinion 34 between engaged and disengaged positions with the worm gear 32 . Under normal conditions, the worm gear 32 is mounted to the lower portion of the gear shaft 30 and engages the second stage pinion 34 with pins 33 (see FIG. 2 ) or the like.
[0024] This arrangement allows for the emergency release of the input shaft 26 from the teeter 14 permitting manual opening of the door in an emergency. Alternatively, second stage pinion 34 may have one or more arm extensions received in one or more recesses in worm gear 32 . With such arrangements, the electric door operator may be permitted to selectively engage the second stage pinion with respect to the worm gear, and thus, disengage the door operating mechanism entirely from the doors.
[0025] A second shaft 36 is mounted rotatable, preferably parallel, to the gear shaft 30 . A second stage gear 38 is fixed to the second shaft 36 and arranged for engagement with the second stage pinion 34 . A third stage pinion 40 is fixed to the second shaft 36 . Said third stage pinion 40 is for directly or indirectly transferring torque to the output gear 48 fixed to the output shaft 16 . In the particular embodiment illustrated in the drawings, there is a third shaft 42 having a third stage gear 44 fixed thereto for engagement with the third stage pinion 40 on the second shaft 36 . A fourth stage pinion 46 is fixed to the third shaft 42 for engagement with a fourth stage or output gear 48 fixed to the output shaft 16 . An advantage of this embodiment is that the gear ratios may be altered to vary the output torque available given the electric motor selected. A particular advantage of this embodiment is that the frictional forces between the second stage pinion 34 and the first stage gear 38 at the time of disengagement by axial movement of the first stage pinion can be minimized.
[0026] A drum cam shaft 50 is rotatable perpendicular to the housing 12 . A drum cam 52 slides over the drum cam shaft. A pin 54 extends from the drum cam shaft 50 engaging a cam slot 56 in the drum cam. A lifting plate 58 is fixed to the drum cam 52 and extends to engage a circumferential slot 56 in the second stage pinion 34 to move the second stage pinion between engaged and disengaged positions. The cam slot 60 in the cam drum may have dwell portions 60 A and 60 B at each end thereof. In this case, the drum cam slot has a cam lifting portion having a face that extends circumferentially and axially and at the ends thereof has substantially circumferential dwell portions. As drum shaft 50 is rotated, the pin 54 travels from one dwell portion to the other either raising or lowering the drum cam 52 as the pin rides in the slot. The dwell portions 60 A and 60 B enhance engagement and reengagement of the first stage pinion and the worm gear by allowing some additional rotation without lifting or lowering the drum cam. In the illustrated embodiment, ball bearing 62 is press fit on the drum cam shaft 50 and abuts the housing 12 to axially constrain the drum cam shaft. Alternatively, a slot and retainer (not shown) and/or snap ring may be positioned on the drum cam shaft with a bearing or bushing to restrain axial movement of the drum cam shaft.
[0027] Referring again to FIG. 1 , a disengagement lever 64 and engagement/disengagement cam 66 are fixed to the drum cam shaft. A pin 68 extends from the disengagement lever 64 . A cable sheath bracket 70 is provided for fixing the sheath 72 of a release cable 74 to the housing 12 . The release cable is fixed to a slotted end piece 76 . The aperture 78 in the slotted end piece receives the pin 68 extending from the disengagement lever 64 . A return spring 80 urges the slotted end piece 76 away from the cable sheath bracket 70 .
[0028] When the release cable 74 is pulled, the drum cam shaft 50 rotates the pin 54 extending from the drum cam shaft 50 and the drum cam 52 moves to lift the lifting plate 58 and second stage pinion 34 to the disengaged position.
[0029] The engagement/disengagement cam 66 has spaced engagement cam surface portions 66 A and disengagement cam surface portions 66 B. An electrically operated actuator, for example, a solenoid 82 is fixed to the housing 12 for pulling a spring biased stop 84 away from the disengagement lever such that when the release cable is pulled, the slotted end piece 76 rotates the disengagement lever 64 and the rotation of the disengagement lever rotates the engagement/disengagement cam allowing the spring biased stop 84 to enter the disengagement cam surface portion preventing return of the first stage pinion to the engaged position until the solenoid is activated. Typically, actuation of the solenoid is only controlled by the vehicle operator.
[0030] Once the cable is released but before the disengagement lever 64 is rotated out of the emergency disengaged state, the cable may be spring biased by return spring 80 to return to the pre-emergency position urging the slotted end piece 76 to the opposite end of the aperture 78 (slot). Although the spring 80 may urge rotation of the engagement lever to the engaged position, the spring biased stop 84 in contact with the disengagement cam surface portion 66 B prevents such rotation. Accordingly, the aperture in the slotted end piece 76 allows the cable to move back to its pre-emergency position but the worm gear 32 and second stage pinion 34 remain decoupled. The aperture (slot) 78 further allows a secondary drive to actuate the emergency release.
[0031] In one embodiment for transit bus doors, the decoupling of the electric door operator would allow the transit doors to freely rotate. Accordingly, in the emergency release state, the current design minimizes back-drive force by decoupling the spur gears in from the worm gear.
[0032] In order to return the transit doors to an operational state, the solenoid 82 is used to retract the stop 84 to allow the disengagement lever 64 to rotate back to the operational position. Such rotation of the lever is accomplished by a torsion spring 86 around the drum cam shaft urging the drum cam into the engagement position thus moving the second stage pinion into engagement with the worm gear. Thus second stage pinion 34 may be reengaged with the worm gear 32 once rotated into a position for engagement. This positioning may be accomplished by dithering of the motor 22 .
[0033] According to a preferred embodiment, sensors are provided to detect the door open and/or closed positions of the teeter 14 and to detect when the worm gear 32 and second stage pinion 34 have been reengaged. As seen in FIG. 1 , a target tab 88 rotates with the output shaft between sensors (for example, magnetic or optical sensors) 90 , 92 enabling detection of the open and closed positions of the teeter 14 (and consequently the transit doors). Also as seen in FIG. 1 , a target tab 94 rotates with the drum cam shaft 50 and is aligned with sensor 96 when the disengagement lever is in the engaged position. This is useful in order to command the discontinuance of motor dithering used to urge reengagement of the worm gear and the second stage pinion. The sensors could be located at various other positions and could be replaced with limit switches.
LIST OF REFERENCE NUMERALS
[0000]
12 structure
14 teeter
15 drive arm
16 output shaft
18 journal
20 journal
22 motor
24 electro/mechanical brake
26 input shaft
28 first stage pinion (worm)
30 gear shaft
32 first stage gear (worm gear)
33 pin
34 second stage pinion
36 second shaft
38 second stage gear
40 third stage pinion
42 third shaft
44 third stage gear
46 fourth stage pinion
48 fourth stage gear
50 drum cam shaft
52 drum cam
54 pin
56 slot
58 lifting plate
60 cam slot
60 A dwell portion
60 B dwell portion
62 ball bearing
64 disengagement lever
66 engagement disengagement cam
66 A engagement cam surface
66 B disengagement cam surface
68 pin
70 bracket
72 sheath
74 cable
76 slotted end piece
78 aperture (slot)
80 return spring
82 solenoid
84 stop
86 torsion spring
88 target tab
90 sensor
92 sensor
94 target tab
96 sensor | An electric door operator for opening and closing one or a spaced pair of transit vehicle passenger doors for being mounted over an opening for the doors. A rotatable input shaft has an electric motor secured to the input shaft for driving the input shaft, a worm centrally positioned on the motor shaft, and an electric brake mounted to the input shaft at an end opposite of the electric motor. A drum cam lifts a pinion from a worm gear disconnecting the worm gear from an output gear train in an emergency. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Application No. 60/165,726 filed Nov. 15, 1999. That application and the present inventor's U.S. Provisional Application Nos. 60/165,727 and 60/166,039 filed respectively on Nov. 15, 1999 and Nov. 17, 1999 are hereby incorporated by reference. The present application also incorporates by reference the present inventor's application Ser. No. 09/712,261 and the No. 60/165,727 Provisional Application) filed concurrently herewith.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a system and method for music and/or video playback, and more particularly, providing to the user recommendations of items which have not yet been sampled by the user, based on a list of items already sampled by the user, utilizing a method for the dynamic addition, subtraction and sorting of a queue of items for playback.
2. Description of Related Art
The concept of a playlist is old, i.e. a static list of items to be played one by one through its entirety, in the order listed in the playlist. So far, only rudimentary attempts at dynamic playback have been made, consisting mainly of randomizing the order in which selections from the playlist are played. Some attempts have been made to let people quickly create playlists based on particular artists, or albums, or styles of music. However, all of them are still a static list after they are created, and don't automatically reorder themselves in a pleasing way, or incorporate new content which would fit with them as it is made available. Additionally, any slightly complex concept such as building a playlist which contains more than one piece of meta-data, such as, for example, more than one artist, typically requires complex Boolean logic statements to build, making such playlist creation processes inaccessible to those unskilled in Boolean techniques.
A system is needed that is easy to use, adapts to personal tastes, and can easily add or subtract music or videos, as they become available. Such a system should provide more than random sorting and shuffle-play options to overcome the deficiencies of a static playlist, so that the playlist becomes dynamic.
It is therefore a principal object of the present invention to provide a dynamic playlist system and method for a dynamic playlist of digital items that automatically adds items to, or subtracts items from, the playlist, as the items become available.
An object of the present invention is to provide the dynamic playlist system where the data items are music or video items.
Another object of the present invention is to provide a dynamic playlist that dynamically adapts to usage patterns.
Another object of the present invention is to provide a dynamic playlist that dynamically adapts to personal preferences.
Another object of the present invention is to provide a dynamic playlist that is easy to use.
SUMMARY OF THE INVENTION
The above objects are obtained according to the present invention in which a method and system is provided for creating a dynamic playlist including meta-data having potential association with a respective content item configured to be played on a content player.
The system maintains a database of linkages between elements associated with content items as well as weighted linkages between elements and respective properties. The system is a hybrid content based and collaborative filtering system, wherein the insertion of a new item into the database results in the new item sharing preference weights and number of preferences associated with items pre-existing in the database. Thus, an initial input query list of items potentially results in the return of many content items available from one or more content providers, wherein the retrieved content, called a “dynamic playlist”, has a high correlation with the user's preference or with whatever other basis was used to frame the input list, and individual content items on the dynamic playlist may not have been previously experienced by the user.
A dynamic playlist is a list of items that can be played in linear order, as is done with a traditional playlist, or in more exotic sequences after application of sorting or ordering algorithms. User profiles can be applied to the sorting process, i.e., by ranking items based on the user's meta-data, which can include usage patterns or explicit preferences, and further, by order reflected by usage of other users.
The most useful aspect of a dynamic playlist is the dynamic addition and subtraction of playlist items. This is accomplished by accepting at least one meta category defined as a set of at least one criterion, where each criterion has a potential association with a content item, and retrieving from at least one content provider a first result set of meta-data fitting any of the criteria, wherein the first result set enables acquisition of content items to be played. Next, a filtered first result set is calculated by application of a collaborative filtering query algorithm to the first result set, and then the filtered first result set is added to the dynamic playlist. Next, the system seeds a next meta-category, if any, with the result set and repeating the retrieving, calculating, inserting and seeding steps until all meta-categories have been processed. In accordance with this method, an initial meta-category of selection preferences potentially results in the return of many content items available from one or more content providers, wherein the retrieved content has a high correlation with the user's preference or with whatever other basis was used to frame the meta-category.
The collaborative filtering query algorithm can be arranged to include the dynamic playlist itself, which becomes especially meaningful subsequent successive playlist updates. The algorithm can also include user play pattern data including manual intervention detected during playing of contents associated with the dynamic playlist, or rating data indicative of preference or distaste for selected content items.
The method for creating a dynamic playlist also includes accessing a database configured to include meta-data elements, wherein each element defines at least one relationship between a user and a respective content item, identifying at least one meta-category from the database, and updating the database to include at least parts of the dynamic playlist.
The method for creating a dynamic playlist also includes applying a reordering algorithm to the filtered first result set to obtain the dynamic playlist. The ordering algorithm is selected from a group of algorithms including a ranking algorithm, a random element removal algorithm, a retention of top N most popular elements algorithm, and a pairing sort algorithm.
In a separate embodiment, a respective second result set is obtained for each meta-category, wherein the respective second result set includes meta-data identifying all content items fitting any at least one criterion of each meta-category. An ordering algorithm is applied to the second result set to obtain the dynamic playlist.
The pairing sort algorithm begins with selecting a first and second item from the playlist, determining if both elements are in an elements table, inserting whichever element is missing into the elements table, incrementing by 1 a pair link between the first and second elements, and incrementing by 1 a counter associated with the second element. If a pair link exists between the first and second items, the algorithm inserts a new pair link of strength 1 between the first and second items and increments by 1 a counter associated with the second item. If a pair link does not exist between the first and second items, and if another item remains in the playlist, the algorithm identifies the first item as the second item and the other item as the second item. The sequence is repeated until no items remain in the playlist.
Alternatively, the input set can either be associated with other input sets by a profile ID, or be a seed user profile, i.e., a single individual or source that submits the input sets, or the input set is simply collected on a stand-alone basis. This allows the creation of aggregate profiles between a series of queries or seed actions. Finally, if the action is a query, several profile ID's could be used to create a composite view of the multiple profiles, such as, for example, to find a song both a husband and wife would enjoy.
The pairing sort algorithm as applied to at least one user profile begins with selecting a seed user profile, and processes the steps of comparing the seed user profile against all available profiles, ranking all compared profiles by similarity to the selected seed profile, clustering the most similar profiles with the seed profile, counting the frequency of all elements in the clustered profiles, building a hash profile of the most frequent items to represent each respective cluster, placing the respective hash profile in a hash table, removing the seed and clustered profiles from the profile list, identifying a next user profile, if available, as the seed user profile, and continuing the sequence until no profiles are available.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the present invention and the attendant advantages will be readily apparent to those having ordinary skill in the art, and the invention will be more easily understood from the following detailed description of the preferred embodiments taken in conjunction with the accompanying drawings, wherein like reference characters represent like parts throughout the several views.
FIG. 1 is a highly simplified schematic drawing of components of the dynamic playlist system 100 according to the present invention;
FIG. 2 is a simplified schematic drawing showing more details the system shown in FIG. 1;
FIG. 3 is a logic flow diagram of the basic mode dynamic playlist algorithm according to the present invention;
FIG. 4 is a logic flow diagram of the recommendation mode dynamic playlist algorithm according to the present invention;
FIG. 5 is a schematic drawing of the recommendation mode dynamic playlist algorithm according to the present invention;
FIG. 6 is a schematic drawing of a sample pairing sort system according to the present invention;
FIG. 7 is a logic flow diagram of a sample pairing sort seed algorithm according to the present invention;
FIG. 8 is a simplified logic flow diagram of a hash clustering system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A simplified arrangement of components of the dynamic playlist system 100 according to the present invention is schematically shown in FIG. 1, which includes a dynamic playlist content player 10 , a content provider system 20 , and a sort server 30 , all interconnected by a communications interface 40 . Any number of computers 10 , 20 , and 30 can be interconnected according to the present invention. For example, multiple client computers 10 can obtain content provided by one or more content provider computers 20 .
Communications interface 40 can be any type of bus, local area network, wide area network, or a global network such as the Internet. Alternatively, communications interface 40 includes wireless communications, satellite connections, or any other connection means, and is not shown in detail as such interfaces are well-known and commonly used in conjunction with distributed systems.
In a dynamic playlist, the playlist items can be played in linear order, as is done with a traditional playlist, or in more exotic sequences after application of sorting or ordering algorithms. For example, the playlist items can be sorted by grouping frequency, i.e., application of a pairing sort to the items. User profiles can be applied to the sorting process, i.e., by ranking items based on the user's meta-data, as discussed later, in connection with FIG. 8 . The items can be ranked by other user order frequencies, such as, for example, the order reflected in use by other users. While these all create a much more interesting playback order, somewhat like having a disk jockey who understands both the music/videos and the person listening/watching them, the most useful aspect of a dynamic playlist is the dynamic addition and subtraction.
Specifically, meta-elements can be added to the playlist, such as with music, the addition of an artist to the playlist. Then, when the playlist is used, the playlist queries a main server for the existence of content relating to that meta-data. I.e. adding an artist or group would add the entire given artist or groups content to the playlist, or would add the content not removed by anti-links (listed dislikes) existing in a user's profile. Additionally, it could be configured to add the content that was highest ranked as returned by a collaborative filtering query focused on the rest of the playlist's content, up to a certain number of songs. What this would allow is the creation of themed playlists that were random, yet fit together. Additionally, it would allow users to subscribe to artists and automatically have their playlists updated with new content, such as when an artist releases a new song, by having playlists which contained the meta-category of a particular artist included in their playlist. That would be a valuable opportunity for both users and artists to connect.
A playlist could also be made entirely of meta-elements. For example, it could contain two artists (a meta-category). First the system would build a result list of all the elements which have the meta-categories which are in the playlist, such as all the songs an artist has produced. Next, a collaborative filtering query could be executed on the result list, to rank and/or cull the items that the current user would most enjoy in the list. After that, various randomization or ordering algorithms could be applied to make the playlist “flow” in an effective manner from item to item. For example, the pairing sort described in FIG. 6, to be described later, could be executed. A playlist made in that manner would be fresh each time it was played, as it would pick new content and alter its playback order each time it was used.
Additionally, several ranking and/or culling techniques can be applied to the generated playlists before or during playback. For example, a pairing order sort could be applied to the playlist, which would have the effect of ordering it in the most popular order. Therefore, musical pieces could be ordered to flow in the manner that most people have ordered them, which will most likely result in the most compatible ordering. A sample pairing sort routine is shown in FIG. 6, to be described later. Additionally, the most incompatible elements could optionally be discarded from the sorted list.
As another example, a popularity sort could also be applied, wherein the results are then ranked based on overall popularity among all listeners, or the subset closest to the current playlist creator. As another option, the least popular items could be culled, or given higher weightings if the user desired. Other common sort mechanisms, such as by artist, random, meta-category, least popular, or album ordered could also be implemented.
FIG. 2 shows the arrangement of FIG. 1 in greater detail, including a simplified schematic diagram of the major functional components of the dynamic playlist system 100 . The arrangement of FIG. 2 is one of many possible arrangements of the functional elements of the present invention and serves to facilitate their description and general concept of the present invention. Other arrangements will be described later.
The dynamic playlist system 100 is conceptionally organized into three separate systems, including a dynamic playlist content player system 110 and content provider server system 120 arranged to operate in a known client-server mode. Sort server system 130 is optional to the extent that its function is to provide sophisticated filtering services by way of collaborative filtering algorithms, and operates in support of the dynamic playlist content player system 110 in those embodiments calling for such services. Moreover, content item storage can be a shared function with local storage being locally accessible by dynamic playlist content player system 110 with additional content being accessible from remote storage associated with one or more content provider systems 120 .
The dynamic playlist client system 110 includes a content player 10 , which includes known devices for playback of audio or video files, taking the form of popular computer programs for use on personal computers, as well as integrated video and audio stereo systems. In the preferred embodiment, content player 10 is operably connected to a content selection program 11 and a playback program 12 arranged to operatively control peripheral devices including an output device 13 , which can be any device configured to play or display file objects such as, for example, audio, graphic, and video files. Video files can include motion picture films, computer games, and the like. Content player 10 also includes, and is operably responsive to, known input, display, memory, and processor devices commonly associated with computers. Content player 10 includes a data storage device 15 configured to operate one of any type of data storage model, including, but not limited to, a relational data base. Regardless of the data storage model employed, data storage device 15 includes storage of a meta-data playlist 16 , optional storage of local content items 17 , and at least one user profile 18 , all to be described later.
The content provider system 120 includes a content provider server 20 , which is a local storage system 22 configured for storing content items, such as, for example, audio or video content items. The content items stored on content provider system 20 are stored in any of the known data storage models, such as, for example, a relational database. Stored content items are associated with respective meta-information, both of which can be accessed over communication interface 40 by content selection program 11 located on content player 10 . As discussed in detail below, retrieved content items optionally can be post-processed by data mining relational algorithms 32 located on sort server 30 and sorting and culling algorithms 14 associated with the content player 10 , and then output on output device 13 . Any of the known relational algorithms can be used in connection with the present invention and all variations of algorithm type and installation configurations are intended to be included within the scope of the present invention, such as, for example, the Firefly system as disclosed in U.S. Pat. No. 5,749,081, the Hey systems as disclosed in U.S. Pat. Nos. 4,870,579 and 4,996,642, or the approaches in the Rose system as disclosed in U.S. Pat. No. 5,724,567. All variations of algorithm type and installation configurations are intended to be included within the scope of the present invention.
A sort server system 130 includes a server 30 configured to run profile based subjective recommendation or data mining algorithms 32 , which also are not shown in detail, as their use is well-known and commonly used in the art of collaborative and recommendation filtering. Alternatively, algorithms 32 can be located at any of the three computers 10 , 20 , and 30 , provided sufficient computational power and network throughout are available. The sort server 30 is comprised of a known collaborative filtering engine and a pairing sort system, as described in FIGS. 6 and 7.
It should be understood that the present invention might be readily adapted for alternate embodiments and modes of operation. For example, the content selection program 11 and playback program 12 could be accomplished using the directory structure of a hard drive, or the indexed database of content to which a user has access. The dynamic playlist system could be implemented in a variety of devices and mediums. For example, a computer program written in any of the many languages such as C++, that would allow advanced data structures on any platform that would allow content playback, could serve as the playlist content player 10 . Another form of the playlist content player 10 could take the form of a set top television box, or be within a stereo sound system, with the database of available titles being stored either within the devices themselves, or on a remote server system, which, potentially, can also serve the content. Additionally, aspects of the sort server system 130 and the content provider system 120 can be integrated into the content player system 110 .
FIG. 3 is a simplified flow diagram illustrating operation of one embodiment, the basic form, in which only a content provider 120 and a playlist consumer 110 are required. At step S 1 , when a playlist is executed, the playlist consumer picks a seed meta-category from the playlist. At step S 2 , It then queries available content providers for all content pieces fitting the seed meta-category. At step S 3 , optionally, it then applies ranking or culling algorithms to the results, such as randomly removing elements, or only keeping the top N most popular result items. Next, at step S 4 it inserts the results into the play queue, and continues at steps S 5 and S 6 to the next meta-category in the playlist and repeats the process. Finally, at step S 7 , it performs an optional ranking or culling sort on the play queue, such as randomizing the play order, and begins playback. This mode of operation can be implemented in a non networked environment, but is less powerful than the recommendation mode of operation, to be described next, as it cannot apply advanced sort routines to the playlist. However, it does allow a playlist can be unique each time it is expanded, and can add new content without having to modify the playlist when the content providers make new content accessible.
FIG. 4 is a simplified flow diagram illustrating operation of one alternate embodiment, called the recommendation form, in which a third system element, sort server system 130 , is added to the basic form illustrated in FIG. 3 . The addition of a central sort server system 130 allows advanced profile based collaborative filtering or pairing sort queries to be performed upon the dynamic playlists. In operation, the recommendation form playlist expansion is similar to that of the basic form, with the addition of the more sophisticated sort algorithms ranking and culling results after each step.
At step S 8 , a meta-category is chosen as the seed from the playlist. At step S 9 , the content providers are queried for available content in the seed meta-category and then the result content list is ranked and culled by performing a collaborative filtering query based on any static items within the playlist, with any results not in the content list received from the content providers discarded. At optional step S 10 , any additional ranking or culling algorithms can be performed, such as randomly discarding some elements, or ranking based on raw popularity. Next, at steps S 11 -S 13 the content list is inserted into the play queue, and the next meta-category in the playlist is chosen. At that point the process is repeated, using the results currently in the play queue to seed a collaborative filtering request after each list of available content pieces is returned from the content providers. Upon seeding the play queue with all meta-categories, a final ranking and culling pass can be performed, using any of the common playlist manipulation algorithms, and optionally, a pairing sort algorithm, to be described in connection with FIGS. 6 and 7.
Finally, playback can commence. As items are played back from the play queue, the system also reports to the sort server that the user has listened to the item, to allow the collaborative filtering system to increase its understanding of the content. Additionally, each time two songs are listened to in sequence, their pairing is submitted to the sort server's pairing sort system to allow the pairing sorted to increase its understanding of the content as well.
FIG. 5 is a preferred rearrangement of the “client-server” configuration shown in FIG. 2, wherein elements in common between FIGS. 2 and 5 share common reference numerals. Dynamic playlist content player 50 serves as content player 10 and further includes local content storage functionality as well as operating to access content stored remotely at content provider 120 . This jukebox style arrangement includes a program configured to access aspects of sort server 30 and content provider system 20 . The content player 10 is operably connected with content selection program 11 , the playback program 12 , at least one sorting and culling algorithm program 14 , stored content items 22 , and an output device 13 .
In operation, the dynamic playlist content player system 50 preferably is connected over the Internet to a separate sort server system 130 , and is configured to access both local content 22 and available streamable content 22 from content provider systems 120 . Thus, many content players can access any of multiple content provider systems as well as their respective individually stored content. The content provider systems 120 include a known indexed database of content items and respective meta-information. The content provider system is implemented using a relational database such as, for example, the Oracle™ relational database. The content providers serve their available content by any known means, such as, for example, through a streaming media server like RealServer™ or via known direct http streaming systems, such as Icecast™.
In the preferred embodiment, a user using system 50 builds a playlist containing both local content items and streamable items. The playlist is a stored index of meta-data elements each having an association with separately stored one or more content items. The content items may be stored locally or are streamable from a remote content provider. The meta-data elements can be of any configuration, and preferably include descriptors of at least one associated content item and optionally include descriptors relating to preferences of one or more users.
When the user plays the playlist, the playlist is submitted to the sort server system 130 , which performs the algorithm described in connection with FIG. 2 to expand all meta-categories into specific content items, by drawing upon the content available from the user's locally stored content pool and from streaming content providers. The system the returns the expanded playlist to the jukebox program, which then uses the playlist like a standard static playlist. Optionally, when the user expresses dislike for a particular content item, either by skipping the item or through a rating system, the system records such instances in the meta-data associated with the user, i.e., the user profile. Upon resubmission of the playlist to the sort server, a new playlist now adapted to the expressed tastes of the playlist listener is generated and the rejected content items are not selected based on the updated user profile. After the user stops or plays completely through the playlist, the list is submitted to the sort server to execute a pairing algorithm, described in connection with in FIGS. 6 and 7, to allow the pairing sort engine shown in FIG. 6 to further adapt to how the user ordered the playlist.
FIG. 6 is a simplified schematic diagram of a sample pairing sort engine suitable for use by dynamic playlist system 100 to further adapt to how the user ordered the playlist. Other pairing algorithms which produce comparable results are also suitable in the present invention. CPU 60 receives input 62 in the form of the playlist as executed by the user using dynamic contest content player system 110 . CPU 62 applies a flow order sort algorithm, or pair sort algorithm, illustrated in FIG. 7, to input 62 and updates elements table 64 and pairs table 66 , stores the result for further use and optionally makes the result available on display 68 .
FIG. 7 is a simplified flow diagram of the flow order sort algorithm used in the sample pairing sort engine shown in FIG. 6 . At step S 20 , system 100 selects the first two items, item 1 and item 2 , in the playlist. At steps S 21 and S 22 , if it is determined that both items (elements) are not in the elements table 64 shown in FIG. 6, then the missing items(s) are inserted into table 64 . At steps S 23 -S 25 , the system increments a weight between the first item and the second item. This is accomplished, by determining that both items are in the elements table and whether a pair link exists between item 1 and item 2 . If a pair link does not exist, then at step S 24 , a new pair link of strength 1 is inserted between items 1 and 2 and a TotalLinks counter of item 2 is incremented by 1. If a pair link does exist between items 1 and 2 , then at step S 25 , the existing link in incremented by 1 and the TotalLinks counter of item 2 is incremented by 1. In either case, after the appropriate insertion step, step S 26 determines whether more items exist in the playlist. If yes, at step S 27 , the inquiry is advanced by one item in the playlist so that item 2 becomes item 1 and a new item becomes item 2 . If no more items remain in the playlist, then at step S 28 , the sort ends.
FIG. 8 is a simplified flow diagram of a hash clustering system according to the present invention in which successive seed profiles are compared with all profiles. At step S 39 , the dynamic playlist system 100 selects a user profile 18 from storage 17 and at step S 40 , compares the seed against all profiles available to system 100 . At step S 41 , all compared profiles are ranked by similarity to the selected seed profile. At step S 42 , the most similar profiles are clustered with the seed profile, and at step S 43 , the frequency of all elements in the clustered profiles are counted. At step S 44 , the most frequent items are used to build a hash profile to represent each respective cluster, and at step S 45 , the respective hash profile is placed in a hash table and the seed and clustered profiles are removed from the profile list. If more profiles are left to be considered, then at step S 46 , select the next user profile, make it the seed profile, and continue the sequence at step S 40 .
While this invention has been described in conjunction with specific embodiments thereof, it is evident that many alternative modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the true spirit and scope of the invention as defined in the following claims. | Method and system provided for creating a dynamic playlist including meta-data having potential association with a respective content item configured to be played on a content player, and having dynamic addition of subtraction of playlist items. The system maintains a database of linkages between elements associated with content items as well as weighted linkages between elements and respective properties. The system is a hybrid content based and collaborative filtering system, wherein the insertion of a new item into the database results in the new item sharing preference weights and number of preferences associated with items pre-existing in the database. Thus, an initial input query list of items potentially results in the return of many content, called a “dynamic playlist”, has a high correlation with the user's preference or with whatever other basis was used to frame the input list, and individual content items on the dynamic playlist may not have been previously experienced by the user. | 8 |
This is a continuation of co-pending application Ser. No. 416,750 filed on Sept. 10, 1982, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to protected documents of the color copy resistant type wherein a cancellation phrase appears substantially hidden to the human eye on the original documents, but, which is readily apparent to the casual observer on color copies made of the original.
2. Prior Art
Present protected documents include a cancellation phrase (VOID) of a single tone (includes percent of area covered by dots or other marks and the number of the dots or marks per inch) positioned precisely into a background tone composed of a set of dots or marks significantly different in size and number per inch from that used for the cancellation phrase. Dot sizes and number of lines per inch may be made up of several different combinations such as:
1. Void dots about 0.010 diameter with 65 lines per inch coupled with a background dot of about 0.005 diameter with 130 lines per inch.
Transmission densitometer readings in production grade negatives may be show about 0.65 units for the 0.005 diameter dots.
2. Other combinations such as 62.5 lines per inch for the cancellation phrase and 125 lines per inch for the background also may prove useful. In addition to the dot size combinations set forth in No. 1 above, other variations may also prove useful.
Suitably combined sets of cancellation phrase dots and background dots have been successfully camouflaged by another patterned screen exposed in combination with the phrase and the background screen. Depending on procedure, the resultant photographic film will have dots or marks removed from the phrase and the background or base dots enlarged in the phrase and in the background. This combined film can be used to make printing plates or photographic film copies for distribution to various printing operations.
The above-described system gives good protection against copying to suitably printed documents when copies are made at normal copier settings. However, protection is not complete over the full copier range.
It has been recognized that different dot size pairs (e.g., 65 line, 0.010 diameter and 130 line, 0.005 diameter) have greater or lesser ability to emphasize the cancellation phrase above the background when copied at lighter or darker copier settings.
Efforts to develop a combination of more than a single screen pair have proved aesthetically unsatisfactory despite the fact that the effective range was increased.
The unhappy approach took the form of blocks or bands with one pair of screens per block or band.
All of the cancellation phrases could be camouflaged successfully but the bands or blocks remained and rendered the document unsightly because of the obtrusive background pattern.
The present invention provides a means of combining two or more significantly different background and phrase combinations into a single area on the document thereby avoiding the obtrusive patterns which inevitably result from previous approaches.
BRIEF DESCRIPTION OF THE INVENTION
Object of the Invention
Accordingly, it is an object of the present invention to provide a protected document in which two or more significantly different background and cancellation phrase combinations are combined in a single area of said document.
It is another object of the present invention to provide a protected document in which two separate screen combinations are utilized to prepare said document.
It is also an object of the present invention to provide a protected document in which a first combination of screens includes a first screen capable of producing 65 line, 0.010 diameter phrase dots and a second screen capable of producing 130 line, 0.005 diameter background dots and a second combination of screens which includes a first screen capable of producing 65 line, 0.012 diameter phrase dots and second screen capable of producing 130 lines, 0.006 diameter background dots. A camouflaging pattern which removes about 50% of the area is prepared in both a positive and a negative form and is also included.
It is still a further object of the present invention to provide an improved protected document wherein the four pieces of film described above are combined in a succession of exposures by a pin registration system to give a single piece of film which contains the dual cancellation and background structures.
SUMMARY OF THE INVENTION
In the preferred embodiment of this invention, a method and a means are disclosed which provide an extended range protected document upon which has been introduced two properly selected pairs of dot sizes in both cancellation phrase and background pattern.
An alternative method is also disclosed which introduces two pairs of dot sizes by using an appropriate mask to allow continued exposure in parts of the image while protecting other parts from additional exposure. The continued exposure creates dots different in size from the protected dots but avoids the need for precise double exposure and masking.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the method for producing the extended range protected document.
FIG. 2 is the first screen combinations shown in FIG. 1.
FIG. 3 is Overall Screen Tint C used in fabricating the first screen combination of FIG. 2.
FIG. 4 is the Negative Mask B also used in fabricating the first screen combination of FIG. 1.
FIG. 5 is a detailed diagram of the first camouflage pattern positive of FIG. 1.
FIG. 6 is a detailed diagram of the second camouflage pattern negative of FIG. 1.
FIG. 7 is a detailed diagram of the results of the exposure of the first screen combination and first camouflage pattern positive of FIG. 1.
FIG. 8 is a detailed diagram of the results of the exposure of the second screen combination and second camouflage pattern negative of FIG. 1.
FIG. 9 is a detailed diagram of the composite negative shown in FIG. 1.
FIG. 10 is a detailed diagram of the camouflage overlay mask shown in FIG. 1.
FIG. 11 is a detailed diagram of the multi-tone finished negative shown in FIG. 1.
FIG. 12 is a block diagram of an alternative method of making a multi-tone finished negative.
FIG. 13 is a detailed diagram of a positive mask used in an alternative method for making the first and second screen combinations.
FIG. 14 is a detailed diagram of Overall Screen Tint D also used in making the first and second screen combinations.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram showing a general description of the method, steps and system for providing the extended range protected document. The first step of the method requires first and second screen combinations 10 and 12. Screen combination 10 could have 65 line, 0.010 diameter phrase dots and 130 line, 0.005 diameter background dots. Second screen combination 12 might have 65 line, 0.012 diameter phrase dots and 130 line, 0.006 diameter background dots. Other ways can be used to describe the combination in terms of percentages or densities. Any consistent system will do.
A pair of first and second camouflaging patterns 14 and 16 removing about 50% of the area and retaining 50% of the area are prepared in positive and negative form.
The four above pieces of film 10, 12, 14, and 16 may be combined in a succession of exposure 18, 20, and 22 (designated by heavy arrows) to give a single piece of film 23, a composite negative containing the dual phrase and background dot structures. The procedures are similar to those used for color correction masking in process color separation. This process uses a pin register system which depends on holes in the film which fit over pins.
Exposure 25, combines composite negative 23 with camouflage overlay mask 24 to give the multi-tone finished negative 26.
Looking more specifically at first screen combination 10 of FIG. 1, more detail is shown in FIG. 2. For brevity, only the "V" of the word "VOID" is shown. First screen combination 10 is a composite negative which has a latent image of the 65 line dots covering the area of the "V", and 130 line dots covering the area of the background. The procedure for making the composite negative is as follows. The word "VOID" and the background are exposed on separate negatives and then combined to make the composite negative. The negative having the area "VOID" is made by laying an unexposed piece of film, emulsion up, on an exposure frame. It is covered with Overall Screen Tint C, shown in FIG. 3, with emulsion down. This set is overlayed with Negative Mask B, shown in FIG. 4, with emulsion down. Light passes through the clear area of Negative Mask B, through the unshadowed area of Overall Screen Tint C, to the emulsion layer of the unexposed film. This gives a latent image of the 65 line dots in the area of the "V". Development at this stage will give patterned blocks of 65 line dots which make the text visible, but without background dots. An emulsion to emulsion contact gives an emulsion down negative. A similar set of steps gives the background dots surrounding the text but on a separate piece of film. An emulsion to emulsion contact gives an emulsion down negative. Additional emulsion to emulsion exposures to another piece of film merge the two dot patterns into the composite negative screen combination 10.
To accomplish the above exposures, pin registration techniques are needed to get precisely aligned screen sets for the word and background combinations. The pin registration holes are shown as 30, 32, 34 in FIG. 1. The screen sets must be precisely aligned and punched so that the large dots and small dots fall into nearly exact alignment.
The steps are repeated to obtain second screen combination 12 having the word "VOID" with 65 line, 0.012 diameter dots in a background having 130 line, 0.006 diameter dots. The different sized dots give the extended range for protection in the color copier.
After first and second screen combination negatives 10 and 12 have been made they are ready to be used in the process to make the finished multi-tone negative 26. First camouflage pattern positive 14 and second camouflage pattern negative 16 are used to combine screen combination negatives 10 and 12 into a third negative 19. This negative will have 50% of its word and background area having 0.010 diameter word dots and 0.005 diameter background dots. The other 50% of the area will have 0.012 diameter word dots and 0.006 diameter background dots.
To accomplish this, first and second camouflage patterns 14, 16, shown in more detail in FIG. 5 and FIG. 6 respectively, are put in registration and holes punched in the two screens. A sheet of unexposed film with emulsion layer up is loaded onto registration pins. Next, first screen combination 10 is loaded on the registration pins followed by first camouflage pattern 14. The set is exposed for the time required to obtain the 0.010 and 0.005 dot sizes for the 65 and 130 line cancellation phrase and background. This is step 19 of FIG. 1. Screen combination 12 and camouflage pattern 14 are then removed. Development of the exposed film at this stage would show a pattern as in FIG. 7. However, the film is not developed at this stage.
Repetition of the above steps using second screen combination 12 and second camouflage pattern 16 will give a film 21 with 0.012 and 0.006 dot sizes for the 65 and 130 line cancellation phrase and background. In this case, film 21 is developed to make a negative, a line pattern of which is shown in FIG. 8.
The latent image of film 19 is now overlayed on the registration pins by negative 21 and exposure 22 takes place. The result is an undeveloped latent image film 23 which is shown in FIG. 9. This figure shows the word having both the 65 line, 0.010 and 0.012 dots with the background having the 130 line, 0.005 and 0.006 dots. Development at this point would provide the multi-tone finished negative 26. However, prior to development, if the joints and areas of flat tone show too clearly, camouflage overlay mask 24, shown in FIG. 10, may be placed over the registration pins and exposed. This provides an additional level of camouflaging. Development would then provide the multi-tone finished negative 26, shown in FIG. 11.
An alternate and preferred way of obtaining composite film 23 avoids the step of having to develop film 21. Instead of developing film 21, second combination screen 12 and second camouflage pattern 16 are overlayed over the latent image of film 19. The set is then exposed to obtain the required 0.012 and 0.006 dot sizes for the 65 and 130 line cancellation phrase and background. As described previously, development will produce multi-tone finished negative 26. Camouflage overlay mask 24 may also be considered for use.
The multi-tone finished negative of block 26 is shown in more detail in FIG. 11. A contact negative made from multi-tone composite negative 26 is then used to make test plates to give the finished print. The finished print appears identical to multi-tone finished negative 26 except that white is black and black is white. It should be noted that the checkerboard pattern would not be used in practice since it does not confuse the eye sufficiently, but it illustrates the method well. FIG. 12 shows an alternate method of making a multi-tone finished negative. This procedure has fewer steps and less precise registration requirements than the previous procedure. The second procedure depends on the fact that dot sizes are affected by continuing exposure. In other words, if a two minute exposure gives a 0.010 diameter dot, a five minute exposure may give a 0.011 dot. In some cases, a clear sheet of material may be placed over the receiving film to allow more light to get to the edges of the latent dot if larger sizes are needed.
The screen combination 40 may also be the same as screen combination 10 of FIG. 1 and may be fabricated in the same manner. The word "VOID" will have 65 line, 0.010 dots and the background will have 130 line, 0.005 dots.
To begin the process a piece of unexposed film 42 is put on registration pins. Screen combination 40 is then placed in registration over unexposed film 42. The set is exposed to get 65 line, 0.010 dots and 130 line, 0.005 dots. Next a camouflage pattern 44, similar to camouflage pattern 14 of FIG. 1, is overlayed on the set. This will shield 50% of the word and background from further exposure and maintain 0.010 and 0.005 dots in that area. The remaining area will continue being exposed to get a large dot. A clear piece of plastic installed over the unexposed film will assist in "spreading" the dots. This yields the composite negative 46 which contains all of the dot sizes. This composite negative will be similar to composite negative 23 of FIG. 1. A camouflage mask 48, similar to camouflage mask 24 of FIG. 1, will then be used after removal of camouflage mask 44. The result is a finished multi-tone composite negative 50, similar to multi-tone composite negative 26. of FIG. 1. A contact will give a negative suitable for making plates in running the finished prints.
An alternative method, also exists of making the screen combination negative 10, 40, shown respectively in FIGS. 1, 12. A suitably accurate pin register system allows a single receiving piece of film to have sequential placement of the various elements and exposure of the several sets of elements in appropriate order for appropriate times. Development of the exposed film gives screen combination 10, 40 in one development step. The method is as follows. Positive Mask A, shown in FIG. 13, and Negative Mask B, shown in FIG. 4, are aligned and registration holes are punched. The same is done with Overall Screen Tint C, shown in FIG. 3, and Overall Screen Tint D, shown in FIG. 14. An exposed film is put on the registration pins, emulsion side up. Screen Tint C is loaded, emulsion side down, over the unexposed film. Negative Mask B is then loaded, emulsion side down. The set is exposed to obtain 0.010 dot sizes for the 65 line screen. Negative Mask B and Screen Tint C are unloaded. Screen Tint D with emulsion side down is loaded over the film. Then Positive Mask A, emulsion side down, is loaded. The set is exposed to obtain 0.005 dot sizes for the 130 line dots. Development will give screen combination 10 of FIG. 1. The same procedure is used to obtain screen combination 12 of FIG. 1.
In conclusion, in the past basically two dot sizes and a single camouflaging pattern were used to remove dots to break up the flat tones and conceal the cancellation phrase. This provided a very satisfactory and practical solution to the problem, however, it has limitations as to range of settings and type of copiers. The present invention introduces a preferred method using two pairs of dot sizes in both word and background. The suggested combinations of dot size selections provides a document which performs over an extended range. The two dot pairs are combined in a randomized pattern using double exposure and masking techniques. An alternate method introduces two pairs of dot size using an appropriate mask to allow coninued exposure in parts of the image while protecting other parts from additional exposure. This continued exposure creates dots different in size from the protected dots, while avoiding the need for precise double exposure and masking. | A protected document has a cancellation phrase, normally invisible to the human eye, which will appear if the document is copied on a color copier. The protection of these documents is improved in the following protected document. The document is made up of a substrate, first and second cancellation phrase images which form a combined cancellation phrase image printed on the substrate, first and second background images forming a combined background image printed on the substrate and a camouflage overlay image (merged with) the combined cancellation and combined background images. The first and second cancellation phrase images appear on the document when it is copied on a color copier. The two images extend the range of protection for color copy machines having multiple darkness settings. | 1 |
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to signal processing in fiber optic gyroscope systems. This invention relates particularly to automatic gain control (AGC) circuits in fiber optic gyroscope signal processing systems. Still more particularly, this invention relates to an AGC circuit that achieves a stable response irrespective of the actual gain level.
[0002] A closed-loop fiber optic gyroscope requires a high bandwidth, high performance signal processing scheme to capture the differential phase difference induced by the rotation rate. A description of the control loop is contained in U.S. Pat. No. 5,883,716, which issued to Mark and Tazartes on Mar. 16, 1999 and which is assigned to Litton Systems, Inc., assignee of the present invention. The disclosure of U.S. Pat. No. 5,883,716 is incorporated by reference into the present disclosure. In order to achieve the high degree of performance required while accommodating wide variations in loop gain, an active gain control scheme is required. Loop gain variations are due to aging of the light source, variations in optical output or loss over the operating temperature range, and temperature sensitivity of electro-optic components such as photodetectors. In addition, the optical signal can vary by a significant amount from instrument to instrument due to component and manufacturing tolerances.
[0003] Automatic gain control loops have therefore been utilized in the past to ensure that the total loop gain remains constant, which is essential to achieving maximum bandwidth and high order loop response. In the past, analog multipliers were used as gain stages in the detection path of the fiber optic gyroscope. While these devices provided an ideal linear control law (i.e. the gain is directly proportional to the applied control voltage), they exhibited a number of undesirable characteristics. These include bandwidth limitations, noise, cost, and linearity as a function of signal level.
[0004] For high performance, low noise fiber optic gyroscopes, an alternate gain control block was therefore considered. This is a variable gain amplifier whose gain in dB is proportional to the applied control voltage. In essence, this implies that the gain of the amplifier is an exponential function of applied control voltage as opposed to a linear function as in the earlier embodiments. Such devices are now readily available and offer lower noise and of course, a wider range of gain adjustment without substantial degradation in signal gain linearity. A gain range of 10:1 is easily achievable with such a device.
[0005] The desire to adapt such variable gain amplifiers in a fiber optic gyroscope circuit introduced a new problem which this invention addresses. Because of the non-linear gain control law, the time constant or response time of the AGC (automatic gain control) itself could be highly variable, thus limiting its ability to start-up rapidly and to track changes rapidly.
SUMMARY OF THE INVENTION
[0006] The present invention overcomes the deficiencies of the prior art by providing a stable AGC response irrespective of the actual gain level.
[0007] A closed loop gain control circuit according to the present invention for controlling the gain of a variable gain amplifier that is arranged to amplify electrical signals indicative of optical signal signals output from a fiber optic gyroscope comprises a perturbation injection circuit arranged to provide a perturbation signal ±d. A phase modulator is connected between the perturbation injection circuit and the fiber optic gyro. The phase modulator is arranged to apply the perturbation to the fiber optic gyroscope so that the perturbation signal is superimposed on the gyro output. A variable gain amplifier is arranged to receive the electrical signals indicative of optical signal signals output from the fiber optic gyroscope and provide an amplified signal. A perturbation compensation circuit is arranged to apply perturbation compensation signals to signals output from the variable gain amplifier. The perturbation compensation circuit produces a compensated signal by reducing the magnitude of the perturbation in the amplified signal output from the variable gain amplifier. A gain error circuit is connected to the perturbation compensation circuit. The gain error circuit produces a gain error signal that indicates the magnitude of the perturbation signal remaining in the amplified signal after perturbation compensation. A system processor is connected between the gain error circuit and the variable gain amplifier. The system processor provides a gain control signal to the variable gain amplifier to reduce the magnitude of the gain error signal. Processing circuitry is connected between the perturbation compensation circuit and the phase modulator for determining the rotation rate sensed by the fiber optic gyroscope and for controlling the phase modulator to apply a rate nulling signal to the fiber optic gyroscope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a simplified block diagram of a fiber optic gyroscope system that includes automatic gain control circuitry according to the present invention;
[0009] [0009]FIG. 2 is a block diagram of the primary loop of the fiber optic gyroscope system of FIG. 1; and
[0010] [0010]FIG. 3 is a block diagram of an algorithm that may be included in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Referring to FIG. 1, a fiber optic rotation sensor system 10 includes a fiber optic gyroscope 12 that includes a fiber optic sensing coil (not shown) that detects rotations about a sensing axis perpendicular to the plane of the sensing coil by means of the well-known Sagnac effect. The fiber optic gyroscope 12 produces an optical signal of fluctuating intensity determined by interference between counter-propagating waves in the sensing coil. The interference pattern indicates the rate of rotation of the sensing coil about its sensing axis.
[0012] The present invention includes a perturbation injection circuit 14 that provides a perturbation signal to a modulator 16 . The modulated perturbation signal is then input from the modulator 16 to the fiber optic gyroscope 12 . The modulated perturbation signal is superimposed on the optical signal produced by the fiber optic gyroscope 12 in accordance with the Sagnac effect.
[0013] The signal output from the fiber optic gyroscope 12 is incident upon a photodetector 18 , which produces an analog electrical signal that indicates the intensity of the optical output from the fiber optic gyroscope 12 . The electrical signal from the photodetector 18 is then amplified by a variable gain amplifier 20 . The amplified analog signal is input to an analog to digital (A/D) converter 22 that produces a digital signal that is used in further processing of the output of the fiber optic gyroscope 12 .
[0014] The digital signal output from the A/D converter 22 is input to a compensation circuit 24 that compensates for the injected perturbation. The output of the compensation circuit 24 is input to a rate demodulation processing circuit 26 and to a demodulator 28 .
[0015] The rate demodulation processing circuit 26 determines the rotation rate. A signal indicative of the rotation rate is output by the rate demodulation processing circuit 26 and input to a gyro control loop and modulation control circuit 30 . The fiber optic rotation sensor 10 is arranged in the well-known phase nulling configuration. Accordingly, the gyro control loop and modulation control circuit 30 provides a signal to the modulator 16 that nulls the phase shift in the sensing coil caused by the Sagnac effect.
[0016] The demodulator 28 detects errors in the gain of the variable gain amplifier 20 . A digital signal that indicates gain errors is input to a linearization and integration circuit 32 , which provides the linearized and integrated gain error signal to a digital to analog (D/A) converter 34 . The D/A converter 34 then provides the analog gain error signal to the gain control input of the variable gain amplifier 20 .
[0017] The AGC function is accomplished by injecting a know perturbation ±d in the loop and demodulating the resulting compensated signal with appropriate signs based on the polarity of the compensation.
[0018] The variable gain amplifier 20 used in the present invention employs a variable gain element whose gain in dB is proportional to the control voltage. Prior designs used a linear amplifier (not shown). The non-linear characteristic provided by the variable gain amplifier 20 is used advantageously in the gain control loop.
[0019] [0019]FIG. 2 is a more detailed block diagram of the AGC system according to the present invention. The fiber optic gyro 12 is responsive to the sum of the Sagnac phase shift and the phase shift produced by the modulator 16 . A summing junction 40 receives a signal input from the phase modulator 16 and a signal (SSF)Ω that represents the phase shift induced by the angular rate Ω where SSF is the Sagnac scale factor of the fiber gyro 12 . The summing junction 40 adds the signal received from the phase modulator 16 by the scale factor to produce a signal that is input to the fiber gyro 12 . The fiber gyro 12 uses the Sagnac effect to produce a signal I 0 /2 sin φ M where φ M is the phase difference between the modulated counter-propagating waves in the sensing coil. The optical signal output of the fiber gyro 12 is converted to an electrical signal by the photodetector 18 . The photodetector 18 has a scale factor K pd which relates the electrical current output from the photodetector 18 to the optical power incident thereon. The photodetector typically has a scale factor K pd =0.9 A/W.
[0020] The photodetector output is then amplified by a transimpedance amplifier 42 that has a scale factor K TI . The transimpedance amplifier 42 is connected between the photodetector 18 and the variable gain amplifier 20 and serves to match the output impedance of the photodetector 18 to the input impedance of the variable gain amplifier 20 . The amplified electrical signal output from the variable gain amplifier 20 is input to a filter circuit 44 , which has scale factor k filt , that is preferably about 0.6.
[0021] The signal output from the filter circuit 44 is input to the A/D converter 22 , which converts the analog electrical signals into digital signals that are used for processing the fiber gyro output and for AGC of the variable gain amplifier 20 . The digital signal output from the D/A converter 22 is input to a scaling circuit 46 . The A/D converter 22 and the scaling circuit 46 together have a scale factor K A that preferably is about 6554 bits/volt.
[0022] The output of the scaling circuit 46 is input to a summing junction 24 which also receives an input signal ±rd that is used for dither compensation. Signals output from the summing junction 24 are input to a rate loop control circuit 50 and to an AGC demodulator 52 .
[0023] The rate loop control circuit 50 may include one or more integrators that operate on the signals. U.S. Pat. No. 5,883,716, which issued to Mark and Tazartes on Mar. 16, 1999 and assigned to Litton Systems, Inc., assignee of the present invention discloses a rate loop control circuit that may used as the rate loop control circuit in the present invention. The output of the rate loop control circuit 50 is input to a digital gain circuit 64 that applies a gain of 2 S to the output of the rate loop controller 50 . The output of the digital gain circuit 64 is input to a summing junction 66 , which applies the modulation by the dither signal ±d. After the dither is introduced into the circuit, the output of the summing junction 66 is input to a summing circuit 68 that produces a ramp signal output that is input to a scaling circuit 70 . The scaling circuit 70 multiplies the ramp signal by 2 −16 and provides an output signal to a multiplier 72 that also receives a signal to indicate the phase modulator scale factor PMSF. Signals output from the multiplier 72 are input to a D/A converter 76 , which converts the digital signal input thereto into an analog signal suitable for input to the phase modulator 16 .
[0024] The dither compensated signal input to the AGC demodulator 52 is demodulated with the appropriate signs based on the polarity of the compensation. The demodulated signal is then input to an integrator 78 which in turn provides an output to a system processor 80 . Ideally, if the forward gain of the fiber optic gyroscope signal path is correct, the compensation ±rd will exactly cancel the signal generated by the perturbation, and the demodulated value will be zero. If, however, the gain is in error, a residual signal will survive, which results in a non-zero demodulated value. The sign and magnitude of the demodulated value are indicative of whether the gain is high or low and by how much. The system processor 80 produces a gain control signal to adjust the gain accordingly to bring the residual signal to zero. The gain control signal from the system processor 80 is input to a gain control A/D converter, 82 , which, in turn, provides the analog gain control signal to the gain control input of the variable gain amplifier 20 .
[0025] The following mathematical analysis explains additional details of the method of operation of the AGC function provided by the present invention. The gain characteristic for the amplifier 20 is given by
G ( V )=g 0 10 αV , (1)
[0026] where α is a constant and V is the voltage applied to the gain control input of the amplifier 20 .
[0027] The gain expressed in dB is written as
20 log( G ( V ))=20 log( g 0 )+20 αV, (2)
[0028] where g 0 is the normalizing gain, and 20α is the gain sensitivity in dB/volt.
[0029] Alternatively, the gain control law may be rewritten to relate to the binary control word driving the D/A converter 34 , which in turn generates the control voltage. Accordingly, the gain is given by
G ( b )= g 0 10 βb (3)
[0030] where β is the digital control word written to the D/A converter 34 (for example
1 256 1 bit
[0031] ) and b is the number of bits in the binary control word (for example between 0 and 255 bits).
[0032] The gain may also be expressed in dB using the following expression:
20 log ( G ( b ))=20 log( g 0 )+20 βb, (4)
[0033] where 20β is the gain sensitivity in dB/bit. It should be noted that
β α
[0034] is the AGC DAC scale factor in volts/bit.
[0035] Following the loop in FIG. 2 from the point of injection of the perturbation ±d to the demodulator 28 where the AGC error is detected yields (after demodulation)
D = r d - π 2 16 I 0 2 sin φ M K PD K TI GK FILT K A d . ( 5 )
[0036] The gain G 0 =G(b 0 ) that satisfies the overall loop gain is defined by the following relationships:
G L = π 2 31 I 0 2 sin φ M K PD K TI G 0 K FILT K A · 2 S ( 6 )
[0037] and
r=G L ·2 −S . (7)
[0038] where GL is the overall desired loop gain. Thus the following expressions are obtained:
D = ( G L · 2 - S - G L G 0 · 2 S G ( b ) ) d
and ( 8 ) D = 2 - S G L ( 1 - G ( b ) G 0 ) d . ( 9 )
[0039] Define the quantity G(b) as
G ( b )=G 0 (1−ε), (10)
[0040] where ε is the gain error. Using Eq. (10) in Eq. (9) then gives the result that
D=2 −S G L βd. (11)
[0041] In actuality the AGC error signal is summed over many gyro transit times. The gyro transit time is the time interval required for an optical signal to propagate through the length of the sensing coil. The resulting summation is written as:
∑ D = Δ T τ 2 - S G L ɛ d ( 12 )
[0042] where ΔT is the integration time and τ is the transit time. The estimate of the relative gain error is then given by
ɛ ^ = τ Δ T 2 S G L d ∑ D . ( 13 )
[0043] The gain control law is expressed as
1 - ɛ = G ( b ) G 0 = G ( b ) G ( b 0 ) = 10 β ( b - b 0 ) = 10 βΔ b ( 14 )
[0044] where Δb is the error in the gain control D/A converter 34 .
[0045] Taking the natural logarithm of Eq. (14) gives
1 n (1−ε)=βΔb1 n (10). (15)
[0046] Solving Eq. (15) for Δb gives
Δ b = ln ( 1 - ɛ ) β ln ( 10 ) . ( 16 )
[0047] Eq. (16) may be differentiated with respect to ε to yield:
∂ Δ b ∂ ɛ = - 1 β ln ( 10 ) 1 1 - ɛ . ( 17 )
[0048] Eq. (17) is used to form the linearized update equation:
Δ b ≈ ∂ Δ b ∂ ɛ ɛ ^ = - 1 β ln ( 10 ) ɛ ^ 1 - ɛ , ( 18 )
[0049] which is rearranged to yield
b ( n - 1 ) = b ( n ) - Δ T t c Δ b = b ( n ) + Δ T t c 1 β ln ( 10 ) ɛ ^ 1 - ɛ , ( 19 )
[0050] where t c is the desired time constant for the AGC loop. In order to ensure stability of the above equations, the value of {circumflex over (ε)} should be limited in accordance with the gain range. For a 10 to 1 range, the limits are −9.0≦{circumflex over (ε)}≦0.9.
[0051] [0051]FIG. 3 illustrates an algorithm of signal processing that may be used to control the gain of the amplifier 20 . At initialization:
κ e = τ Δ T 2 S G L d ( 20 )
[0052] where
[0053] τ is the loop transit time;
[0054] ΔT is the demodulator integration time;
[0055] s is the loop controller shift count;
[0056] G L is the primary loop gain (1.0 for deadbeat control, 0.2 for integral control);
[0057] and
[0058] d is the dither perturbation value.
κ AGC = Δ T t c 1 β ln ( 10 ) ( 21 )
[0059] where t c is the desired AGC loop time constant and (20)β is the variable gain amplifier sensitivity in dB/bit.
[0060] The gain control command b is set to a value
b=b init (22)
[0061] where b init is the initial gain control D/A converter 34 command to be read from memory. At the integration interval (i.e., every ΔT),
ε=K ε ΣD (23)
[0062] where ΣD is the demodulator output integrated over the interval ΔT. The limit of the estimated gain error ε is limited to [−9.0, 0.9]. The digital gain control command b supplied to the gain control D/A converter 34 may then be written as
b = b - κ AGC ɛ 1 - ɛ . ( 24 )
[0063] Nominal values for parameters used in the algorithm are given in the following table.
τ 5.4 μs ΔT 500 μsec − 1 sec s 5 to 16 G L 0.1-1.0 d 2 16 to 2 28 t c 1.0 msec − 30 sec 20β 20 β = 20 256 dB / bit β β = 1 256 | A closed loop gain circuit controls the gain of a variable gain amplifier and provides a stable AGC response irrespective of the actual gain level. The amplifier may be arranged to amplify electrical signals output from a fiber optic gyroscope. A perturbation injection circuit provides a perturbation signal ±d to a phase modulator connected to the fiber optic gyro. A perturbation compensation circuit applies perturbation compensation signals to signals output from the variable gain amplifier and produces a compensated signal by reducing the magnitude of the perturbation in the amplified signal output from the variable gain amplifier. A gain error circuit connected to the perturbation compensation circuit produces a gain error signal that indicates the magnitude of the perturbation signal remaining in the amplified signal after perturbation compensation. A feedback system provides a gain control signal to the variable gain amplifier to reduce the magnitude of the gain error signal. | 7 |
FIELD OF THE INVENTION
A personal radiation detection device is provided which provides an immediate indication of exposure to radiation at a particular level. The device is designed to detect ionizing radiation such as x- and gamma-rays. The device may be worn by an individual working in an environment where there is potential for exposure and emits an audible sound and/or visual warning in response to the presence of x-rays above a predetermined level. The device may be worn in conjunction with the standard film badge as a single unit.
BACKGROUND OF THE INVENTION
In certain work environments such as for example, healthcare workers involved with x-ray equipment, technicians, doctors and other operators of x-ray equipment including computed tomography operators, there is potential for exposure to ionizing radiation. Personnel in these areas must be constantly monitored to make sure that they are not exposed to radiation above specified limits.
The effect of exposure to ionizing radiation in humans is cumulative and the U.S. Government through the Occupational Safety and Health Administration has set acceptable limits for an average exposure over time (e.g., 10 rems/year for healthcare workers and 5 rems/year for the general population wherein rein is defined as roentgen equivalent man). To monitor worker exposure, workplaces require the use of film badges that are worn by the personnel. The film is sensitive to the ionizing radiation and after a certain interval of usage, the film is sent to a laboratory for analysis. The information concerning personnel exposure is thus not readily available and actual information concerning an exposure may not be received until months after the exposure had occurred. No information would be available at the immediate time of exposure.
Various types of portable monitoring equipment have become available such as, for example, Geiger counters and ionization chambers that provide information concerning an instantaneous value of a radiation field. These devices are large and cumbersome and cannot be worn by personnel in the working environment. Other devices have been developed utilizing sophisticated crystals and semiconductors in which exposures to photon radiation are converted into electronic and audible signals to indicate that threshold levels have been exceeded. Other personal dosimeters include complicated time measuring devices that provide additional information to the user or depend on a one-to one relationship on the energy spectrum of a radiation capable of being received by a detector.
Many of these devices provide instantaneous readings of exposure levels but are cumbersome to wear and are also very expensive. Often these devices require a detective element to be charged or regenerated. Other devices require many mechanical parts that are susceptible to breakage. Finally, many of these devices do not provide for any test features to assure that the equipment is in proper working order. Thus many of these types of personal dosimeters have not been commercially successful.
There is a need for a personal detection device to monitor exposure to ionizing radiation that provides immediate information concerning exposure over the acceptable threshold limit that is lightweight and easy to operate. There is also a need for a detection device that provides for monitoring cumulative exposure to radiation in addition to providing immediate information.
SUMMARY OF THE INVENTION
A radiation detection device is provided having a housing containing within at least one sheet of ram earth intensifying screen that interacts with ionizing radiation when present at a specified exposure level to generate visible light and a plurality of photoresistors that is sensitive to the visible light and conducts voltage upon the detection of light. A specular reflector such as reflective tape, foil, or a finely polished mirror is also provided to reflect any stray visible light in the direction of the photoresistors. The photoresistors conduct a signal to a resistor and an operational amplifier which then in conjunction with a variable resistor activates an indicator including a light and/or an audible buzzer to alert the user of an overexposure to ionizing radiation. The small housing may also be provided with a slot on an outside surface of the housing to hold standard photographic film used to monitor cumulative exposure to radiation. A battery source is provided to generate power to operate the device.
The sheet of rare earth phosphor is preferably a screen of Gadolinium oxysulfide:terbium activated (Gd 2 O 2 S:Tb). The photoresistors are preferably cadmium sulfide (CaS). Three 3-volt lithium batteries are the preferred power source.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the monitoring device having a housing to which a clip is adhered for affixing to the person wearing the device.
FIG. 1a is a front view of the monitoring device shown in FIG. 1.
FIG. 1b is a top view of the monitoring device shown in FIG. 1.
FIG. 1c is a back view of the monitoring device shown in FIG. 1.
FIGS. 1d and 1e are side views of the monitoring device shown in FIG. 1.
FIG. 2 is a schematic: diagram of the circuits of the device of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
A detection device is provided to alert personnel of immediate exposure to ionizing radiation at a predetermined level. The ionizing radiation sought to be detected is in the range between 25 keV through about 100 keV, which is equivalent to a wavelength of 10 nm or less and includes x-ray and gamma-ray radiation. Radiation in this range can be harmful to the human body. The device herein described provides an early warning signal to immediate exposure and also is capable of providing quantitative information concerning any exposure.
The invention is best understood by reference to the accompanying drawings. FIG. 1 shows a perspective of the device 1 in which all of the operational elements are housed within a plastic housing or casing 13 on a printed circuit board located within the housing 13 directly behind window 18 of the housing. This device enables the personal measurement of exposure (dose) to ionizing radiation including x-rays and gamma radiation. The description of the operation of the device described herein utilizes x-rays as the ionizing radiation and is designed to detect a dose rate of 310 mrem/min or more. The housing 13 is designed so that no ambient light is permitted to enter into the interior which is the location of the main circuitry. The device 1 with housing 13 is attached to the user via a clip 14 located at the back of the housing 13 (as shown in FIG. 1c). Alternate means of attaching the housing 13 to the user may also be employed such as pins or the use of interlocking loops and hooks such as Velcro® tabs. A battery compartment 17 is provided for the ease of replacing the batteries (as shown in FIG. 1c).
Also visible on the outside surface of the device 1 is an audible indicator 11 and a visual indicator 10 (as shown in FIG. 1a). The audible indicator 11 may include any noise generating device that is miniaturized so that it fits within the housing 13 such as for example, a piezo buzzer, an electro-mechanical buzzer, or a piezo transducer. This audible indicator 11 is triggered by the detection of ionizing radiation above a predetermined level. Similarly, the visual indicator 10 may include any light generating device that is miniaturized so that it also fits within the housing 13 such as for example a light-emitting diode (LED). Although FIG. 1 shows that both the audible and visual indicators are present, the inventive device may also function equally well with only one of the indicators present, either the audible or visual.
An optional feature includes a slot 12 for holding a conventional radiation film badge, as described above, which is worn for a period of time (i.e., 30 to 90 days) and then sent to a laboratory for analysis. The film is visible through window 18 on the front face of the housing as can be seen in FIGS. 1 and 1a. Additional information concerning the user may also be visible from the window. Also located on the side of the housing 13 are the power switch 15 and test switch 16. These can be seen in FIG. 1d. FIG. 1e shows the opposing side of the housing. The housing 13 is sealed around the side edges and bottom with conventional sealing means so that it is substantially impermeable to light. The ionizing radiation preferably penetrates the top of the housing 13 (FIG. 1b) where the ionizing radiation then interacts with the elements contained within the housing. Although it is preferred that the ionizing radiation enter the top of the housing for maximum sensitivity, the device is capable of functioning albeit with slightly less sensitivity if the radiation enters from other areas of the housing.
Referring to FIG. 2, the ionizing radiation (as described herein, x-rays having a wavelength of 10 nm or below) enters the housing and impinges on the rare earth intensifying screen 119. The rare earth intensifying screen 119 is preferably a phosphor screen made of Gadolinium oxysulfide:terbium activated Gd 2 O 2 S:Tb, a photographic material commercially available from Eastman Kodak Corporation of Rochester, N.Y. The rare earth material is available in different speeds depending on the application. For the inventive ionizing radiation detection device, the minimum speed of the screen should be of a 400 speed class. Screens 119 with higher speeds are more sensitive and thus interact with the ionizing radiation to produce more visible light than lower speed class screens. Thus screens 119 with speeds of 800 are preferred and screens of 1200 or greater are most preferred. Only one screen 119 of speed 800 or greater is required within the housing. A second screen may be added if desired.
The screen 119 may generally have a thickness of between 4 to 6 mils. A thicker screen with a thickness of up to 10 mils may lead to a more sensitive screen. The screen also has a conversion efficiency of 18%. Screens with higher conversion efficiencies may also yield more sensitive screens. Alternatively, screens having a heavy metal higher than that of gadolinium (Gd with an atomic number of 64) such as lead may also be employed thus improving the sensitivity of the rare earth intensifying screen.
When the radiation energy impinges on the rare earth intensifying screen 119, the energy reacts with the screen to produce a green light in the visible light spectrum. Specifically, the x-ray energy impinges on the rare earth screen 119 causing the originally white surface with no light emission to emit a green light with a wavelength of 544 nm. The light produced by the interaction of the x-ray photons and the screen is emitted in all directions.
The light emitted by the rare earth screen 119 is detected by the Cadmium Sulfide (CaS) photoresistors 100-109. The number of photoresistors may vary depending on the particular application and dose rate to be detected. The light detected by these photoresistors is further enhanced with the use of a specular reflector 116 that is positioned in an overlapping manner with the rare earth screen 119 so that any light emitted towards the reflector 116 is reflected back towards the photoresistors 100-109 which are located on the other side of the rare earth screen 119. The specular reflector 119 is a reflecting surface and includes such materials as a shiny metal reflecting tape or foil and is most preferably a finely polished mirror.
The CaS photoresistors 100-109, most sensitive to light in the 565 nm wavelength spectrum, are situated in parallel on one side of the rare earth screen 119 so as to quickly reduce the resistance in the circuit when exposed to light according to the formula: ##EQU1##
The photoresistors begin to conduct voltage immediately upon detecting the light having a wavelength of approximately 544 nm. A variable resistor 118, in parallel with the photoresistors 100-109 is employed to reduce the total resistance of the photoresistors to a threshold slightly below that of causing the 741 operational amplifier 113 to change its output. The 741 operational amplifier is manufactured by Tandy Corporation and commercially available from Radio Shack stores located throughout the United States. The voltage is detected across resistor 112 which is connected to the input of the operational amplifier 113.
A variable resistor 120 is provided to apply voltage to the input of the operation amplifier 113. The operational amplifier 113 switches its output when the voltage rises to a predetermined voltage. For the specific application, the variable resistor 120 provides 1.90 volts and the photoresistors upon the detection of the green light generates at least 0.05 volts which are detected by the resistor 112. Thus 1.95 volts are provided to the operational amplifier 113 which causes the operational amplifier to switch its output from high to low and closes the loop thus supplying sufficient voltage for the visual indicator (LED 114) and audible indicator (piezo buzzer 116) to be activated.
A conventional battery source 117 (FIG. 2) is used to supply the necessary power to operate the detector 1. A particularly preferred battery source consists of three 3 volt lithium button cell batteries. To test the operation of the device, a test switch 111 may be momentarily closed to provide a 9 volt potential on the input of the operational amplifier 113 and trigger the LED 114 and acoustic buzzer 115 to emit light and noise. The power switch 110 when closed supplies the 9 volts necessary to operate the device. When the power switch is open, the circuitry is interrupted and the device is rendered inoperative.
In operation, ionizing radiation enters the device through the top permeable section as shown in FIG. 1. The energy impinges upon the rare earth intensifying screen 119 and interacts with the rare earth screen such that visible light having a wavelength of about 544 nm (green light) is produced. The light produced is emitted in all directions such that it is detected by the CaS photoresistors 100-109. Stray light is also reflected back to the CaS photoresistors by the specular reflector 116. The photoresistors 100-109 are highly sensitive to light of the particular wavelength and upon detection of the light, the photoresistors begin to conduct a voltage. The photoresistors are in parallel to that the resistance decreases very rapidly causing accelerated conduction. The resultant voltage is detected across resistor 112. The amount of voltage detected across resistor 112 is dependent upon the dose rate of ionizing radiation detected by the device such that a higher dose rate will cause a brighter rare earth screen and higher voltage generated.
Variable resistor 118 is calibrated so that the total resistance of the photoresistors 100-109 is reduced to slightly below the threshold of conductance. The variable resistor 120 puts a bias voltage of 1.90 volts on the inverted input (-) of the operational amplifier 113. The non-inverted input (+) has a zero potential. When resistor 112 has a voltage of more than 0.05 volt potential across it, the inverted input (-) has a 1.95 volt potential at that input and the output goes to zero volts causing the LED 114 and acoustic buzzer 115 to function.
When the energy rate falls below 310 mR/min, the photoresistors cease to conduct which causes deactivation of the LED and buzzer.
The device is worn on the user's collar or waist band or belt. The overall weight of the device is approximately 31 grams.
Other features of the invention will be apparent from the description, drawings and claims. Embodiments of the invention utilizing the same or equivalent principles may be used and structural changes may be made as desired by those skilled in the art without departing from the present invention and the purview of the appended claims. | A personal radiation detection device is provided having a housing containing within at least one sheet of rare earth intensifying screen that interacts with ionizing radiation when present at a specified exposure level to generate visible light and a plurality of photoresistors which is sensitive to the visible light and conducts a voltage upon the detection of the light. A specular reflector such as reflective tape, foil, or a finely polished mirror is also provided to reflect any stray visible light in the direction of the photoresistors. The photoresistors send a signal through a resistor to an operational amplifier which then activates an indicator including a light and/or an audible buzzer. The lightweight housing may also be provided with a slot on an outside surface to hold standard photographic film used to monitor cumulative exposure to radiation. A battery is provided to generate power to operate the device. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
The present application is a continuation-in-part of U.S. application Ser. No. 08/745,699, filed Nov. 12, 1996.
BACKGROUND OF THE INVENTION
The present invention relates to digital and print-on-demand printing systems; and more particularly, to a high-speed printer controller system that is configured to control a multitude of print engines simultaneously, and is configured to synchronize the deposition of image pixels and to “lock-step” the transport mechanisms on the multitude of print engines to a single clock source, thereby reducing beat frequency and other errors between the print engines.
An ink jet printing system is an example of a printing system that is notorious for having registration problems and beat frequency errors between various print engines (ink jet printheads) controlled by at least one printer controller. Ink jet printing is a non-impact print method which is based upon controlling the behavior of a fluid ink stream using pressure, ultrasonic vibration and electrostatic forces. A typical ink jet printhead will include a multitude of nozzle orifices, aligned in an array, for emitting a corresponding multitude of fluid ink streams, commonly referred to as an array of ink. Pressure is created by a push rod to force the ink from the ink chamber and through an array of nozzle orifices.
A high frequency ultrasonic vibration (referred to as a “modulation signal”) is applied to the push rod and, in turn, to the ink stored in an ink chamber within the ink jet printhead, to establish a standing wave pattern within the ink. To create the modulation signal, the typical ink jet print head will utilize an internal clock source which is sent to a piezoelectric crystal, typically mounted within the push rod assembly. The piezoelectric crystal will thus vibrate at the frequency of the clock source. The vibrational waves will conduct into the ink chamber, causing the standing wave pattern within the ink. This standing wave pattern in the ink causes the ink to break into individual droplets, corresponding to individual pixels of the printed image, when the ink emerges from the nozzle orifices. The resulting array of ink droplet streams is directed (typically downward) towards the substrate to receive the printed image.
A multitude of electrodes are positioned adjacent to each of the ink droplet streams, near the nozzle orifices. The electrodes, controlled by the ink jet printhead, apply a voltage to the droplets which are not intended to contact the substrate. Below the electrodes, the droplet streams pass through a high voltage field which forces the charged droplets to be deflected into a gutter and which allows the uncharged droplets to pass through the field and onto the substrate, thus forming the printed image.
The nozzle orifices are typically arranged on the ink jet printhead in a row, where each nozzle orifice corresponds to one column of image pixels on the final printed image. The printed image is formed by emitting successive horizontal lines of the ink droplets (referred to as “strokes”) applied to the continuously moving substrate (moving in the vertical direction). Each stroke forms one row of pixels on the final printed image. The electrodes are controlled for each stroke by the ink jet printhead in accordance with the bitmap data sent to the print head by the raster printer controller.
In low-speed printing operations, where the substrate is moved at low speeds under the ink jet printheads, the width of the row of nozzle orifices is not a concern. However, in high-speed printing operations, where the substrate is moved at high speeds under the ink jet printheads (i.e., to print 1000 feet per minute), the size of the row of nozzle orifices becomes a real concern because of the time it takes for the vibrational waves in the chamber to travel from the push rod to the far ends of the printhead. Accordingly, to be able to print detailed, full size images in high speed ink jet print operations, it is necessary to utilize a plurality of the ink jet print heads, where each print head is responsible to print one vertical portion or “swath” of the image. One “swath” of an image corresponds to the number of vertical columns of pixels that one ink jet printhead will be able to print. Typically, the width of each swath can range from approximately 20 to 1024 pixels (i.e., the swath would comprise 20 to 1024 columns of pixels), however the range can vary depending upon the application.
Because the physical width of the ink jet printhead exceeds the width of the swath printed by the ink jet printhead, the multiple ink jet printheads cannot be aligned side by side with respect to each other without experiencing noticeable gaps between the swaths. Therefore, to get a continuous image across the width of the entire printed page, with no noticeable gaps between the swaths, it is necessary to stagger the ink jet print heads vertically with respect to the substrate such that they do not interfere with each other. It is also necessary to simultaneously control the multiple ink jet printheads such that their respective swaths are vertically and horizontally aligned with respect to the substrate. The process of vertically and horizontally aligning these swaths on the substrate to form one image is commonly referred to as “stitching”.
Stitching the multiple ink jet swaths down to the pixel level in order to obtain sub pixel resolution is extremely challenging. Mechanical alignment is the most common method of aligning the printheads to achieve stitching of the swaths. Utilizing micrometer adjustment and measurement devices on the x and y axes, the position of the printheads can be adjusted to approach sub pixel resolution. However, such alignment is only useful for a particular ink viscosity, temperature of the environment, humidity of the environment and print speed. Once any one of these variables changes, i.e., the viscosity of the ink changes, the pixel resolution will again become misaligned. Furthermore, even if the printheads are perfectly aligned, the piezoelectric crystals in each printhead will be driven at a slightly different frequency, thus causing beat frequency drift errors between the printheads which eventually leads to very visible alignment errors between the pixels of the different swaths.
Electronic alignment methods and mechanisms, while more flexible than mechanical alignment systems, also cannot achieve sub pixel resolution because of the piezo beat frequency drift errors, which will eventually cause drift between the printheads, independent of the mechanical and/or electronic methods and systems used for stitching the swaths together.
The problem of beat frequency drift errors is not limited to ink jet engines. As will be appreciated by those of ordinary skill in the art, similar errors may occur in other types of print engines that are linked together to print upon a single substrate or web. For example, magnetographic engines utilize magnetic recording heads to create a latent magnetic image on the surface of a revolving hard metal drum, which is then exposed to magnetic toner particles and transferred/fused to paper. The modulation frequency of the magnetic recording heads is controlled by a clock source, which may be slightly different on each of the print engines. Therefore, if a plurality of the magnetographic print engines are used in series to print a single image, the slight differences in the magnetic recording heads' clock sources may cause slight (but perceptible) registration errors in the printed pixels of the image. Similar beat frequency errors may occur in LED engines, Ion deposition engines, laser engines, magnetographic, xerographic engines and the like.
Accordingly, a need exists for a system and method for simultaneously controlling the plurality of staggered ink jet printheads such that stitching between the swaths generated by the ink jet printheads can be easily accomplished electronically, regardless of the ink viscosity, print speed, temperature and humidity. Furthermore, a need exists for a system and method for synchronizing the piezo clock sources on each of the ink jet printheads to each other such that the stitching can be accomplished down to sub pixel levels without experiencing beat frequency drift errors between the pixel swaths. Furthermore, a need exists for a system and method for synchronizing clock sources controlling the deposition frequency of image pixels on print engines connected (in series, in parallel or otherwise) so as to eliminate beat frequency errors between the print engines. Finally, a need exists for a system and method for synchronizing the drive mechanisms of print engines controlled by a single controller so as to “lock-step” the transport mechanisms of the printers.
SUMMARY OF THE INVENTION
The present invention provides a system and method for simultaneously controlling a plurality of print engines connected (in series, in parallel, or otherwise) that facilitates electronic stitching between the print engines. More specifically, the present invention provides a system and method for synchronizing the pixel deposition frequencies between the various inter-connected print engines so as to eliminate beat frequency errors between the print engines. The present invention also provides a system and method for synchronizing the transport mechanisms of the inter-connected print engines so as to reduce overall errors and failures of the printing system.
In a specific embodiment, the present invention provides a system and method for simultaneously controlling a multitude of continuous-flow ink jet printheads which facilitates the electronic stitching between the ink jet printheads; and furthermore, the present invention provides a system and method for synchronizing the piezo clock sources on each of the ink jet printheads to each other such that the electronic stitching can be accomplished down to the pixel levels.
The method for synchronizing the pixel deposition frequencies between a plurality of print engines comprises the steps of: (a) coupling the plurality of print engines together with at least one printer controller, (b) embedding a first clock signal in data; (c) transmitting the data to the print engines; (d) each of the print engines receiving the data; (e) each of the print engines deriving a pixel deposition clock signal from the data received, which is directly proportional to the first clock signal; and (f) each of the print engines driving its corresponding pixel deposition mechanism with the pixel deposition clock signal. Accordingly, all of the pixel deposition clock sources will be synchronized in frequency with each other, eliminating beat frequency drift errors between the print engines. The pixel deposition mechanism, as apparent to those of ordinary skill in the art, includes the LED switching device for LED engines, the ion generating cartridge for Ion deposition engines, the magnetic recording heads for magnetographic engines, the piezoelectric crystal coupled to the ink-well push rod for ink jet printheads, and the like.
Preferably, the print engines and controller are connected together in a daisy-chain configuration and the method also includes the steps of: (i) determining the time it will take for the data to propagate to each of the print engines; and (ii) adjusting the phase of the second clock signal to reflect the propagation measurement. Accordingly, all of the pixel deposition clock signals will also be synchronized in phase as well as frequency to each other.
The above method is accomplished by operating a plurality of print engines with a high-speed raster printer controller. The type of print engine is not critical and a plurality of different print engine technologies can be used. Each print engine includes a customized communication circuit, which in the preferred embodiment is a separate circuit board, hereinafter referred to as a “target adapter board” (“TAB”). The TAB provides a direct interface between the print engine electronics and the controller. The controller and each TAB includes a serial data input port and a serial data output port. The controller is attached to the plurality of TABs in a daisy-chained ring configuration, such that the controller will transmit commands and data to the first TAB on the daisy-chain, and the commands and data will flow in the same direction along the daisy-chain to the rest of the TABs, and will eventually flow back to the controller. Furthermore, the controller is adapted to transmit rasterized bitmap image data to the TABs, and in turn to the print engines, in an on-demand manner. The daisy-chained serial communication ring configuration of the controller and the plurality of TABs is hereinafter referred to as “the ring.”
The ring configuration allows all of the TABs to see all of the data all of the time. This also provides a clean mechanism for the raster printer controller to receive status from all of the print engines with minimal cabling requirements. Furthermore, use of fiber optic links in the ring provides high bandwidth data transfer capabilities, excellent electrical isolation and immunity from excessive high voltages associated with print engine electronics.
The raster printer controller has a multiplexed command/data-stream protocol structure at its fiber optic interface in which the controller transmits a command followed by the associated data. The controller initiates all commands, and manages the allocation of fiber optic band-width to receive all print engine status. Each TAB is adapted to listen for commands addressed to it, and responds appropriately; and further, the TAB never responds unless commanded by the controller. Nevertheless, each TAB must retransmit the entire command/data-stream it receives on its fiber optic input port back to its fiber optic output port, and in turn, to the next TAB on the ring. This allows all of the TABs to see all of the controller commands and data, all of the time.
Each TAB includes a fiber optic receiver/decoder, a fiber optic encoder/transmitter, a standard discrete output bus, a standard discrete input bus, a print engine instruction register, print engine status register, a bitmap data memory storage, a stroke rate counter and associated stroke rate count preload register, a high-speed fiber optic message processing circuit, and an on-board CPU. Therefore, each TAB essentially includes all the necessary print engine components.
The CPU and message processing circuit are adapted to manage the incoming and outgoing commands, to manage the TAB's hardware, and to provide an interface to the print engine electronics. The message processing circuit monitors the fiber optic input and executes the commands transmitted by the raster printer controller if the commands are addressed to it. The message processing circuit also continuously retransmits the commands/data-stream back to the fiber optic encoder/transmitter, supports the general purpose discrete output bus and instruction register in response to the commands, reads the general purpose discrete input bus and print engine status register which can be incorporated into messages sent directly to the raster printer controller as status, and also manages the data update of the bitmap data memory storage when commanded by the raster printer controller.
The raster printer controller's multiplexed command/data protocol scheme allows the raster printer controller to transmit bitmap data to the print engines in any order and at any time, thus providing print-on-demand capabilities to the print engines; allows the controller to embed a “Print Trigger” command within the command/data stream at any time thus providing real-time print trigger generation to the print engines; and allows the controller to embed a stroke rate signal within the command/data stream indicative of the web velocity and/or acceleration.
The command/data stream is transmitted over the fiber optic ring utilizing a self-clocking data transmission code such as 8B/10B code. The fiber optic encoder on the raster printer controller embeds a clock signal into the command/data stream by encoding the raw data. This allows the fiber optic decoders on each of the TAB boards to extract the embedded digital clock signal from the encoded data and to decode the command/data stream back into its raw data.
The extracted digital clock is used by each TAB to generate the pixel deposition clock signal for driving the pixel deposition mechanism on its corresponding print engine. Because each extracted clock signal will have the exact frequency (directly proportional to the clock signal embedded by the raster printer controller), each pixel deposition clock signal generated from the external clock source will also have the exact frequency.
Preferably, the pixel deposition clock signal is generated as follows: The extracted digital clock drives a free running counter whose count output is sent to a memory device which acts as a lookup table. The lookup table includes a voltage amplitude value for every count input. The voltage amplitude values in the lookup table each correspond to a particular voltage amplitude level in one period of the pixel deposition clock signal's sinusoidal wave, square wave and the like. Thus, the memory device will output the particular voltage amplitude value from the lookup table, depending upon the count input received from the counter; therefore, for each cycle through the counter, the voltage amplitude values corresponding to one period of the pixel deposition clock signal's output will be output from the lookup table. The voltage amplitude value is sent to a digital-to-analog converter, the amplified output of this digital-analog converter is the analog clock source for the pixel deposition clock signal.
To reset the counters, the raster printer controller will broadcast a CLOCK RESET command to the first TAB on the ring. The first TAB will receive this command and restart its counter to start generating its pixel deposition clock signal. As discussed above, the first TAB will also pass this command to the next TAB on the ring; which will restart its counter in response to the command and will in turn pass the command to the next TAB on the ring. This is repeated until the command is passed back to the raster printer controller.
Because it will take time for the a CLOCK RESET command to propagate to each TAB on the fiber optic ring, the present invention includes a method to assure that all the pixel deposition clock signals are synchronized in phase as well as frequency. Thus, each counter includes a preload input coupled to a phase-shift preload register. Each phase-shift preload register will be initialized by the raster printer controller during the boot-up process to a count pre-set value which corresponds to the time it takes for the CLOCK RESET command to reach the particular TAB. Thus, even though each pixel deposition clock signal will be started at progressively different instances, each phase-shift preload register is set to a particular count value to assure that the output voltage level of the piezoelectric clock source of a given TAB upon receiving the CLOCK RESET command is at the same voltage amplitude levels of all pixel deposition clock signal started prior to the present one.
Each pixel deposition clock signal is therefore locked in both phase and frequency to each other.
In a specific embodiment of the present invention, a method for synchronizing the plurality of piezoelectric crystals on a corresponding plurality of ink jet printheads comprises the steps of: (a) coupling the plurality of printheads together with a printer controller, (b) embedding a first clock signal in data; (c) transmitting the data to the printheads; (d) each of the printheads receiving the data; (e) each of the printheads deriving a second clock signal from the data received, which is directly proportional to the first clock signal; and (e each of the printheads driving its corresponding piezoelectric crystal with the second clock signal. Accordingly, all of the piezoelectric crystal clock sources will be synchronized in frequency with each other, eliminating beat frequency drift errors between the printheads.
The method for synchronizing or “lock-stepping” a plurality of print engines comprises the steps of: (a) coupling the plurality of print engines together with at least one printer controller, (b) embedding a first clock signal in data; (c) transmitting the data to the print engines; (d) each of the print engines receiving the data; (e) each of the print engines deriving a drive clock from the data received, which is directly proportional to the first clock signal; and (f) each of the print engines driving its corresponding drive mechanism with the drive clock.
Accordingly, it is an object of the present invention to provide print system with multiple print engines which can dispatch rasterized bitmap data to the print engines in an on-demand manner; which can transmit print trigger and stroke rate information to the print engines at any time; which synchronizes the pixel deposition clock signals for each print engine to a single clock source; which synchronizes the pixel deposition clock signals for each print engine in both phase and frequency; and which provides a system which facilitates electronic stitching of the print engines down to the pixel level. These and other objects will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a block diagram representation of the present invention, depicting a plurality of print engines coupled together in a daisy-chain ring configuration with a printer controller;
FIG. 1 b is a block diagram of a specific embodiment of the present invention, depicting a plurality of ink jet print heads arranged in a staggered array to print upon a web and controlled by a single printer controller, the ink jet printheads and the controller being coupled in a daisy-chain ring configuration;
FIG. 2 is a schematic block diagram of a print engine communication device for use with the present invention;
FIG. 3 is a schematic block diagram of a stroke machine circuit for use with the present invention;
FIG. 4 is a schematic block diagram of an alternate arrangement of the printer controllers and print engines; and
FIG. 5 is a block diagram representation of a print engine (such as an ion-deposition, LED or magnetographic print engine) for use with the present invention.
DETAILED DESCRIPTION
As shown in FIG. 1 a , at least one high speed raster printer controller 10 is used to simultaneously drive a plurality of print engines 12 a - 12 c each of which are to print portions of an image onto a substrate 14 moving through each of the print engines in the direction indicated by arrow A. In a specific embodiment, as shown in FIG. 1 b , the plurality of print engines is a plurality of ink jet printheads 12 a - 12 d each of which have a nozzle array 13 a - 13 d for ejecting strokes of ink to a substrate or web 14 moving in a vertical direction indicated by arrow A. The ink jet printheads 12 a - 12 d are positioned in a staggered formation along the web 14 and each ink jet printhead is controlled by the controller 10 to transfer a corresponding swath 16 a - 16 f of an image 18 to the web 14 .
The print engines 12 , may include an LED engine, an ion deposition engine, a xerographic engine, a magnetographic engine, a laser engine, an ink jet engine or any other type of high-speed print engine, or any combination of such engines, as is known to those of ordinary skill in the art. With each of these high speed print engines, a pixel deposition mechanism is utilized, which includes a clock input for providing a pixel deposition frequency. As shown in FIG. 5, at least with LED engines, ion deposition engines and magnetographic engines, the pixel deposition mechanism 6 , includes a source 7 of a pixel deposition clock signal for providing a deposition frequency for the mechanism 6 . The pixel deposition mechanism 6 is controlled to transfer a latent image on a rotating drum 8 . Toner particles are transferred onto the latent image by a toner supply 9 , which are then transferred onto the paper or substrate 14 in the form of the final image. Motorized drive mechanisms 11 are used to drive the paper through the printer at a controlled speed. The speed of the rotating drum 8 is synchronized with the drive mechanisms 11 , and is essentially a drive mechanism itself. In LED engines, the pixel deposition mechanism includes an array of LEDs 6 and a switching device for switching the arrays on and off for creating the latent image on a revolving charged drum 8 . In magnetographic engines, the pixel deposition mechanism is a plurality of magnetic recording heads 6 that are selectively energized to create the latent magnetic image on the surface of the revolving hard metal drum 8 . In ion deposition engines, the pixel deposition mechanism is an ion generating cartridge 6 which digitally creates the latent image on the rotating dielectric drum 8 .
The pixel deposition mechanism for ink jet print heads, discussed above in detail, includes an ink chamber having a multitude of nozzle orifices, aligned in an array, for emitting a corresponding multitude of fluid ink streams, commonly referred to as an array of ink. Pressure is created by a push rod to force the ink from the ink chamber and through an array of nozzle orifices. A piezoelectric crystal is coupled to the ink-well push rod so as to create a high frequency ultrasonic vibration to the push rod and, in turn, to the ink stored in the ink chamber. This high frequency vibration in the ink chamber causes the ink droplets to emerge from the nozzles at the same frequency.
Referring to FIGS. 1 a and 1 b , the high speed raster printer controller 10 is preferably a multi-processor system for interpreting and processing an image or images defined by a page description language and for dispatching rasterized bitmap data generated by the processing of the page description language as described, for example, in U.S. Pat. No. 5,796,930. Each print engine or printhead 12 a - 12 d is coupled to one of a plurality of print engine communication circuits, which preferably reside on individual circuit boards, hereinafter referred to as “target adapter boards” (“TAB”) 20 a - 20 d . For the purposes of this disclosure, when it is disclosed that one component is “coupled” to another component, it will mean that the one component is linked to the other component by any data link such as an electronic data link (wires or circuits), a fiber optic data link, an RF (radio frequency) data link, infrared data link, an electromagnetic data link, or any other type of data link known to one of ordinary skill in the art.
Each TAB 20 a - 20 d provides an interface between the raster printer controller 10 and the respective plurality of print engines 12 a - 12 d . Preferably each TAB includes a universal controller interface section to provide a means to communicate with the raster printer controller 10 ; and a customized print engine interface section which provides a direct interface between the print engine electronics and the raster printer controller 10 .
The raster printer controller 10 includes a serial data output port 22 and a serial data input port 24 . The output port 22 is preferably a fiber optic transmitter and the input port 24 is preferably a fiber optic receiver. Each of the TABs 20 a - 20 d also include a serial data input port 26 and a serial data output port 28 (see FIG. 2 ); where the input port 20 is preferably a fiber optic receiver and the output port is preferably a fiber optic transmitter. Therefore, both the raster printer controller 10 and the plurality of TABs 20 a - 20 d each have duplex communications via fiber optics.
As is further shown in FIGS. 1 a and 1 b , the raster printer controller 10 is coupled to the plurality of TABs 20 a - 20 d in a daisy-chain configuration; and furthermore, the last TAB 20 d on the daisy-chain is coupled again to the raster printer controller to form a daisy-chain “ring”. The raster printer controller 10 transmits a command/data stream to the first TAB 20 a on the ring over a serial data link, which is preferably a fiber optic link 30 ; the last TAB 20 d on the ring transmits command/data stream back to the raster printer controller 10 over a serial data link, which is preferably a fiber optic link 32 ; and each of the TABs 20 a - 20 c transmit command/data stream to the next TAB on the ring, over serial data links, which are preferably fiber optic links 34 a - 34 c . The data output port 22 of the raster printer controller 10 transmits coded data serially over the fiber optic link 30 . The data is encoded from raw digital data by an encoder device 35 . The raw digital data is passed over a parallel data line to the encoder device 35 from the control circuitry 37 of the raster printer controller. The data input port 24 receives the coded data back from the fiber optic link 32 . This data is then decoded back into raw digital data by a decoder device 39 . The raw digital data is then passed on to the control circuitry 37 of the raster printer controller in parallel form. The fiber optic links 30 , 32 , 34 a - 34 c provide substantial electrical isolation and immunity from excessive high voltages associated with print engine electronics and the fiber optic links are scalable, i.e., their data rates can be easily slowed down if desired.
As will be discussed in significant detail below, the a printer controller embeds a first clock signal (from a first clock source 73 ) in data and transmits the data to the fiber optic ring. Each TAB 20 a - 20 d on the fiber optic ring derives a pixel deposition clock signal 68 from the data received, which is directly proportional to the first clock signal. Finally, each of the print engines 12 a - 12 d drives its corresponding pixel deposition mechanism 6 a - 6 d with the pixel deposition clock signal 68 . Accordingly, all of the pixel deposition clock sources will be synchronized in frequency with each other, eliminating beat frequency drift errors and/or other synchronization errors between the print engines. It is within the scope of the invention that pixel deposition clock signal be used to synchronize the drive mechanisms 11 , 8 between the print engines, thereby “lock-stepping” the operations of the various print engines together.
It should be apparent to one of ordinary skill in the art, that while fiber optic links are preferred for the present embodiment of the invention, it is within the scope of the invention to utilize any other type of serial data link capable of performing applications described herein. For example, the fiber optic links could be replaced with coax or twisted pair links.
Furthermore, while the above daisy-chain ring configuration is preferred, it is within the scope of the invention to couple the controller 10 to the plurality of TABs 20 a-d in a configuration (daisy-chain or otherwise) which is not configured as a ring. For example, as shown in FIG. 4, it is within the scope of the invention to couple the printer controller 10 ′ to the plurality of print engines 12 ′ in a “star” or “spoked wheel” configuration where the controller 10 ′ will be at the “hub” and is coupled to each of the print engines 12 ′ separately with individual data links 200 . As is also shown in FIG. 4, it is also within the scope of the invention to utilize print engine communication circuits 20 ′ to interface between the controller 10 ′ and one or a plurality of print engines 12 ′ in the “star” configuration.
The preferred daisy-chained serial configuration of the raster printer controller and plurality of TABs is hereinafter referred to as “the ring.”
Each TAB is configured to transmit the entire command/data stream received on its input port 26 back to its output port 28 . Accordingly the raster printer controller 10 will transmit the command/data stream to the first TAB 20 a on the ring and the command/data stream will flow in the same direction along the daisy-chain to the rest of the TABs 20 b - 20 d , and eventually will flow from the last TAB 20 d on the ring back to the raster printer controller 10 . This configuration allows all the TABs to see all the command/data stream all of the time.
As shown in FIG. 2, each TAB 20 includes a digital decoder 36 for decoding the data stream received by the fiber optic receiver 26 into raw digital input data on the input data bus 38 , and a digital encoder 40 for transforming the raw digital output data on the output data bus 42 into an encoded data stream to be transmitted by the fiber optic transmitter 28 . Also included on each TAB is a high-speed message processing circuit 44 , coupled between the decoder 36 and encoder 40 . The high-speed message processing circuit 44 is designed to monitor the digital input data on the input data bus 38 and to execute the commands embedded in the command/data stream when the embedded TAB address field matches the TAB's internal address. The high speed message processing circuit 44 also continuously retransmits this digital input data to its fiber optic encoder 40 as digital output data on the output data bus 42 , which is in turn transmitted to the next TAB on the ring (or back to the raster printer controller if the present TAB is the last TAB on the ring) by the fiber optic transmitter 28 .
Preferably, the high-speed message processing circuit 44 is a non-intelligent device, that is, it is a “hardware” device whose internal functions are not directed by a software program. Therefore the high-speed message processing circuit is very fast and is able to handle the bandwidth requirements for the multiplexed command/data protocol structure described below. Furthermore, the high-speed message processing circuit 44 is not as susceptible to the errors and failures which may commonly occur in software controlled devices. The high-speed message processing circuit 44 may be fabricated from standard TTL devices, CMOS devices, 7400 series logic, or incorporated into single or multiple chip implementations such as programmable logic arrays (PALs), field programmable gate arrays (FPGAs), application specific integrated circuits (ASICs) or any hardware description language (HDL) based device; and in a preferred embodiment, the high-speed message processing circuit 44 is an ASIC device.
The high-speed message processing circuit 44 is coupled to a discrete output buffer 46 and a discrete input buffer 48 via a data busses 50 , 51 , respectively. In executing commands transmitted by the raster printer controller, the high-speed message processing circuit 44 can set or reset lines on the discrete output buffer 46 and can report back to the raster printer controller messages pertaining to the status of lines on the discrete input buffer 48 . Such output discretes can include, for example, “print on-line,” “printer reset,” and “reset communications.” Such input discretes can include, for example, “engine error.” Thus, the discrete buffers provide a mechanism for handling general purpose I/O requirements of print engine.
The TAB 14 also includes a bitmap data transfer circuit 57 which includes a bitmap data memory storage buffer 52 for interfacing directly to the corresponding print engine's video data input port 54 . Therefore, the message processing circuit 44 is also designed to update the bitmap data memory storage buffer 52 when commanded by the raster printer controller 10 . This bitmap data memory storage buffer, in the preferred embodiment, is a FIFO buffer; however, the bitmap data memory storage buffer 52 may also be video memory, a single byte of memory (i.e., a register), a dram array, or any other type of memory device as required by the design of the print engine interface. Therefore, the message processing circuit will update the bitmap memory storage buffer 52 by activating a “FIFO memory write” signal 55 coupled to the memory storage buffer. For at least ink jet applications, the transfer circuit 57 also includes a multiplexor device 56 coupled between the ink jet printhead's video data input port 54 and the bitmap data memory storage buffer 52 for injecting NULL data between the vertical swaths of bitmap data.
The TAB includes an optional on-board CPU 58 which is used to manage higher level tasks as warranted by some types of print engines; a control port 60 controlled by the message processing circuit 44 or the on-board CPU 58 , which can be used as part of the print engine interface to transmit ink print engine instructions (otherwise known as “print engine commands”) and instruction parameters (otherwise known as “print engine command parameters”) to the print engine; and an print engine status buffer 62 monitored by the message processing circuit 44 or the on-board CPU 58 , which can be used to access print engine status information from the print engine. The CPU 58 , the control port 60 and the status port 62 are coupled to each other by a bidirectional data bus 61 .
At least in ink jet applications, the TAB also includes a Stroke Machine 63 , coupled to the bidirectional data bus 61 , for determining when to transfer a scanline (“stroke”) of the bitmap data from the memory storage buffer 52 to the ink jet printhead's video data input port 54 . This is accomplished by the activation of a “FIFO memory read” signal 64 by the Stroke Machine 63 . The stroke machine 63 provides a video data control signal 65 to the ink jet printhead 12 and controls the multiplexor 56 through a multiplexor control signal 66 . Furthermore, as will be described in further detail below, the stroke machine 63 generates the pixel deposition clock signal 68 for driving the piezoelectric crystal 70 on the corresponding ink jet printhead 12 .
Each digital decoder 36 derives an extracted digital clock signal 72 from the command/data stream transmitted by the raster printer controller 10 over the fiber optic data links 30 , 32 , 34 a-c to the ring. The command/data stream is transmitted by the raster printer controller 10 over the fiber optic ring utilizing a self-clocking data transmission code as commonly known to one of ordinary skill in the art, such as the 8B/10B encoding algorithm as described in U.S. Pat. Nos. 4,486,739 and 4,665,517. The 8B/10B code is a block code which encodes 8-bit data blocks into 10-bit code words for serial transmission. The devices supporting this 8B/10B standard range in frequency from 125 MHZ to 1.5 GHz (today), with future enhancements up to 2 to 4 GHz.
The message processing circuit 44 includes a message processing state machine 76 , an address decrement device 78 , a bi-directional command data buffer circuit 80 which couples the bidirectional data bus 61 to the output data bus 42 (or input data bus 38 ), and a bidirectional discrete data circuit 82 which couples the discrete input and output buffers 48 , 46 to the output data bus 42 (or input data bus 38 ). The bidirectional command data buffer circuit 80 includes an output data register 84 , fed by an output data buffer 86 which is controlled by the output data enable line 88 activated by the message processing state machine 76 . Likewise, the bi-directional command buffer circuit 80 includes an input data register 90 , for feeding an input data buffer 92 which is controlled by the input data enable line 94 activated by the message processing state machine 76 . The bidirectional discrete data circuit 82 includes an output discrete data buffer 96 , controlled by an output discrete data enable line 98 , activated by the message processing state machine 76 . Likewise, the bi-directional discrete data circuit 82 includes an input discrete data buffer 100 , controlled by an input discrete data enable line 102 which is activated by the message processing state machine 76 . The address decrement device 78 is controlled by a control line 104 activated by the message processing state machine 76 .
The discrete output buffer 46 , the discrete input buffer 48 , the bitmap data memory storage buffer 52 , and the other print engine interface components described above, controlled by the message processing state machine 76 , in response to commands embedded in the command/data stream sent over the ring, provide an interface between the print engines 12 and the fiber optic ring. Furthermore, this design allows the raster printer controller 10 to utilize a multiplexed command/data protocol for communicating with the plurality of TABs 20 a - 20 d , in which the raster printer controller transmits a command followed by a corresponding data-stream on the fiber optic ring.
The raster printer controller 10 initiates all commands and manages the allocation of fiber optic bandwidth to receive all print engine discretes and status. Each command contains an address field, and each TAB includes its own internal address. Thus, each TAB 20 a - 20 d monitors the commands using their respective high-speed message processing circuits 44 , and if addressed, the TABs respond appropriately. A TAB 20 a - 20 d will never respond to a command unless that particular TAB is addressed by the command or unless the command is a “broadcast” command (i.e., a particular bit of the address field could be reserved for as a broadcast bit) intended to be processed by all of the TABs. Nevertheless, as discussed above, even if the particular TAB is not addressed by the command, its message processing circuit 44 will always retransmit that command and corresponding data-stream to the next TAB on the daisy-chain (or if the present TAB is the last TAB 20 d on the daisy-chain, back to the raster printer controller). This allows all TABs 20 a - 20 d to see all of the commands all of the time
Referring to FIGS. 1 and 2, the encoder device 35 on the raster printer controller 10 embeds a digital clock signal derived from an internal clock source 73 into the encoded data transmitted on the ring. The digital decoding devices 36 , utilized by each TAB, derive the extracted digital clock signal 72 from the encoded data received on the input port 26 utilizing an on-chip data tracking phase locked loop “PLL” as is known to one of ordinary skill in the art. Therefore, each extracted digital clock signal 72 on each of the TABs 20 a-d , will have substantially the exact frequency, or a frequency that is exactly proportional to, the controller's internal clock source 73 . Therefore, because this extracted digital clock signal 72 is used to create the piezoelectric clock source 66 as described in detail below; each piezoelectric clock source 66 on each TAB will have substantially the exact frequency, eliminating beat frequency drift errors between the pixel swaths.
In one embodiment, the encoder device 35 , utilized by the raster printer controller 10 , and the digital encoders 40 , utilized by the TABs 20 a-d , are CY7B923 HOTLink™ Transmitter devices available through Cypress Semiconductor Corp. (HOTLink is a trademark of Cypress Semiconductor Corp.). These devices convert the 8-bit raw digital data blocks into 10-bit code words which are subsequently transmitted on the ring. The decoder device 39 , utilized by the raster printer controller 10 , and the digital decoders 36 , utilized by the TABs 20 a-d , are CY7B933 HOTLink™ Receiver devices also available through Cypress Semiconductor Corporation. These devices receive the 10-bit coded data, and using a completely integrated PLL clock synchronizer, recover the timing information, in the form of the extracted digital clock signal 72 , necessary for reconstructing the 8-bit raw digital data. The digital encoder 35 of the raster printer controller 10 utilizes the on-board clock source 73 as the byte rate reference clock “CKW” which is used by the encoder to create a bit rate clock embedded into the 10-bit coded data stream transmitted to the fiber optic ring. An on-board clock source 74 is used by the digital decoders 36 as a clock frequency reference (“REFCLK”) for the clock/data synchronizing PLL which tracks the frequency of the incoming bit stream and aligns the phase of its internal bit rate clock to the serial data transmissions. The extracted digital clock signal output 72 is the byte rate clock output of the digital decoders 38 , which is aligned in phase and frequency to the on-board clock source 73 of the raster printer controller. The operation and design of the HOTLink™ CY7B923/933 devices is described in detail in the HOTLink™ User's Guide (Copyright 1995, Cypress Semiconductor Corp.); and in particular, the CY7B923/933 Datasheet section (pp.1-28) of the User's Guide, the disclosure of which is incorporated herein by reference.
As shown in FIG. 3, in ink jet applications, the stroke machine 63 generates the pixel deposition clock signal 68 for driving the piezoelectric crystal 70 on the corresponding ink jet printhead 12 . It will be apparent to those of ordinary skill in the art that, with simple modifications, the design of the stroke machine described herein for ink jet applications can be used to generate the pixel deposition clock signal 68 for all other printing applications such as magnetographic, ion deposition, xerographic, laser, LED and the like. The stroke machine 63 includes a pixel deposition clock generation circuit 110 , a stroke frequency generation circuit 112 , a dispatch control circuit 114 , and a registration control circuit 116 . The extracted digital clock signal 72 , a 25 MHz signal in the present embodiment, is used by the pixel deposition clock generation circuit to generate the pixel deposition clock signal 68 for driving the piezoelectric crystal 70 on the corresponding ink jet printhead 12 .
The extracted digital clock signal 72 drives a digital counter 118 . The MSB 120 of the output count value is the clock used by the stroke frequency generation circuit 112 , the dispatch control circuit 114 , and the registration control circuit 116 . The other bits 122 of the output count value are sent to a memory device 124 which operates as a lookup table. The lookup table includes a voltage amplitude value for every count value 122 received. These voltage amplitude values 126 are sent to a digital-to-analog converter 128 which converts the voltage amplitude values 126 to their corresponding analog voltages 130 . To obtain the pixel deposition clock signal 68 , a voltage amplifier device 132 is used to amplify the analog voltages 130 to the voltage levels required for the pixel deposition clock source.
The voltage amplitude values 126 output by the memory device 124 are derived from the lookup table. The lookup table contains a particular voltage amplitude value 126 corresponding to a particular voltage amplitude level in one period of the pixel deposition clock signal's sinusoidal wave. Thus, the memory device 124 will output the particular voltage amplitude value 126 from the lookup table, depending upon the count value 122 received from the counter 118 . For example, if the count value is a five-bit value (0-31), as in the present embodiment, the lookup table will have thirty-two voltage amplitude values (for transmitting to the digital-to-analog converter 128 ) corresponding to thirty-two uniformly spaced-apart output voltages along a 5 v peak-to-peak (the peak-to-peak voltage output from the digital-to-analog converter is selected depending upon the level of amplification desired to reach the 60V peak-to-peak pixel deposition clock source signal) sinusoidal period as shown in the table below:
Count
Output
Value
Voltage
(122)
(130)
0
0.0
V
1
1.01
V
2
1.97
V
3
2.86
V
4
3.62
V
5
4.24
V
6
4.69
V
7
4.94
V
8
4.99
V
9
4.84
V
10
4.49
V
11
3.95
V
12
3.26
V
13
2.43
V
14
1.50
V
15
0.51
V
16
−0.51
V
17
−1.50
V
18
−2.43
V
19
−3.26
V
20
−3.95
V
21
−4.49
V
22
−4.84
v
23
−4.99
V
24
−4.94
V
25
−4.69
V
26
−4.24
V
27
−3.62
V
28
−2.86
V
29
−1.97
V
30
−1.01
V
31
0.0
V
In the present embodiment, a frequency divider device 134 is inserted before the digital counter 118 to further reduce the frequency of the extracted digital clock signal 72 from 25 MHz to 3.2 MHz. Accordingly, the pixel deposition clock signal 68 for the piezoelectric crystal 70 will have a frequency of {fraction (1/32 )}the frequency of the divided-down digital clock signal 136 (i.e., in the present embodiment, the pixel deposition clock signal 68 will have a frequency of 100 KHz).
The extracted digital clock signal 72 is thus used by each TAB 20 a - 20 d to generate the pixel deposition clock signal 68 for driving the pixel deposition mechanism and/or its drive mechanism on its corresponding print engine 12 a - 12 d . Therefore, because each extracted digital clock signal 72 on each of the TABs 20 a-d will have substantially the exact frequency, as discussed above, synchronization errors between the print engines will be virtually eliminated.
The present invention also includes a system and method to eliminate any phase offset errors between all of the pixel deposition clock signals 68 . As discussed above, the embedded command in the command/data stream transmitted on the ring by the raster printer controller 10 includes an address field, which specifies which TAB is to receive the command. However, in the preferred embodiment every TAB is set up with an identical predefined internal address of zero (address=0); and further, every TAB is configured to modify the address field of every command received by decrements the address field by one prior to retransmitting the command/data stream back to the ring. Thus, for example, if there are four TABs on the ring, and the raster printer controller intends to transmit a command to the fourth TAB on the ring, the address field of the command sent to the first TAB on the ring will equal three. The first TAB will not accept the command because the address field does not equal zero. The first TAB will subtract one from the address field, and it will then retransmit the command to the second TAB on the ring. The second TAB will not accept the command because the address field does not equal zero (address field now equals two). The second TAB will subtract one from the address field, and it will then retransmit the command to the third TAB on the ring. This is repeated for each TAB until the command finally reaches the fourth TAB on the ring. At this time, the address field equals zero, and therefore, the fourth TAB on the ring will accept and process the command. Because the fourth TAB does not know that it is the last TAB on the ring, it will also decrement the value of the address field prior to retransmitting the command back to the raster printer controller.
When the raster printer controller 10 boots up, it does not know the number of TABs 20 a - 20 d on the ring. Accordingly, the raster printer controller will send an initialization command to the ring. The address field of this initialization command will be decremented by each of the TABs on the ring; and thus, upon receiving the initialization command back from the ring, the raster printer controller will be able to determine the number of TABs on the ring and it will know how to address each of the TABs based upon the number of times the address field has been decremented prior to receiving the initialization command back from the ring.
The pixel deposition clock generation circuit 110 includes a preload register 138 coupled to the load port 140 of the digital counter 118 and updatable by the raster printer controller 10 via commands transmitted on the ring. As shown in FIGS. 2 and 3, the state machine 76 for controlling the operations of the message processing circuit 44 , includes a counter reset line 142 , coupled to the reset port 144 of the digital counter 118 . The preload register 138 stores a preload count which the digital counter 118 will start counting from upon being reset by the state machine 76 .
During boot-up, the raster printer controller will send a PHASE SYNC command to each TAB on the ring. This command will instruct the state machine 76 to fill the preload register 138 with the count value contained in the associated data sent with the PHASE SYNC command. The count value loaded into the preload register 138 will correspond to the number of counts the digital counter 118 will count in the time required for a command to propagate from the first TAB 20 a on the ring to the present TAB. Thus, in the present embodiment, the preload register 138 of the first TAB 20 a will be set to 0; in the present embodiment, if the time required for a command to propagate from the first TAB 20 a to the second TAB 20 b on the ring is 1.25 micro-seconds, the preload register 138 for the second TAB will be set to 4 (which corresponds to the number of counts that the digital counter 118 , counting at 3.2 MHz, will count in 1.25 micro-seconds); in the present embodiment, if the time required for a command to propagate from the first TAB 20 a to the third TAB 20 c on the ring is 2.50 micro-seconds, the preload register 138 for the second TAB will be set to 8 (which corresponds to the number of counts that the digital counter 118 , counting at 3.2 MHz, will count in 2.50 micro-seconds); and, in the present embodiment, if the time required for a command to propagate from the first TAB 20 a to the fourth TAB 20 d on the ring is 3.75 micro-seconds, the preload register 138 for the second TAB will be set to 12 (which corresponds to the number of counts that the digital counter 118 , counting at 3.2 MHz, will count in 3.75 micro-seconds).
Preferably, to allow for any number of print engines to be coupled to the ring at any one time, each fiber optic link between the TABs 20 , will have the same length. Thus, the time it takes for a command to propagate from one TAB to the next will always be equal and deterministic; and the preload register 138 preload setting will be calculated by the raster printer controller 10 as directly proportional to the position that a particular TAB will have on the ring (i.e., whether a particular TAB is the first, second, third, etc. TAB on the ring).
To reset the digital counters 138 to their respective preload values, the raster printer controller will broadcast a CLOCK RESET command to the ring. The CLOCK RESET command will, of course first be received and executed by the message processing circuit 44 of the first TAB 20 a on the ring. The state machine 76 of the first TAB's message processing circuit will, in response to the CLOCK RESET command, will activate the counter reset line 142 , which in turn resets the counter 118 to start counting at its corresponding preload value, read from its corresponding preload register 138 . The first TAB will then pass the command to the next TAB 20 b on the ring. Likewise, each successive TAB, upon receiving this command will reset its counter 118 to start counting at its corresponding preload value, read from its corresponding preload register 138 ; and the will then pass the command to the next TAB on the ring, until the command is eventually passed back to the raster printer controller 10 . Because each preload register 138 on each TAB is set to an initial count value corresponding to the time it takes for the command to propagate to the respective TAB, the voltage levels 130 output from the digital-to-analog converter 128 on all the TABs will be equal at any given time. Thus, in addition to each piezoelectric clock source being locked in frequency as described above, each piezoelectric clock source will also be locked in phase.
As shown in FIG. 3, the stroke frequency generation circuit 112 , includes a stroke clock counter 146 and a stroke rate preload register 148 updatable by the raster printer controller 10 . The terminal count output 149 of the stroke clock counter 146 is the stroke clock signal 150 sent to the registration circuit 116 and the dispatch circuit 114 . A typical stroke frequency is approximately 50 Khz. The 50 Khz stroke signal could be embedded into the command/data protocol and sent to each of the TABs; however, this would impair the bandwidth capabilities of the command/data protocol. Therefore, the raster printer controller will send a command within the command/data stream to each of the TABs on the ring at a 1 or 2 Khz rate indicative of the web velocity and/or acceleration. Based upon this velocity/acceleration data in the command, the microcontroller 58 will calculate a preload value to load into the stroke rate preload register 148 which is the accurate count of the number of piezo cycles between the dispatch of real bitmap data. The terminal count output 149 of the stroke clock counter 146 will activate every time the stroke clock counter 146 counts down from the preload value (stored in the preload register 148 ) to zero. All piezo cycles between the stroke periods get null data. Therefore, the stroke frequency generation circuit 112 provides an alternate approach to stroke clock generation when real-time shaft clock transmission over the fiber optic cable is not feasible.
The registration circuit 116 , the design of which is practical knowledge to those of ordinary skill in the art, controls the issuance of the Top of Form signal 152 based upon the stroke clock signal 150 and the piezo cycle frequency signal 120 . In generating the Top of Form signal 152 , the registration circuit may also take into account clamp distance values and/or flight delay values as updated by the raster printer controller 10 using the command/data protocol scheme of the present invention.
The dispatch circuit 114 , the design of which is practical knowledge to those of ordinary skill in the art, controls the issuance of the FIFO Memory Read signal 64 and the multiplexor control signal 66 (for injecting null data) based upon the stroke clock signal 150 , the Top of Form signal 152 , an End of Page signal 154 generated by the bitmap memory storage device 52 , and the piezo cycle frequency signal 120 . In generating the FIFO Memory Read signal 64 , the dispatch circuit may take into account drops-per-dot values and/or stroke width values as updated by the raster printer controller 10 using the command/data protocol scheme of the present invention.
In conclusion, the present invention provides a high-speed printer controller system which is configured to control and “lock-step” a multitude of print engines simultaneously, and which is also configured to synchronize, in frequency as well as phase, all of the pixel deposition mechanisms located within the print engines. Further, while the system and method described herein constitutes the preferred embodiments of the present inventions, it is to be understood that the present inventions are not limited to their precise form, and that variations may be made without departing from the scope of the invention as set forth in the following claims, | The present invention provides a system and method for simultaneously controlling a plurality of print engines connected together (in series, in parallel or otherwise) that facilitates electronic stitching between the print engines. More specifically, the present invention provides a system and method for synchronizing the pixel deposition frequencies and the drive mechanisms between the various inter-connected print engines so as to eliminate synchronization between the print engines. The method for synchronizing the pixel deposition frequencies and/or drive mechanisms between a plurality of print engines comprises the steps of: (a) coupling the plurality of print engines together with a printer controller, (b) embedding a first clock signal in data; (c) transmitting the data to the print engines; (d) each of the print engines receiving the data; (e) each of the print engines deriving a second clock signal from the data received, which is directly proportional to the first clock signal; and (f) each of the print engines driving its corresponding pixel deposition mechanism and/or its drive mechanisms with the second clock signal. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to an electric iron and in particular to a control for the thermostat thereof.
Electric steam irons for household use employ a thermostat for regulating the temperature thereof. Typically, an electric heating element is in heat transfer relation with the soleplate to provide heat thereto. A thermostat senses the temperature of the soleplate and regulates the supply of electrical power to the heating element so that a desired operating temperature for the soleplate can be established.
Many present day electric irons use a rotary control knob that is operated by the user and is mounted on either the handle or the saddle portion of the housing of the iron to enable the user to establish a desired operating temperature for the iron. The rotary control knob is directly connected to the thermostat. Other irons known in the prior art use a linear motion control knob in lieu of a rotary control member to enable the user to adjust the set point of the thermostat. The linear motion of the control member is converted to rotary motion via such means as a rack and pinion system to obtain the desired adjustment of the thermostat. An example of the foregoing is described in U.S. Pat. No. 4,748,755.
The designs of the prior art are limited to simple control motions, e.g. rotary or linear and cannot be used if a complex motion is required.
The aesthetic styling of contemporary irons is becoming quite important as it has been found that the shape and appearance of an iron is an important feature in attracting consumer interest in the iron. The trend in styling an iron is to form the iron housing in rather complex shapes. Further, in irons of rather small size, it has been particularly advantageous to mount the user temperature control on the housing saddle.
Accordingly, it is an object of this invention to provide a user temperature control for the thermostat for an electric iron which can be employed with iron housings having rather complex shapes.
SUMMARY OF THE INVENTION
The foregoing object and other objects of the invention are attained in an electric iron comprising a soleplate and an electric heating element connected to the soleplate for providing heat thereto. A skirt is connected to the soleplate. A housing including a handle portion and a saddle portion is connected to the skirt. A thermostat is mounted on the soleplate for sensing the temperature thereof. An actuator is rotatably connected to the thermostat for establishing an operating temperature for the soleplate. A track is formed in the saddle portion of the housing. The track extends arcuately in a horizontal plane through the skirt and has a vertical slope. A control member is movably retained in the track. Linkage means interconnect the control member to the actuator for converting the combined arcuate and vertical movement of the control member to rotational movement of the actuator.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded perspective view illustrating the iron, the water cassette, and the base for the iron and cassette;
FIG. 1A is an exploded perspective view of the cassette and portion of the base illustrating further details thereof;
FIG. 2 is a side elevational view, partially in section, of the iron being placed on the base;
FIG. 3 is a view similar to FIG. 2 with the iron on the base;
FIG. 4 is a side elevational view of the iron, with parts broken away for clarity, illustrating the iron on the soleplate thereof;
FIG. 5 is a view similar to FIG. 4 with the iron on its heel rest;
FIG. 6 is a view similar to FIGS. 4 and 5 with the iron in the base;
FIG. 7 is a side elevational view of the iron, partially in section, with the iron on the soleplate;
FIG. 8 is an enlarged sectional view of the steam control assembly employed in the iron;
FIG. 9 is an exploded perspective view of the steam control assembly;
FIG. 10 is a side elevational view with parts broken away to illustrate a thermostat control used in the iron;
FIG. 11 is a top plan view of the iron further illustrating the thermostat control;
FIG. 12 is an enlarged sectional view of a portion of the iron illustrating the thermostat control;
FIG. 13 is a side perspective view of the iron with parts broken away to illustrate a spray nozzle assembly employed on the iron;
FIG. 14 is an enlarged perspective view of the spray nozzle assembly;
FIG. 15 is an enlarged perspective view of the nozzle assembly;
FIG. 16 is a side perspective view of the iron with parts broken away to illustrate a reservoir fill control for the iron;
FIG. 17 is a partial sectional view of the iron illustrated in FIG. 16;
FIG. 18 is an exploded perspective view of the iron and base illustrating details of the water reservoir of the iron; and
FIG. 19 is a plan view partially in section and partially broken away of the water reservoir.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the various figures of the drawing, a preferred embodiment of the present invention shall now be described in detail. In referring to the various figures of the drawing, like numerals shall refer to like parts.
Referring specifically to FIGS. 1, 1A, 2 and 3, there is shown an iron assembly 10 embodying the present invention. Iron assembly 10 includes an iron 11, a water cassette 16, and a base 14. Base 14 includes a generally planar platform member 15 terminating in a downwardly inclined portion 41 at its rear end. Base 14 includes an upwardly extending rim 17. Platform 15 includes three standoffs 18 formed from nonabrasive material such as rubber or the like. Standoffs 18 contact the bottom surface of soleplate 54 of the iron when the iron is placed on the base. As standoffs 18 are made from nonabrasive material, the standoffs will not scratch the surface of the soleplate. Further, the standoffs are made from high temperature resistant material so that the iron may be placed directly in base 14 immediately after ironing is discontinued.
Base 14 includes a pair of inwardly extending hook-like projections 20 formed at the top of rim 17 and located at the front of platform 15. Hook-like projections 20 extend into a groove 55 formed between the top of soleplate 54 and the bottom of skirt 58 of the iron when iron 11 is placed on the base. A rectangular slot 26 and a generally circular opening 28 are formed in platform 15 to enable base 14 to be placed on a mounting bracket for enabling iron assembly 10 to be stored on a wall or similar surface when iron 11 is not in use.
Base 14 further includes a pivotal latch 22 having a hook-like portion 27 at one end and an elongated finger 25 extending from hook-like portion 27. The latch is preferably L or reverse J shaped. A handle 23 is connected to latch 22 to pivot the latch between locking and unlocking positions. As shown in FIGS. 2 and 3, latch 22 further includes a spring 24 which keeps the latch in its iron engaged position when the iron is placed on base 14. As illustrated in FIG. 3, a somewhat rectangular slot 29 is formed at the rear face of the iron between soleplate 54 and skirt 58. Hook-like portion 27 projects within slot 29 to retain iron 11 on base 14.
When the iron is not located on the base, for example when the iron is being used, finger 25 extends upwardly above the surface of platform 15. As iron 11 is moved towards the base, as shown in FIG. 2, finger 25 extends into the path of movement of the iron. When the iron is placed on the base, the rear portion of soleplate 54 contacts finger 25. The force developed by soleplate 54 engaging finger 25 rotates latch 22 counterclockwise into its locking position. When the user desires to remove iron 11 from base 14, the user rotates handle 23 clockwise to pivot latch 22 clockwise to release the iron. Even if engaging finger 25 is moved below the plane of platform 15 when the iron is not in the base, when the front of the iron is placed in the base so that projections 20 are inserted into groove 55, the rear face of skirt 58 will contact portion 27 and rotate the latch clockwise until finger 25 contacts soleplate 54 of iron 11. Further movement of the iron into the base will result in the latch pivoting counterclockwise into its locking position.
As shown in FIGS. 1 and 1A, base 14 includes a rear section 34 defining the rear wall of the base. Rear section 34 includes a vertically extending inwardly projecting abutment member 30 and a tail portion 32 extending upwardly from the top face 33 of rear section 34. Tail portion 32 comprises a generally horizontal extending floor member 35, a pair of inwardly inclined sidewalls 37 and an inwardly inclined front wall 39. The rear of tail section 32 is open.
Water cassette 16 includes a bottom wall 36 having a generally rectangularly shaped slot 43 formed therein. Slot 43 is configured to complement the shape of tail portion 32 so that the tail portion may be slid within the slot to join the cassette to the base. Slot 43 terminates in a vertical wall 45 which mates with vertical wall 39 of tail portion 32 when the tail portion is inserted into the slot. Cassette 16 further includes a plurality of horizontally extending ribs 38 to give rigidity to the wall 49 of cassette 16. The ribs also function as a cordwrap for power cord 59 when the iron is stored. A cap 51 is threadably received on the spout (not shown) of the cassette.
Housing 12 includes a nose portion 50. Housing 12 is attached to skirt 58 which, in turn, is attached to soleplate 54. Groove 55 is formed between the top surface of soleplate 54 and the bottom surface of skirt 58. Groove 55 enables the user to readily iron garments having buttons and also functions to receive projections 20 as previously described. Skirt 58 is generally L-shaped and comprises a horizontal leg 58A and a substantially vertical leg 58B.
Spray nozzle 52 extends forwardly of nose portion 50 of housing 12. Nose portion 50 further includes fill opening 48. Housing 12 further includes handle 40. Steam control valve 42 extends upwardly from handle 40. Handle 40 further includes spray pump control 44. Control 44 activates pump 44A (See FIG. 17).
An on/off switch 46 is positioned on the saddle portion 47 of housing 12. An arcuate opening 62 is formed in saddle portion 47. The arcuate opening forms a track for thermostat control knob 60. Arcuate opening 62 is inclined downwardly about 2° from its rear to its forward faces. The inclination of the track follows the general contour of saddle portion 47.
A rear cover 56 is attached to the outer surface of vertical leg 58B of skirt 58. An opening is formed between the outer surface of leg 58B and the opposed surface of cover 56. A cord bushing 57 extends outwardly through the opening. Cord bushing 57 surrounds power cord 59. Power cord 59 is connected to a source of electrical power for delivering electrical power to the iron for actuating among other components the electrical resistance heater (shown in FIG. 18) associated with the soleplate in heat transfer relation as is conventional in the art. A rotatable foot-like member 70 is attached to cover 56 for a reason to be more fully explained hereinafter.
Referring now in detail to FIGS. 4-9, the function of foot member 70 in conjunction with the steam control, on/off switch, and base shall be more fully explained.
As illustrated, foot member 70 is pivotally connected to cover 56 at pivot 72. As shown in FIG. 4, when the soleplate is placed in a horizontal plane and the iron is supported on an underlying garment on the surface of the ironing board, foot member 70 lies generally parallel to the soleplate and is spaced above the underlying support surface. An actuator arm 102 of steam control assembly 100 extends within the pivotal path of movement of foot member 70. When the iron is positioned as shown in FIG. 4, actuator arm 102 is urged towards cover 56.
Further as illustrated in FIG. 4, on/off switch 46 is in its on position connecting iron 11 to the source of electrical power. On/off switch 46 is pivotally connected to skirt 58 via bracket 76. On/off switch 46 includes a trigger member 78. Rotatable actuator 80 is positioned in the path of movement of foot member 70 when the iron is placed on base 14 as illustrated in FIG. 6. Movement of actuator 80 results in contact between the actuator and trigger member 78.
FIG. 5 illustrates the iron supported on its heel rest. The rear surface of cover 56 defines the heel rest for the iron. As the iron is rotated from its horizontal position to its heel rest position, the weight of the iron provides a force to rotate foot member 70 in a counterclockwise direction to achieve the position illustrated in FIG. 5. The weight of the iron also provides a force which causes the foot member to translate parallel to the soleplate in the direction of the arrow shown in FIG. 5. When so translated in the direction shown, notch 81 of the foot member engages a complementary surface 82 on the cover to latch the foot member in the position illustrated. Spring 83 is compressed as a consequence of the rotational movement of foot member 70.
When foot member 70 has been rotated to the position illustrated in FIG. 5, the foot member extends the effective length of the heel rest. It should be noted that iron 11 has a rather unique shape. Particularly, it should be noted that the upwardly extending leg 58B of skirt 58 is at an obtuse angle relative to horizontal leg 58A of the skirt. Typically, the upwardly extending leg of a skirt is perpendicular or at an acute angle to the horizontally extending leg of the skirt. Thus, the cover of the iron attached to the upwardly extending leg readily provides a suitable support for the iron when the iron is placed in the heel rest position. Due to the rather unique shape of the present iron 11, and in the absence of foot member 70, the weight of the iron will cause the iron to rotate in a counterclockwise direction if the iron were placed on cover 56. Foot member 70 when extended in the position shown in FIG. 5, increases the length of cover 56 so that the fulcrum or pivot point for the iron is shifted to the left (towards the soleplate) as viewed in FIG. 5 so that the clockwise moment arm tending to maintain the iron on its heel rest increases in magnitude and the counterclockwise moment arm decreases in magnitude. A relatively light weight 86 may be added to the handle to increase the magnitude of the clockwise moment arm to further insure the stability of the iron when the iron is placed on its heel rest. Since the fulcrum has been moved as a consequence of the extension of foot member 70, weight 86 may be relatively light so as not to unduly increase the total weight of the iron.
As illustrated in FIG. 5, the rotational movement of foot member 70 results in leg 70A thereof contacting actuator arm 102 of steam valve assembly 100. The force provided by leg 70A moving into contact with actuator arm 102 of steam valve 100 moves the actuator to the left as viewed in FIG. 4 or upwardly as viewed in FIG. 5. As shall be more fully explained hereinafter, this movement of the actuator arm results in the stoppage of flow of water from water reservoir 120 into steam chamber 122.
When iron 11 is moved from the heel rest position illustrated in FIG. 5 to the ironing position illustrated in FIG. 4, notch 81 disengages from surface 82, enabling foot member 70 to rotate in a clockwise direction as viewed in FIG. 4. Spring 83 provides the force to rotate foot member 70 from its heel rest position (FIG. 5) to the ironing position (FIG. 4). If the foot member is jammed into its heel rest position when the iron is returned to its ironing position, the lower edge 70D of foot member 70 extends below the bottom surface of soleplate 54. Edge 70D contacts the underlying support surface (ironing board or garment) and the force of such engagement triggers the foot member to translate in the direction opposite to the arrow illustrated in FIG. 5. This movement releases notch 81 from surface 82.
Referring now to FIG. 6, iron 11 is shown mounted on base 14. When the iron is placed on its base, abutment member 30 of rear section 34 of the base engages foot member 70 to rotate foot member 70 in a counterclockwise direction. As noted previously, the foot member is rotated in a counterclockwise direction when the iron is placed on its heel rest; however the shape of abutment member 30 causes the foot member to have a larger arc of rotation when the iron is placed on base 14 than when the iron is placed on its heel rest.
Foot member 70 is rotated counterclockwise when iron 11 is placed on the base, to move actuator arm 102 of steam valve assembly 100 to the left as shown in FIG. 6. Further, upper face 70C of the foot member engages actuator 80 associated with on/off switch 46. The actuator in turn engages trigger member 78 of the switch to rotate the switch in a counterclockwise direction from its on position to its off position. Thus, when iron 11 is placed on base 14, engagement of foot member 70 with abutment member 30 results in the foot member moving the actuator arm 102 to discontinue flow of water into steam chamber 122 and also results in the electrical power to the iron being interrupted since the on/off switch is moved into its off position. Inclined portion 41 of platform member 15 enables foot member to rotate to the position shown in FIG. 6 when the iron is placed on base 14. Inclined portion 41 accepts the extended portion of foot member 70 terminating in edge 70D.
Referring now to FIGS. 7, 8, 9, and 18, steam control assembly 100 shall now be described in detail. Steam control assembly 100 is mounted in a track 124 formed in the top surface 126 of skirt 58 and includes a longitudinally extending actuator arm 102 which, has one end as previously described extending into the path of travel of foot member 70. As shown in FIG. 9, actuator arm 102 is connected to a rib 106 which in turn is connected to an actuator fork 108 having a U-shaped slot 110 formed therein. One end 112 of a spring bellows 114 extends within slot 110.
The other end of spring bellows 114 terminates in a longitudinally extending pin 116. As shown in FIGS. 7 and 8, the pin and associated end of the spring bellows extend into an orifice 130 of conduit 132. Conduit 132 extends outwardly from the sidewall 134 of valve housing 136. Valve housing 136 includes a chamber 128. Passageway 140 communicates orifice 130 with chamber 128. Passageway 140 also communicates chamber 128 with outlet 142. Pin 116 extends through the passageway into the chamber to clean the passageway and meter the flow of water from the chamber into the passageway. End 112 of bellows 114 closes the passageway when the bellows is moved to the left as viewed in FIG. 8 and interrupts flow between chamber 128 and outlet 142. Actuator arm 102 moves bellows 114 to terminate the flow of water from water reservoir 120 into steam chamber 122.
Housing 14 includes steam control valve 42 for enabling the user to operate iron 11 in either dry or steam modes. FIG. 7 illustrates control valve 42 when the iron is being operated in its steam mode. Steam control valve 42 is connected via valve stem 144 to valve 146. As shown, when valve 146 is spaced above chamber 128, water will flow from water reservoir 120 into valve chamber 128 and thence into outlet 142 and steam chamber 122. When in the position shown, iron 11 may be used to steam and iron a garment. If dry ironing is desired, control valve 42 is moved downwardly to move valve stem 144 and attached valve 146 downwardly to close off the flow of water from reservoir 120 into chamber 122.
When the iron is rotated into its heel rest position, foot member 70 is rotated in a counterclockwise direction which, in turn, moves actuator arm 102 to the left as viewed in FIGS. 7 and 8. Movement of the actuator arm in this manner results in end 112 of bellows 114 closing the orifice to discontinue the flow of water from the water reservoir through chamber 128 and then into outlet 142. The same movement of the foot member and actuator arm occurs when the iron is placed in the base and the foot member engages abutment member 30.
Referring now to FIGS. 10-12, there is disclosed a preferred embodiment of the thermostat control for iron 11. As noted previously, saddle 47 of the iron includes an arcuate track 62 in which control knob 60 is movably mounted. Track 62 extends arcuately in a horizontal plane through the saddle portion and, as shown in FIG. 12 has a vertical slope so that track 62 is angled downwardly from the rear end of iron 11 towards nose portion 50 thereof. The slope of the track is substantially 2° and the arcuate travel of knob 60 in track 62 is substantially 10°.
As shown in FIG. 12, control knob 60 is connected to a vertically extending pin 150. The vertical axis of pin 150 is offset inwardly towards the center of iron 11 with respect to a vertical plane passing through the center of knob 60. Pin 150 extends within horizontally extending slot 152 of actuator lever 154. Lever 154 is integrally formed with rotatable actuator 156. Actuator 156 is attached to upwardly extending shaft 149 of thermostat 148. Thermostat 148 senses the temperature of soleplate 54. Pin 150 and actuator lever 154 comprise a linkage connecting control knob 60 to actuator 156, which in turn controls the operation of thermostat 148. The length of the radius establishing arcuate track 62 is substantially larger when compared to the length of the radius establishing the rotational path of movement of actuator 156. Movement of control knob 60 through a 10° arcuate path of travel results in substantially a 120° rotational movement of actuator 156 and shaft 149 of thermostat 148.
As shown in FIG. 11, as control knob 60 is arcuately moved along track 62, pin 150 transfers the force developed by movement of the knob to the actuator lever 154 and then to actuator 156 for establishing a set or operating point for thermostat 148. As the arcuate path for travel of knob 60 is substantially less than the arcuate path of travel of actuator 156, the distance between pin 150 and the center of rotation of actuator 156 is constantly changing. Further, the vertical position of the pin relative to slot 152 changes during movement of knob 60 due to the inclination of track 62. Pin 150 slides within slot 152 of lever 154 as a consequence of the movement of the control knob. In effect, the slot compensates for the vertical movement of pin 150 relative to lever 154 and also enables the distance between pin 150 and the center of rotation of actuator 156 to change. The described control enables thermostat control knob 60 to be mounted on a saddle having a rather complex geometrical shape.
Referring now to FIGS. 13-15, there is disclosed a preferred embodiment of the spray nozzle assembly 52 as used in the present iron assembly 10. Spray nozzle assembly 52 is mounted at the nose portion 50 of iron 11. Spray pump control 44 extends upwardly from handle 40 of iron 11. When the user desires to spray an underlying garment, the user presses downwardly on pump control 44 which creates a pumping action to pump water via pump 44A (See FIG. 17) from water reservoir 120 through line 182 and then through nozzle 52A of nozzle assembly 52. Nozzle assembly 52 includes nozzle 52A having a generally frusto-conically shaped outer wall 162 and an end wall 164 having a spray opening 166 generally located at the center thereof. Outer wall 162 defines a longitudinally extending bore 168. A spreader element 170 is disposed within the bore for reciprocating movement therein. Spreader element 170 includes a generally enlarged cylindrical head 172, a longitudinally extending body portion 174 and a spherical spreader end 176. A coupling 178 extends within an open end 180 of nozzle assembly 52. Line 182 is fitted over the outer end of coupling 178 to communicate bore 184 with water reservoir 120. Coupling 178 includes a valve seat 188 facing towards spherical end 176 of spreader element 170.
In operation, when the user desires to spray a garment being ironed, the user pumps control 44 to pump water from water reservoir 120 via pump 44A through line 182, thence into bore 168. The force of the water moves the spreader to the left as viewed in FIG. 14 so that surface 190 of the spreader contacts the inwardly extending pads 192 of nozzle assembly 52. Cylindrical head 172 of spreader element 170 directs the water in bore 168 towards the perimeter. Raised pads 192 comprise a plurality of circumferentially spaced members disposed on the interior surface of end wall 164. The water forced to the perimeter of bore 168 flows under the spreader and then radially inwardly between the raised pads to the centrally located orifice 166. The water is then sprayed in a desired pattern onto the garment.
When the user ceases pumping control 44, the return action of pump 44A creates a suction on line 182 moving spreader element 170 to the right as shown in FIG. 14 which results in spherical end 176 engaging seat 188 to create a seal. The seal prevents air from being sucked into the discharge side of pump 44A.
Referring now to FIGS. 16 and 17, the details of the fill system for water reservoir 120 shall be described in detail. A somewhat elliptically shaped opening 48 is formed in housing 12 at the nose portion or front end thereof 50. Opening 48 communicates with a water flow passage 194 defined between downwardly extending ribs 196. Ball valve or float valve 198 is disposed within flow passage 194. The specific gravity of ball valve 198 is less than one so that the valve floats on water. Lower wall 208 of reservoir 120 and the ribs entrap the ball valve. When the ball valve is moved upwardly within the passage, the ball valve seats against valve seat 202 to prevent water from splashing outwardly through opening 48.
When the user is filling water reservoir 120, a source of water is placed in communication with flow opening 48. For example, flow opening 48 may be placed beneath a faucet or cassette 16 may be used to add water to reservoir 120. Water fills the water reservoir causing float valve 198 to move upwardly in passage 194. When the iron is in normal use and water is in the reservoir, the float valve again is moved upwardly since its specific gravity is less than one. Valve 198 is forced against seat 202 to prevent the water from splashing outwardly through opening 48 during normal ironing use.
Further, when the iron is placed in a vertical position, for example when it is desired to steam or iron a garment held in a vertical position, if water level in the reservoir is relatively high, the water will cause ball valve 198 to remain seated, preventing water from splashing out when the iron is held upright.
Referring now to FIGS. 18 and 19, the structure of reservoir 120 shall now be more fully described. Reservoir 120 includes a plurality of walls 204 and 206 which extend upwardly part way from the top of lower or bottom wall 208 of reservoir 120. Walls 204 and 206 serve as dam means or as weir means to separate the reservoir into a forward compartment 210 and a rear compartment 211. It should be noted opening 212 in bottom wall 208 is located at the rear of forward compartment 210. In effect, walls 204 and 206 serve as dam means to provide a head of water above opening 212 when the iron is held in a vertical position. The head of water in forward compartment 210 enables iron 11 to be used as a steamer while the iron is held in a vertical position. By trapping water in the forward compartment when the iron is turned vertical, water will continue to flow from reservoir 120, through opening 212, steam valve chamber 128 and then into steam chamber 122. The iron will generate steam for a period of time until the supply of trapped water in compartment 210 is exhausted.
To replenish the supply of water in forward compartment 210, the user need only tip the iron forward and water in rear compartment 211 will flow into the forward compartment. When the iron is returned to its vertical position, divider walls 204 and 206 will retain the water in the forward compartment.
A water window 214 is disposed on saddle portion 47 and in alignment with rear compartment 211. When the iron is placed on its heel rest or held vertical, the user may look at the water window which, since it is in vertical alignment with the rear compartment provides an accurate indicator of the amount of water remaining in the water reservoir. If there is insufficient water in the reservoir to satisfy the steaming function, additional water can be added to reservoir 120 from cassette 16 or from a sink faucet.
While a preferred embodiment of the present invention has been described and illustrated, the invention should not be limited thereto but may be otherwise embodied within the scope of the following claims. | An electric iron includes an electrically heated soleplate and a housing including a handle portion and a saddle portion. A thermostat is mounted on the soleplate for sensing the temperature thereof. An actuator is rotatably connected to the thermostat for establishing an operating temperature for the soleplate. A track is formed in the saddle portion of the housing. The track extends arcuately in a horizontal plane through the skirt and has a vertical slope. A control member is movably retained within the track. A linkage interconnects the control member to the actuator for converting the combined arcuate and vertical movement of the control member to rotational movement of the actuator. | 3 |
PRIORITY OF INVENTION
[0001] This application claims priority under 35 U.S.C. 119(e) from U.S. Provisional Patent Application No. 60/971,395, filed 11 Sep. 2007, the contents of which are incorporated herein in their entirety.
BACKGROUND OF THE INVENTION
[0002] International Patent Application Publication Number WO 2004/046115 provides certain 4-oxoquinolone compounds that are useful as HIV integrase inhibitors. The compounds are reported to be useful as anti-HIV agents.
[0003] International Patent Application Publication Number WO 2005/113508 provides certain specific crystalline forms of one of these 4-oxoquinolone compounds, 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid. The specific crystalline forms are reported to have superior physical and chemical stability compared to other physical forms of the compound.
[0004] There is currently a need for improved methods for preparing the 4-oxoquinolone compounds reported in International Patent Application Publication Number WO 2004/046115 and in International Patent Application Publication Number WO 2005/113508. In particular, there is a need for new synthetic methods that are simpler or less expensive to carry out, that provide an increased yield, or that eliminate the use of toxic or costly reagents.
SUMMARY OF THE INVENTION
[0005] The present invention provides new synthetic processes and synthetic intermediates that are useful for preparing the 4-oxoquinolone compounds reported in International Patent Application Publication Number WO 2004/046115 and in International Patent Application Publication Number WO 2005/113508.
[0006] Accordingly, in one embodiment, the present invention provides a method for preparing a compound of formula 10
[0000]
[0000] or a pharmaceutically acceptable salt thereof, in which a compound of formula 4
[0000]
[0000] or a salt thereof is prepared and converted into a compound of formula 10, characterized in that the compound of formula 4 is prepared from a compound of formula 15
[0000]
[0000] or a salt thereof, by the steps of replacing the bromine atom with a carboxyl group, and replacing the hydroxyl group with a hydrogen atom.
[0007] In another embodiment the invention provides a compound of formula 15:
[0000]
[0000] or a salt thereof.
[0008] In another embodiment the invention provides a method for preparing a compound of formula 15:
[0000]
[0000] or a salt thereof comprising converting a corresponding compound of formula 14:
[0000]
[0000] to the compound of formula 15 or the salt thereof.
[0009] In another embodiment the invention provides a compound of formula 15a:
[0000]
[0000] that is useful as an intermediate for preparing the 4-oxoquinone compounds.
[0010] In another embodiment the invention provides a compound of formula 16:
[0000]
[0000] that is useful as an intermediate for preparing the 4-oxoquinone compounds.
[0011] The invention also provides other synthetic processes and synthetic intermediates disclosed herein that are useful for preparing the 4-oxoquinone compounds.
DETAILED DESCRIPTION
[0012] The following definitions are used, unless otherwise described: halo is fluoro, chloro, bromo, or iodo. Alkyl denotes both straight and branched groups, but reference to an individual radical such as propyl embraces only the straight chain radical, a branched chain isomer such as isopropyl being specifically referred to.
[0013] It will be appreciated by those skilled in the art that a compound having a chiral center may exist in and be isolated in optically active and racemic forms. Some compounds may exhibit polymorphism. It is to be understood that the present invention encompasses processes for preparing any racemic, optically-active, polymorphic, tautomeric, or stereoisomeric form, or mixtures thereof, of a compound described herein, it being well known in the art how to prepare optically active forms (for example, by resolution of the racemic form by recrystallization techniques, by synthesis from optically-active starting materials, by chiral synthesis, or by chromatographic separation using a chiral stationary phase).
[0014] Specific and preferred values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
[0015] Specifically, C 1 -C 6 alkyl can be methyl, ethyl, propyl, isopropyl, butyl, iso-butyl, sec-butyl, pentyl, 3-pentyl, or hexyl.
[0016] A specific value for R a is methyl.
[0017] A specific value for R b is methyl.
[0018] A specific value for R c is 1-imidazolyl.
[0019] A specific value for R is ethyl.
[0020] In one embodiment, the compound of formula 4 or a salt thereof is prepared by metalating the compound of formula 15 or a salt thereof and treating with carbon dioxide to provide the compound of formula 3:
[0000]
[0000] or a salt thereof, and then converting the compound of formula 3 into a compound of formula 4.
[0021] The compound of formula 15 or a salt thereof may be, for example, a salt of formula 15a
[0000]
[0022] In another embodiment, the compound of formula 15 is converted into a compound of formula 16
[0000]
[0000] which is then metalated and treated with carbon dioxide to afford a compound of formula 4.
[0023] It will be appreciated that the step of replacing the bromine atom with a carboxyl group is a carboxylation. This step may conveniently be effected by metalation, for example, by treatment with isopropylmagnesium chloride or isopropylmagnesium chloride lithium chloride complex, followed by treatment with carbon dioxide.
[0024] It will also be appreciated that the step of replacing the hydroxyl group with a hydrogen atom is a dehydroxylation. This step may be effected by treatment with a trialkylsilane, such as triethylsilane, conveniently in the presence of trifluoroacetic acid.
[0025] In another embodiment of the invention the compound of formula 15 or a salt thereof is converted to a compound of formula 3:
[0000]
[0000] or a salt thereof. For example, the compound of formula 15 or a salt thereof can be converted to the compound of formula 3 or a salt thereof by metalating the compound of formula 15 or the salt thereof (e.g. by treatment with isopropylmagnesium chloride) and treating with carbon dioxide to provide the compound of formula 3 or the salt thereof.
[0026] In another embodiment of the invention the compound of formula 3 or the salt thereof is converted to a compound of formula 4:
[0000]
[0000] or a salt thereof.
[0027] In another embodiment of the invention the compound of formula 4 is converted to a compound of formula 5′:
[0000]
[0000] or a salt thereof, wherein R c is a leaving group (such as halo or 1-imidazolyl). The carboxylic acid functional group of Compound 4 can be converted to an activated species, for example an acid chloride or an acyl imidazolide (Compound 5′) by treatment with a suitable reagent, such as, for example, thionyl chloride, oxalyl chloride, cyanuric chloride or 1,1′-carbonyldiimidazole in a suitable solvent (e.g., toluene or tetrahydrofuran). Any suitable leaving group R c can be incorporated into the molecule, provided the compound of formula 5′ can be subsequently converted to a compound of formula 6. The reaction can conveniently be carried out using about 1 equivalent of 1,1′-carbonyldiimidazole in tetrahydrofuran. In one embodiment, the compound of formula 5′ is a compound of formula 5a.
[0000]
[0000] The compound of formula 4 may be converted to the compound of formula 5a by treatment with 1,1′-carbonyldiimidazole.
[0028] In another embodiment of the invention a compound of formula 5′ or a salt thereof, can be converted to a compound of formula 6:
[0000]
[0000] or a salt thereof, wherein R is C 1 -C 6 alkyl. In one embodiment, the compound of formula 5′ is converted to the compound of formula 6 by treatment with the corresponding mono-alkylmalonate salt. An example of a mono-alkylmalonate salt is potassium monoethylmalonate. For example, a compound of formula 5′ can be combined with about 1 to 5 equivalents of a monoalkyl malonate salt and about 1 to 5 equivalents of a magnesium salt in a suitable solvent. Conveniently, a compound of formula 5′ can be combined with about 1.7 equivalents of potassium monoethyl malonate and about 1.5 equivalents of magnesium chloride. A suitable base, for example triethylamine or imidazole, can be added to the reaction. The reaction can conveniently be carried out at an elevated temperature (e.g., about 100±50° C.) and monitored for completion by any suitable technique (e.g., by HPLC). Upon completion of the reaction, Compound 6 can be isolated using any suitable technique (e.g., by chromatography or crystallization).
[0029] In another embodiment of the invention the compound of formula 6 or a salt thereof, can be converted to a corresponding compound of formula 7:
[0000]
[0000] wherein R a and R b are each independently C 1 -C 6 alkyl; and R is C 1 -C 6 alkyl. Compound 6 can be converted to an activated alkylidene analog, such as Compound 7, by treatment with a formate group donor such as a dimethylformamide dialkyl acetal (e.g., dimethylformamide dimethyl acetal) or a trialkylorthoformate. The reaction can be carried out at elevated temperature (e.g., about 100±50° C.). This reaction may be accelerated by the addition of an acid catalyst, such as, for example, an alkanoic acid, a benzoic acid, a sulfonic acid or a mineral acid. About 500 ppm to 1% acetic acid can conveniently be used. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). Compound 7 can be isolated or it can be used directly to prepare a compound of formula 8 as described below.
[0030] In another embodiment of the invention the compound of formula 7 can be converted to a corresponding compound of formula 8:
[0000]
[0000] wherein R is C 1 -C 6 alkyl. Compound 7 can be combined with (S)-2-amino-3-methyl-1-butanol (S-Valinol, about 1.1 equivalents) to provide compound 8. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). The compound of formula 8 can be isolated or used directly to prepare a compound of formula 9 as described below.
[0031] In another embodiment, the invention provides a method for preparing a compound of formula 9:
[0000]
[0000] wherein R is C 1 -C 6 alkyl, comprising cyclizing a corresponding compound of formula 8:
[0000]
[0000] Compound 8 can be cyclized to provide Compound 9 by treatment with a silylating reagent (e.g., N, 0-bis(trimethylsilyl)acetamide, N,O-bis(trimethylsilyl)trifluoroacetamide or hexamethyldisilazane). The reaction can be conducted in a polar aprotic solvent (e.g., dimethylformamide, dimethylacetamide, N-methylpyrrolidinone or acetonitrile). A salt (e.g., potassium chloride, lithium chloride, sodium chloride or magnesium chloride) can be added to accelerate the reaction. Typically, about 0.5 equivalents of a salt such as potassium chloride is added. The reaction may be conducted at elevated temperature (e.g., a temperature of about 100±20° C.) if necessary to obtain a convenient reaction time. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). During the workup, an acid can be used to hydrolyze any silyl ethers that form due to reaction of the silylating reagent with the alcohol moiety of compound 8. Typical acids include mineral acids, sulfonic acids, or alkanoic acids. One specific acid that can be used is aqueous hydrochloric acid. Upon completion of the hydrolysis, Compound 9 can be isolated by any suitable method (e.g., by chromatography or by crystallization). In the above conversion, the silating reagent transiently protects the alcohol and is subsequently removed. This eliminates the need for separate protection and deprotection steps, thereby increasing the efficiency of the conversion.
[0032] In another embodiment of the invention the compound of formula 9 is converted to a compound of formula 10:
[0000]
[0000] Compound 9 can be converted to Compound 10 by treatment with a suitable base (e.g., potassium hydroxide, sodium hydroxide or lithium hydroxide). For example, about 1.3 equivalents of potassium hydroxide can conveniently be used. This reaction may be conducted in any suitable solvent, such as, for example, tetrahydrofuran, methanol, ethanol or isopropanol, or a mixture thereof. The solvent can also include water. A mixture of isopropanol and water can conveniently be used. The progress of the reaction can be monitored by any suitable technique (e.g., by HPLC). The initially formed carboxylate salt can be neutralized by treatment with an acid (e.g., hydrochloric acid or acetic acid). For example, about 1.5 equivalents of acetic acid can conveniently be used. Following neutralization, Compound 10 can be isolated using any suitable technique (e.g., by chromatography or crystallization).
[0033] In another embodiment of the invention the compound of formula 10 can be crystallized by adding a seed crystal to a solution that comprises the compound of formula 10. International Patent Application Publication Number WO 2005/113508 provides certain specific crystalline forms of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid. The entire contents of International Patent Application Publication Number WO 2005/113508 is incorporated herein by reference (in particular, see pages 12-62 therein). The specific crystalline forms are identified therein as Crystal Form II and Crystal Form III. Crystal form II has an X-ray powder diffraction pattern having characteristic diffraction peaks at diffraction angles 2θ(°) of 6.56, 13.20, 19.86, 20.84, 21.22, and 25.22 as measured by an X-ray powder diffractometer. Crystal form III has an X-ray powder diffraction pattern having characteristic diffraction peaks at diffraction angles 2θ(°) of 8.54, 14.02, 15.68, 17.06, 17.24, 24.16, and 25.74 as measured by an X-ray powder diffractometer. International Patent Application Publication Number WO 2005/113508 also describes how to prepare a crystalline form of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carboxylic acid that have an extrapolated onset temperature of about 162.1° C., as well as how to prepare a seed crystal having a purity of crystal of not less than about 70%. Accordingly, seed crystals of 6-(3-chloro-2-fluorobenzyl)-1-[(S)-1-hydroxymethyl-2-methylpropyl]-7-methoxy-4-oxo-1,4-dihydroquinolone-3-carb oxylic acid can optionally be prepared as described in International Patent Application Publication Number WO 2005/113508. Advantageously, the process illustrated in Scheme I below provides a crude mixture of Compound 10 that can be directly crystallized to provide Crystal Form III without additional purification (e.g. without the prior formation of another polymorph such as Crystal Form II, or without some other form of prior purification), see Example 6 below.
[0034] In cases where compounds identified herein are sufficiently basic or acidic to form stable acid or base salts, the invention also provides salts of such compounds. Such salts may be useful as intermediates, for example, for purifying such compounds. Examples of useful salts include organic acid addition salts formed with acids, for example, tosylate, methanesulfonate, acetate, citrate, malonate, tartarate, succinate, benzoate, ascorbate, a-ketoglutarate, and a-glycerophosphate. Suitable inorganic salts may also be formed, including hydrochloride, sulfate, nitrate, bicarbonate, and carbonate salts.
[0035] Salts may be obtained using standard procedures well known in the art, for example by reacting a sufficiently basic compound such as an amine with a suitable acid affording an anion. Alkali metal (for example, sodium, potassium, or lithium) or alkaline earth metal (for example calcium or magnesium) salts of carboxylic acids, for example, can also be made.
[0036] The invention will now be illustrated by the following non-limiting Examples.
[0037] An integrase inhibitor of formula 10 can be prepared as illustrated in the following Scheme 1.
[0000]
Example 1
Preparation of Compound 3
[0038]
[0039] Compound 14 (10 g) was combined with 28 mL of THF and 9 mL of bisdimethylaminoethyl ether before being cooled to 0° C. Isopropylmagnesium chloride (22.9 mL of a 2.07 M solution in THF) was added and the mixture was allowed to warm to room temperature overnight. Additional isopropylmagnesium chloride (5 mL) was added to improve conversion before 3-chloro-2-fluorobenzaldehyde (4.4 mL) was added. After stirring at ambient temperature for 2 hours 38.6 g of a 14 wt % THF solution of isopropylmagnesium chloride lithium chloride complex was added. After stirring overnight at ambient temperature CO 2 gas was bubbled into the reaction mixture. When conversion was complete the reaction was quenched to pH<3 with 2 M hydrochloric acid. The phases were separated and the organic phase was extracted with ethyl acetate. The combined organic layers were washed with saturated aqueous sodium chloride. The organic phase was concentrated and the product precipitated by the addition of MTBE. The slurry was filtered and the product air dried to yield Compound 3: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.15 (br s, 1H), 7.81 (s, 1H), 7.42 (t, J=7.2 Hz, 1H), 7.26 (t, J=6.8 Hz, 1H), 7.15 (t, J=7.8 Hz, 1H), 6.77 (s, 1H), 6.09 (d, J=4.7 Hz, 1H), 5.90 (d, J=4.9 Hz, 1H), 3.84 (s, 3H), 3.80 (s, 3H).
Example 2
Preparation of Compound 4
[0040] Triethylsilane (6.83 g) was added to trifluoroacetic acid (33.13 g) that had been pre-cooled in an ice bath. Compound 3 (10 g) was added to the mixture keeping the temperature below 15° C. After stirring for 2 h MTBE was added to precipitate the product. The slurry was filtered and the product washed with additional MTBE. After drying, 9.12 g of Compound 4 was isolated: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.11 (br s, 1H), 7.47 (s, 1H), 7.42-7.38 (m, 1H), 7.14-7.08 (m, 2H), 6.67 (s, 1H), 3.87-3.84 (m, 8H).
[0041] Alternatively, Compound 4 can be prepared as follows.
[0042] Triethylsilane (7.50 g) was added to trifluoroacetic acid (49.02 g) that had been pre-cooled in an ice bath. Compound 3 (14.65 g) was added to the mixture keeping the temperature below 15° C. After stirring for 1 h a solution of 17.63 g sodium acetate in 147 mL methanol was added. The mixture was heated to reflux for 3 hours then cooled to 0° C. The slurry was filtered and the product washed with additional methanol. After drying 12.3 g of Compound 4 (89.7% yield) was isolated: 1 H NMR (DMSO-d 6 , 400 MHz) δ 12.11 (br s, 1H), 7.47 (s, 1H), 7.42-7.38 (m, 1H), 7.14-7.08 (m, 2H), 6.67 (s, 1H), 3.87-3.84 (m, 8H).
Example 3
Preparation of Compound 5a
[0043] Imidazole (0.42 g) and 1,1′-carbonyldiimidazole (5.49 g) were slurried in 30 mL of THF at ambient temperature. Compound 4 (10 g) was added in one portion and the mixture was stirred at ambient temperature until the reaction was complete by HPLC. The resulting slurry was filtered and the solids washed with MTBE. The solids were dried to yield Compound 5a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.99 (s, 1H), 7.52 (s, 1H), 7.41-7.38 (m, 1H), 7.30 (s, 1H), 7.12-7.08 (m, 2H), 7.04 (s, 1H), 6.81 (s, 1H), 3.91 (s, 2H), 3.90 (s, 3H), 3.79 (s, 3H).
Example 4
Preparation of Compound 6a
[0044] Imidazole (0.42 g) and 1,1′-carbonyldiimidazole (5.49 g) were slurried in 30 mL of THF at ambient temperature. Compound 5a (10 g) was added in one portion and the mixture was stirred at ambient temperature for 4 hours to form a slurry of compound 5a. In a separate flask, 8.91 g of potassium monoethyl malonate was slurried in 40 mL of THF. Magnesium chloride (4.40 g) was added and the resulting slurry was warmed to 55° C. for 90 minutes. The slurry of Compound 5a was transferred to the magnesium chloride/potassium monoethyl malonate mixture and stirred at 55° C. overnight. The mixture was then cooled to room temperature and quenched by the dropwise addition of 80 mL of 28 wt % aqueous H 3 PO 4 . The phases were separated and the organic phase was washed successively with aqueous NaHSO 4 , KHCO 3 and NaCl solutions. The organic phase was concentrated to an oil and then coevaporated with ethanol. The resulting solid was dissolved in 30 mL ethanol and 6 mL water. Compound 6a was crystallized by cooling. The solid was isolated by filtration and the product was washed with aqueous ethanol. After drying Compound 6a was obtained: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.51 (s, 1H), 7.42-7.38 (m, 1H), 7.12-7.10 (m, 2H), 6.70 (s, 1H), 4.06 (q, J=7.0 Hz, 2H), 3.89 (s, 8H), 3.81 (s, 2H), 1.15 (t, J=7.0 Hz, 3H).
[0045] Alternatively, Compound 6a can be prepared as follows.
[0046] Carbonyldiimidazole (10.99 g) was slurried in 60 mL of THF at ambient temperature. Compound 4 (20 g) was added in one portion and the mixture was stirred at ambient temperature for 30 min to form a slurry of compound 5. In a separate flask 15.72 g of potassium monoethyl malonate was slurried in 100 mL of THF. Magnesium chloride (6.45 g) was added and the resulting slurry was warmed to 55° C. for 5 hours. The slurry of Compound 5 was transferred to the magnesium chloride/potassium monoethyl malonate mixture and stirred at 55° C. overnight. The mixture was then cooled to room temperature and quenched onto 120 mL of 28 wt % aqueous H 3 PO 4 . The phases were separated and the organic phase was washed successively with aqueous KHCO 3 and NaCl solutions. The organic phase was concentrated to an oil and then coevaporated with ethanol. The resulting solid was dissolved in 100 mL ethanol and 12 mL water. Compound 6a was crystallized by cooling. The solid was isolated by filtration and the product was washed with aqueous ethanol. After drying 21.74 g Compound 6a (89% yield) was obtained: 1 H NMR (DMSO-d 6 , 400 MHz) δ 7.51 (s, 1H), 7.42-7.38 (m, 1H), 7.12-7.10 (m, 2H), 6.70 (s, 1H), 4.06 (q, J=7.0 Hz, 2H), 3.89 (s, 8H), 3.81 (s, 2H), 1.15 (t, J=7.0 Hz, 3H).
Example 5
Preparation of Compound 9a
[0047] Compound 6a (20 g) was stirred with 6.6 g dimethylformamide dimethyl acetal, 66 g toluene and 0.08 g glacial acetic acid. The mixture was warmed to 90° C. for 4 hours. The mixture was then cooled to ambient temperature and 5.8 g (S)-2-amino-3-methyl-1-butanol was added. The mixture was stirred at ambient temperature for 1 hour before being concentrated to a thick oil. Dimethylformamide (36 g), potassium chloride (1.8 g) and bis(trimethylsilyl)acetamide (29.6 g) were added and the mixture was warmed to 90° C. for 1 h. The mixture was cooled to room temperature and diluted with 200 g dichloromethane. Dilute hydrochloride acid (44 g, about 1N) was added and the mixture stirred at ambient temperature for 20 min. The phases were separated and the organic phase was washed successively with water, aqueous sodium bicarbonate and water. The solvent was exchanged to acetonitrile and the volume was adjusted to 160 mL. The mixture was heated to clarity, cooled slightly, seeded and cooled to crystallize Compound 9a. The product was isolated by filtration and washed with additional cold acetonitrile. Vacuum drying afforded Compound 9a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.61 (s, 1H), 7.86 (s, 1H), 7.45 (t, J=7.4 Hz, 1H), 7.26 (s, 1H), 7.23-7.14 (m, 2H), 5.10 (br s, 1H), 4.62 (br s, 1H), 4.18 (q, J=7.0 Hz, 2H), 4.03 (s, 2H), 3.96 (s, 3H), 3.92-3.84 (m, 1H), 3.78-3.75 (m, 1H), 2.28 (br s, 1H), 1.24 (t, J=7.0 Hz, 3H), 1.12 (d, J=6.4 Hz, 3H), 0.72 (d, J=6.4 Hz, 3H).
[0048] Alternatively, Compound 9a can be prepared as follows.
[0049] Compound 6a (50 g) was stirred with 17.5 g dimethylformamide dimethyl acetal, 90 g DMF and 0.2 g glacial acetic acid. The mixture was warmed to 65° C. for 3 hours. The mixture was then cooled to ambient temperature and 14.5 g (S)-2-amino-3-methyl-1-butanol and 25 g toluene were added. The mixture was stirred at ambient temperature overnight before being concentrated by distillation. Potassium chloride (4.5 g) and bis(trimethylsilyl)acetamide (80.2 g) were added and the mixture was warmed to 90° C. for 2 h. The mixture was cooled to room temperature and diluted with 250 g dichloromethane. Dilute hydrochloride acid (110 g of ˜1N) was added and the mixture stirred at ambient temperature for 30 min. The phases were separated and the organic phase was washed successively with water, aqueous sodium bicarbonate and water. The solvent was exchanged to acetonitrile by distillation. The mixture was heated to clarity, cooled slightly, seeded and cooled to crystallize Compound 9a. The product was isolated by filtration and washed with additional cold acetonitrile. Vacuum drying afforded 48.7 g (81% yield) of Compound 9a: 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.61 (s, 1H), 7.86 (s, 1H), 7.45 (t, J=7.4 Hz, 1H), 7.26 (s, 1H), 7.23-7.14 (m, 2H), 5.10 (br s, 1H), 4.62 (br s, 1H), 4.18 (q, J=7.0 Hz, 2H), 4.03 (s, 2H), 3.96 (s, 3H), 3.92-3.84 (m, 1H), 3.78-3.75 (m, 1H), 2.28 (br s, 1H), 1.24 (t, J=7.0 Hz, 3H), 1.12 (d, J=6.4 Hz, 3H), 0.72 (d, J=6.4 Hz, 3H).
Example 6
Preparation of Compound 10
[0050] Compound 9a (6.02 g) was slurried in 36 mL isopropanol and 24 mL of water. Aqueous potassium hydroxide (2.04 g of 45 wt % solution) was added and the mixture warmed to 40° C. After 3 hours 1.13 g glacial acetic acid was added the mixture seeded with 10 mg of Compound 10. The mixture was cooled in an ice bath for 2 hours and the solid was isolated by filtration. The cake was washed with aqueous isopropanol and dried to give Compound 10: 1 H NMR (DMSO-d 6 , 400 MHz) δ 15.42 (s, 1H), 8.87 (s, 1H), 8.02 (s, 1H), 7.48-7.45 (m, 2H), 7.23 (t, J=6.8 Hz, 1H), 7.17 (t, J=7.8 Hz, 1H), 5.18 (br s, 1H), 4.86 (br s, 1H), 4.10 (s, 2H), 4.02 (s, 3H), 3.97-3.96 (m, 1H), 3.79-3.76 (m, 1H), 2.36 (br s, 1H), 1.14 (d, J=6.3 Hz, 3H), 0.71 (d, J=6.3 Hz, 3H).
[0051] Alternatively, Compound 10 can be prepared from Compound 4 as described in the following illustrative Examples 7-9.
Example 7
Preparation of a Compound of Formula 6a
[0052]
[0053] Carbonyldiimidazole and imidazole are combined with anhydrous tetrahydrofuran. Compound 4 is added to this mixture to form Compound 5 and the reaction is monitored by HPLC. In a separate reactor potassium monoethylmalonate is combined with tetrahydrofuran before anhydrous magnesium chloride is added while maintaining the temperature NMT 30° C. The resulting slurry is warmed to 50° C. and held for at least two hours before the Compound 5 mixture is added. The reaction is monitored by HPLC. Once the formation of Compound 5 is complete, the mixture is cooled to 18 to 25° C. and added to aqueous phosphoric acid to quench. The organic phase is washed with aqueous sodium bisulfate, brine, potassium bicarbonate and brine solutions before being polish filtered. The solvent is exchanged for anhydrous ethanol. Water is added and the mixture is warmed to dissolve solids, cooled to about 40° C., seeded with Compound 6a and cooled to 0 to 5° C. The product is filtered, washed with cold aqueous ethanol and dried at NMT 40° C. to yield Compound 6a.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 4
324.73
1.000
1.00
THF
72.11
7.11
Imidazole
68.08
0.042
0.20
CDI
162.15
0.55
1.10
KEM
170.2
0.89
1.70
MgCl 2
95.21
0.44
1.50
H 3 PO 4 (85 wt %)
98.00
2.3
NaHSO 4
120.06
0.24
KHCO 3
100.12
0.50
NaCl
58.44
0.48
SDA 2B-2 EtOH (0.5% heptane)
46.07
~10 kg
Procedure:
[0000]
1. Charge 0.55 kg CDI and 0.042 kg imidazole to reactor 1.
2. Charge 2.67 kg THF to reactor 1 and agitate to form a slurry.
3. Charge 1.00 kg Compound 4 to reactor 1 in portions to moderate the CO 2 offgas. This addition is endothermic
4. Charge 0.89 kg KEM to reactor 2.
5. Charge 4.45 kg THF to reactor 2 and agitate to form a slurry.
6. Charge 0.44 kg MgCl 2 to reactor 2 (can be added in portions to moderate exotherm).
7. Warm the contents of reactor 2 to 50° C. and agitate at that temperature for at least two hours.
8. Transfer the contents of reactor 1 to reactor 2. Mixture will become thick temporarily if transferred very rapidly.
9. Agitate the contents of reactor 2 for at least 12 hours at 50° C.
10. Cool the slurry to ambient temperature.
11. Quench the reaction by transferring the reaction mixture onto 7.0 kg of 28 wt % aqueous H 3 PO 4 (2.3 kg 85 wt % H 3 PO 4 dissolved in 4.7 kg H 2 O). This addition is exothermic. Final pH of aqueous layer should be 1-2.
12. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaHSO 4 (0.24 kg of NaHSO 4 dissolved in 0.96 kg H 2 O). Final pH of aqueous layer should be 1-2.
13. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaCl (0.24 kg of NaCl dissolved in 0.96 kg H 2 O)
14. Wash the organic (top) phase with 5.0 kg of 10 wt % aqueous KHCO 3 (0.50 kg of KHCO 3 dissolved in 4.5 kg H 2 O). Final pH of aqueous layer should be 8-10.
15. Wash the organic (top) phase with 1.2 kg of 20 wt % aqueous NaCl (0.24 kg of NaCl dissolved in 0.96 kg H 2 O). Final pH of aqueous layer should be 7-9.
16. Concentrate the organic phase and exchange the solvent to EtOH.
17. Adjust the concentration to ˜3.5 L/kg input.
18. Charge 0.6 volumes of water.
19. Warm 70-80° C. to form a clear solution.
20. Cool to 40° C. and seed with 0.1 wt % Compound 6.
21. Cool slowly to 5° C.
22. Hold for at least 2 hours.
23. Filter and wash the cake with two 1.35 kg volume portions of 50:50 EtOH:H 2 O (1.2 kg EtOH combined with 1.5 kg H 2 O).
24. Dry the cake at less than 50° C.
Example 8
Preparation of a Compound of Formula 9a
[0078]
[0079] Compound 6a is combined with toluene, N,N-dimethylformamide dimethyl acetal and glacial acetic acid before being warmed to 100° C. The reaction is monitored by HPLC. Once the formation of Compound 7a is complete the mixture is cooled to 18 to 25° C. before (5)-(+)-valinol is added. The reaction is monitored by HPLC. Once the formation of Compound 8a is complete the mixture is concentrated. The residue is combined with dimethylformamide, potassium chloride and N,O-bisnimethylsilyl acetamide and warmed to 100° C. The reaction is monitored by HPLC. Once complete the mixture is cooled and dichloromethane is added. Aqueous hydrochloric acid is added to desilylate Compound 9a. This reaction is monitored by TLC. Once complete the organic phase is washed with water, aqueous sodium bicarbonate and water. The solvent is exchanged for acetonitrile and the mixture warmed. The mixture is seeded and cooled to crystallize Compound 9a. The product is filtered, washed with cold acetonitrile and dried at NMT 40° C. to yield Compound 9a.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 6a
394.82
1.00
1.00
Toluene
92.14
4.3
Glacial acetic acid
60.05
0.001
0.007
N,N-dimethylformamide dimethyl
119.16
0.33
1.1
acetal
(S)-(+)-Valinol
103.16
0.29
1.1
DMF
73.10
1.8
KCl
74.55
0.09
0.5
N,O-bis(trimethylsilyl)acetamide
203.43
1.13
2.2
1 N HCl
36.5
2.0
DCM
84.93
10
Water
18.02
8
5% Aq. NaHCO 3
84.01
4
CAN
41.05
QS
Compound 9a seeds
475.94
0.005
1. Charge Reactor 1 with 1.00 kg Compound 6a.
2. Charge 0.33 kg N,N-dimethylformamide dimethyl acetal (1.1 eq), 0.001 kg glacial acetic acid and 3.3 kg toluene to Reactor 1.
3. Warm the mixture to ˜100° C. (note that some MeOH may distill during this operation).
4. After 1 h the reaction should be complete by HPLC (˜2% Compound 6a apparently remaining) 1 .
5. Cool the mixture in Reactor 1 to 18-25° C.
6. Charge 0.29 kg (S)-(+)-Valinol (1.1 eq) dissolved in 1.0 kg toluene to Reactor 1 and continue agitation at ambient temperature.
7. After 1 h the reaction should be complete by HPLC (<1% Compound 6a).
8. Concentrate the contents of Reactor 1 to ˜2 L/kg.
9. Charge 1.8 kg DMF, 0.09 kg potassium chloride (0.5 eq,) and 1.13 kg N,O-bistrimethylsilyl acetamide (2.2 eq.) to Reactor 1.
10. Warm the mixture in Reactor 1 to ˜100° C.
11. Reaction should be complete in ˜1 h (˜5% Compound 8a remaining).
12. Cool the contents of Reactor 1 to 18-25° C.
13. Charge 10 kg DCM to Reactor 1.
14. Charge 2.0 kg 1 N aqueous HCl to Reactor 1 over ˜15 min, maintaining the temperature of the mixture<35° C.
15. Agitate the mixture for at least 10 min to desilylate Compound 8a. Monitor the progress of desilylation by TLC. 2
16. Separate the phases.
17. Wash the organic phase with 4.0 kg water.
18. Wash the organic phase with 4.0 kg 5% aqueous sodium bicarbonate.
19. Wash the organic phase with 4.0 kg water.
20. Concentrate the organic phase by distillation to ˜1.5 L/kg Compound 6a.
21. Solvent exchange to ACN by distillation until a slurry is formed. Adjust the final volume to ˜8 L/kg Compound 6a.
22. Heat the mixture to reflux to redissolve the solid.
23. Cool the solution to 75° C. and charge Compound 9a seeds.
24. Cool the mixture to 0° C. over at least 2 h and hold at that temperature for at least 1 h.
25. Isolate Compound 9a by filtration and wash the wet cake with 1.6 kg cold ACN.
26. Dry the wet cake at <40° C. under vacuum.
Notes:
[0000]
1. The HPLC AN of remaining Compound 6a is exaggerated by a baseline artifact. The HPLC in step shows only 2% of Compound 6a relative to Compound 8a. Experiments demonstrated that adding more reagent and extending reaction time typically will not further reduce the observed level of Compound 6a.
2. TLC method:
Eluting solvent: 100% ethyl acetate, Silylated Compound 9a Rf: 0.85, Compound 9a Rf: 0.50.
Example 9
Preparation of a Compound of Formula 10
[0110]
[0111] Compound 9a is combined with aqueous isopropyl alcohol and warmed to 30 to 40° C. Aqueous potassium hydroxide is added and the reaction is monitored by HPLC. Once complete, glacial acetic acid is added and the mixture warmed to 60 to 70° C. The solution is hot filtered and cooled to 55 to 65° C. The solution is seeded (see International Patent Application Publication Number WO 2005/113508) and cooled to 0° C. The product is isolated by filtration, washed with cold aqueous isopropyl alcohol and dried at NMT 50° C. to yield Compound 10.
[0000]
Material
M.W.
Wt. Ratio
Mole Ratio
Compound 9a
475.94
1.00
1.00
Isopropyl alcohol
60.10
4.7
Water
18.02
4.0
45% KOH
56.11
0.34
1.3
Glacial Acetic Acid
60.05
0.19
1.50
Compound 10 seeds
447.88
0.01
1. Charge 1.00 kg Compound 9a to Reactor 1.
2. Charge 4.7 kg isopropyl alcohol and 4.0 kg water to Reactor 1.
3. Charge 0.34 kg 45% aqueous KOH to Reactor 1.
4. Warm the mixture in Reactor 1 to 30-40° C.
5. When hydrolysis is complete add 0.19 kg of glacial acetic acid.
6. Warm the mixture to 60-70° C. and polish filter the solution to Reactor 2.
7. Cool the mixture in Reactor 2 to 55-65° C.
8. Seed with Compound 10 (see International Patent Application Publication Number WO 2005/113508) as a slurry in 0.28 volumes of 6:4 isopropyl alcohol:water.
9. Cool the mixture to 18-25° C. over at least 2 h and agitate to form a slurry.
10. Cool the mixture to 0° C. and agitate for at least 2 h.
11. Isolate Compound 10 by filtration and wash the cake with 3×1 S cold isopropyl alcohol:water (6:4) solution.
12. Dry the isolated solids at <50° C. under vacuum.
Example 10
Preparation of Compound 15
[0124]
[0125] Bisdimethylaminoethyl ether (2.84 g) was dissolved in 42 mL THF and cooled in an ice bath. Isopropylmagnesium chloride (8.9 mL of a 2 M solution in THF) followed by Compound 14 (5 g dissolved in 5 mL THF) were added slowly sequentially. The mixture was allowed to warm to ambient temperature and stirred overnight. Next, 2.1 mL of 3-chloro-2-fluorobenzaldehyde was added. After stirring for ˜1 h, the mixture was quenched to pH˜7 with 2N HCl. The product was extracted into ethyl acetate and the organic phase was dried over sodium sulfate. The solvent was exchange to heptane to precipitate the product and a mixture of heptanes:MTBE (4:1) was added to form a slurry. After filtration the solid was slurried in toluene, filtered and vacuum dried to yield compound 15: 1 H NMR (CD 3 CN, 400 MHz) δ 7.47 (s, 1H), 7.41-7.35 (m, 2H), 7.15 (t, J=7.4 Hz, 1H), 6.66 (s, 1H), 6.21 (br s, 1H), 3.90 (s, 3H), 3.87 (br s, 1H), 3.81 (s, 3H).
Example 11
Preparation of Compound 15a
[0126]
[0127] Compound 14 (5 g), isopropylmagnesium chloride (8.9 mL of 2M solution in THF) and THF (56 mL) were combined at ambient temperature and then warmed to 50° C. for ˜5 hours. After cooling to ambient temperature and stirring overnight, 2.1 mL of 3-chloro-2-fluorobenzaldehyde was added dropwise to form a slurry. After stirring overnight the solid was isolated by filtration and washing with MTBE to yield compound 15a.
Example 12
Preparation of Compound 16
[0128]
[0129] Triethylsilane (1.2 mL) was added to trifluoroacetic acid (2.3 mL) that had been pre-cooled in an ice bath. Compound 15 (1.466 g) was added to the mixture keeping the temperature below 5° C. After stirring for ˜2 h ice was added to quench the reaction. The product was extracted with DCM and the organic phase was washed with aq. NaHCO 3 . The organic phase was dried over Na 2 SO 4 and concentrated to dryness. The product was purified by silica gel column chromatography to provide 1.341 g of Compound 16: 1 H NMR (CDCl 3 , 400 MHz) δ 7.20 (t, J=7.0 Hz, 1H), 6.99-6.91 (m, 3H), 6.46 (s, 1H), 3.91 (s, 3H), 3.81 (s, 5H).
[0130] The compound of formula 16 can be carboxylated to provide a compound of Formula 4 following a method analogous to that described in Example 1.
Example 13
Alternative Preparation of a Compound of Formula 3
[0131] Compound 14 is combined with anhydrous tetrahydrofuran:dioxane (5:0.9), and the mixture is agitated under a nitrogen atmosphere until a homogeneous solution is achieved. The solution is cooled to −3° C. and 1.3 eq. of i-PrMgCl.LiCl in tetrahydrofuran is added. The reaction mixture is agitated at 0° C. until the formation of the mono-Grignard is complete as determined by HPLC analysis. Next, a solution of 1.1 eq. of 3-chloro-2-fluorobenzaldehyde in tetrahydrofuran is added. This mixture is allowed to stir at 0° C. until the formation of Compound 15a is complete by HPLC. Next, additional i-PrMgCl.LiCl solution in tetrahydrofuran (2.5 eq.) is added and the reaction mixture is warmed to about 20° C. After conversion to the second Grignard intermediate is complete, the reaction mixture is cooled to 3° C. Anhydrous CO 2 (g) is charged to the reaction mixture at about 5° C. The reaction mixture is adjusted to about 20° C. After the carboxylation reaction is complete by HPLC, the reaction mixture is cooled to about 10° C. and water is charged to quench the reaction followed by the addition of concentrated hydrochloric acid to adjust the pH to no more than 3. The reaction mixture is then warmed to about 20° C. The phases are separated. The organic phase is solvent exchanged to a mixture of isopropyl alcohol and water and the resulting slurry is cooled to about 0° C. The product is isolated by filtration, washed with a mixture of isopropyl alcohol and water and dried at about 40° C. to yield Compound 3.
Example 14
Alternative Preparation of Compound of Formula 4
[0132] Trifluoroacetic acid (10 eq.) is charged to a reactor and cooled to 0° C. Triethylsilane (1.5 eq.) is added maintaining the temperature<15° C. and the mixture agitated thoroughly. Compound 3 is added to the well-stirred mixture in portions maintaining the temperature<15° C. When the reaction is determined to be complete by HPLC, Compound 4 is precipitated by adding a solution of 5 eq. sodium acetate in methanol (13 volumes) maintaining the temperature not more than 45° C. Warm the slurry to reflux and agitate for 2 to 3 h. The slurry is cooled to about 0° C. and then agitated at that temperature for 2 to 3 h. The product is isolated by filtration, washed with methanol and dried at about 40° C. to yield Compound 4.
Example 15
Alternative Preparation of a Compound of Formula 9a
[0133] Compound 6a is combined with dimethylformamide (1.9 vol.),
[0134] N,N-dimethylformamide dimethyl acetal (1.1 eq.) and glacial acetic acid (0.026 eq.) before being warmed to about 65° C. The reaction is monitored by HPLC. Once the reaction is complete the mixture is cooled to about 22° C. before (S)-2-amino-3-methyl-1-butanol (1.1 eq.) and toluene (1.2 volumes) are added. The reaction is monitored by HPLC. Once the reaction is complete the mixture is concentrated. The residue is combined with potassium chloride (0.5 eq) and N,O-bis(trimethylsilyl)acetamide (2.5 eq.) and warmed to about 100° C. The reaction is monitored by HPLC. Once the reaction is complete the mixture is cooled and dichloromethane (6 vol.) is added. Aqueous hydrochloric acid is added to desilylate the product. This reaction is monitored by TLC. Once the reaction is complete the organic phase is washed with water, aqueous sodium bicarbonate and water. The solvent is exchanged for acetonitrile and the mixture is warmed to form a solution. The mixture is seeded and cooled to crystallize Compound 9a. The product is filtered, washed with cold acetonitrile and dried at NMT 40° C. to yield Compound 9a.
[0135] All publications, patents, and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. | The invention provides synthetic processes and synthetic intermediates that can be used to prepare 4-oxoquinolone compounds having useful integrase inhibiting properties. | 2 |
RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/840,624 filed on Apr. 23, 2001, which issued as U.S. Pat. No. 6,863,801 on Mar. 8, 2005, which is a continuation of U.S. application Ser. No. 09/709,968, filed Nov. 10, 2000, which issued as U.S. Pat. No. 6,521,110 on Feb. 18, 2003, which is a continuation of U.S. application Ser. No. 09/314,251, filed May 18, 1999, which issued as U.S. Pat. No. 6,174,420 on Jan. 16, 2001, which is a continuation-in-part of U.S. application Ser. No. 09/068,828, filed on Mar. 15, 1999, which issued as U.S. Pat. No. 6,179,979 on Jan. 30, 2001, and is also a continuation-in-part of U.S. application Ser. No. 08/852,804, filed on May 7, 1997, which issued as U.S. Pat. No. 5,942,102 on Aug. 24, 1999, the contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
This invention relates to an electrochemical cell for determining the concentration of an analyte in a carrier.
BACKGROUND OF THE INVENTION
The invention herein described is an improvement in or modification of the invention described in our co-pending U.S. application Ser. No. 08/981,385, entitled ELECTROCHEMICAL CELL, filed on Dec. 18, 1997, the contents of which are incorporated herein by reference in its entirety.
The invention will herein be described with particular reference to a biosensor adapted to measure the concentration of glucose in blood, but it will be understood not to be limited to that particular use and is applicable to other analytic determinations.
It is known to measure the concentration of a component to be analysed in an aqueous liquid sample by placing the sample into a reaction zone in an electrochemical cell comprising two electrodes having an impedance which renders them suitable for amperometric measurement. The component to be analysed is allowed to react directly or indirectly with a redox reagent whereby to form an oxidisable (or reducible) substance in an amount corresponding to the concentration of the component to be analysed. The quantity of the oxidisable (or reducible) substance present is then estimated electrochemically. Generally this method requires sufficient separation of the electrodes so that electrolysis products at one electrode cannot reach the other electrode and interfere with the processes at the other electrode during the period of measurement.
In our co-pending application we described a novel method for determining the concentration of the reduced (or oxidised) form of a redox species in an electrochemical cell of the kind comprising a working electrode and a counter (or counter/reference) electrode spaced from the working electrode by a predetermined distance. The method involves applying an electric potential difference between the electrodes and selecting the potential of the working electrode such that the rate of electro-oxidation of the reduced form of the species (or of electro-reduction of the oxidised form) is diffusion controlled. The spacing between the working electrode and the counter electrode is selected so that reaction products from the counter electrode arrive at the working electrode. By determining the current as a function of time after application of the potential and prior to achievement of a steady state current and then estimating the magnitude of the steady state current, the method previously described allows the diffusion coefficient and/or the concentration of the reduced (or oxidised) form of the species to be estimated.
Our co-pending application exemplifies this method with reference to use of a “thin layer electrochemical cell” employing a GOD/Ferrocyanide system. As herein used, the term “thin layer electrochemical cell” refers to a cell having closely spaced electrodes such that reaction product from the counter electrode arrives at the working electrode. In practice, the separation of electrodes in such a cell for measuring glucose in blood will be less than 500 microns, and preferably less than 200 microns.
The chemistry used in the exemplified electrochemical cell is as follows:
where GOD is the enzyme glucose oxidase, and GOD* is the ‘activated’ enzyme. Ferricyanide ([Fe(CN) 6 ] 3− ) is the ‘mediator’ which returns the GOD* to its catalytic state. GOD, an enzyme catalyst, is not consumed during the reaction so long as excess mediator is present. Ferrocyanide ([Fe(CN) 6 ] 4− ) is the product of the total reaction. Ideally there is initially no ferrocyanide, although in practice there is often a small quantity. After reaction is complete the concentration of ferrocyanide (measured electrochemically) indicates the initial concentration of glucose. The total reaction is the sum of reactions 1 and 2:
“Glucose” refers specifically to β-D-glucose.
The prior art suffers from a number of disadvantages. Firstly, sample size required is greater than desirable. It would be generally preferable to be able to make measurements on samples of reduced volume since this in turn enables use of less invasive methods to obtain samples.
Secondly, it would be generally desirable to improve the accuracy of measurement and to eliminate or reduce variations due, for example, to cell asymmetry or other factors introduced during mass production of microcells. Likewise, it would be desirable to reduce electrode “edge” effects.
Thirdly, since the cells are disposable after use, it is desirable that they be capable of mass production at relatively low cost.
SUMMARY OF THE INVENTION
In a first embodiment of the present invention, a biosensor for use in determining a concentration of a component in an aqueous liquid sample is provided, the biosensor including: (a) an electrochemical cell, the electrochemical cell including a first electrically resistive substrate having a first thin layer of a first electrically conductive material on a first face, a second electrically resistive substrate having a second thin layer of a second electrically conductive material on a second face, the substrates being disposed with the first electrically conductive material facing the second electrically conductive material and being separated by a sheet including an aperture, the wall of which aperture cooperates with the electrically conductive materials to define a cell wall, and wherein the aperture defines a working electrode area in the cell, the cell further including a sample introduction aperture whereby the aqueous liquid sample may be introduced into the cell; and (b) a measuring circuit.
In one aspect of the first embodiment, the electrochemical cell further includes a socket region having a first contact area in electrical communication with the first thin layer of the first electrically conductive material and a second contact area in electrical communication with the second thin layer of the second electrically conductive material, whereby the electrochemical cell may be electrically connected with the measuring circuit.
In another aspect of the first embodiment, the measuring circuit includes a tongue plug.
In a further aspect of the first embodiment, at least one of the first electrically conductive material and the second electrically conductive material includes a metal. The metal may further include a sputter coated metal.
In still other aspects of the first embodiment, the aqueous liquid sample includes blood, and the component includes glucose.
In yet another aspect of the first embodiment, the measuring circuit includes an automated instrument for detecting an electrical signal from the electrochemical cell and relating the electrical signal to the concentration of the component in the aqueous liquid sample.
In a further aspect of the first embodiment, the electrochemical cell includes a substantially flat strip having a thickness, the strip having at least two lateral edges, and wherein the sample introduction aperture includes a notch through the entire thickness of the strip in at least one of the lateral edges thereof.
In a second embodiment of the present invention, a biosensor for use in determining a concentration of a component in an aqueous liquid sample is provided, the biosensor including: (a) a thin layer electrochemical cell, the cell including: (i) an electrically resistive sheet including an aperture wherein the aperture defines a working electrode area in the cell; (ii) a first electrode layer covering the aperture on a first side of the sheet; (iii) a second electrode layer covering the aperture on a second side of the sheet; and (iv) a passage for admission into the aperture of the aqueous liquid sample; and (b) a measuring circuit.
In one aspect of the second embodiment, the electrochemical cell further includes a socket region having a first contact area in electrical communication with the first electrode layer and a second contact area in electrical communication with the second electrode layer, whereby the electrochemical cell may be electrically connected with the measuring circuit.
In another aspect of the second embodiment, the measuring circuit includes a tongue plug.
In still other aspects of the second embodiment, the aqueous liquid sample includes blood, and the component includes glucose.
In a further aspect of the second embodiment, the measuring circuit includes an automated instrument for detecting an electrical signal from the electrochemical cell and relating the electrical signal to the concentration of the component in the aqueous liquid sample.
In yet another aspect of the second embodiment, the cell includes a substantially flat strip having a thickness, the strip having at least two lateral edges, and wherein the passage for admission into the aperture includes a notch through the entire thickness of the strip in at least one of the lateral edges thereof.
In a third embodiment of the present invention, an apparatus for determining a concentration of a reduced form or an oxidized form of a redox species in a liquid sample is provided, the apparatus including: (a) a hollow electrochemical cell having a working electrode and a counter or counter/reference electrode wherein the working electrode is spaced from the counter or counter/reference electrode by less than 500 μm; (b) means for applying an electric potential difference between the electrodes; and (c) means for electrochemically determining the concentration of the reduced form or the oxidized form of the redox species in the liquid sample.
In one aspect of the third embodiment, means for electrochemically determining the concentration of the reduced form or the oxidized form of the redox species includes: (i) means for determining a change in current with time after application of the electric potential difference and prior to achievement of a steady state current; (ii) means for estimating a magnitude of the steady state current; and (iii) means for obtaining from the change in current with time and the magnitude of the steady state current, a value indicative of the concentration of the reduced form or the oxidized form of the redox species.
In another aspect of the third embodiment, the cell further includes a socket region having a first contact area in electrical communication with the working electrode and a second contact area in electrical communication with the counter or counter/reference electrode, whereby the cell may be electrically connected with at least one of the means for applying an electric potential difference between the electrodes and the means for electrochemically-determining the concentration of the reduced form or the oxidized form of the redox species in the liquid sample.
In a further aspect of the third embodiment, at least one of the means for applying an electric potential difference between the electrodes and the means for electrochemically determining the concentration of the reduced form or the oxidized form of the redox species in the liquid sample includes a tongue plug.
In yet another aspect of the third embodiment, at least one of the means for applying an electric potential difference between the electrodes and the means for electrochemically determining the concentration of the reduced form or the oxidized form of the redox species in the liquid sample includes an automated instrument for detecting an electrical signal from the electrochemical cell and relating the electrical signal to the concentration of the reduced form or the oxidized form of the redox species in the liquid sample.
In a further aspect of the third embodiment, the cell includes a substantially flat strip having a thickness, the strip having at least two lateral edges, and wherein a notch extends through a wall of the electrochemical cell and through the entire thickness of the strip in at least one of the lateral edges thereof, whereby the liquid sample may be introduced into the cell.
In still other aspects of the third embodiment, the liquid sample includes blood, and the redox species includes glucose.
In a fourth embodiment of the present invention, a method for determining a concentration of a reduced form or an oxidized form of a redox species in a liquid sample is provided, the method including: (a) providing a hollow electrochemical cell having a working electrode and a counter or counter/reference electrode wherein the working electrode is spaced from the counter or counter/reference electrode by less than 500 μm; (b) applying an electric potential difference between the electrodes; and (c) electrochemically determining the concentration of the reduced form or the oxidized form of the redox species in the liquid sample.
In one aspect of the fourth embodiment, step (c) includes: (i) determining a change in current with time after application of the electric potential difference and prior to achievement of a steady state current; (ii) estimating a magnitude of the steady state current; and (iii) obtaining from the change in current with time and the magnitude of the steady state current, a value indicative of the concentration of the reduced form or the oxidized form of the redox species.
In another aspect of the fourth embodiment, the cell further includes a socket region having a first contact area in electrical communication with the working electrode and a second contact area in electrical communication with the counter or counter/reference electrode.
In a further aspect of the fourth embodiment, step (b) further includes the step of: providing an automated instrument for applying an electric potential difference between the electrodes.
In yet another aspect of the fourth embodiment, step (c) includes the steps of: (i) providing an automated instrument for detecting an electrical signal from the electrochemical cell; and (ii) relating the electrical signal to the concentration of the reduced form or the oxidized form of the redox species in the liquid sample.
In a further aspect of the fourth embodiment, the cell includes a substantially flat strip having a thickness, the strip having at least two lateral edges, and wherein a notch extends through a wall of the electrochemical cell and through the entire thickness of the strip in at least one of the lateral edges thereof, whereby the liquid sample may be introduced into the cell.
In still other aspects of the fourth embodiment, the liquid sample includes blood and the redox species includes glucose.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be particularly described by way of example only with reference to the accompanying schematic drawings wherein:
FIG. 1 shows the product of manufacturing step 2 in plan.
FIG. 2 shows the product of FIG. 1 in side elevation.
FIG. 3 shows the product of FIG. 1 in end elevation.
FIG. 4 shows the product of manufacturing step 3 in plan.
FIG. 5 shows the product of FIG. 4 in cross-section on line 5 - 5 of FIG. 4 .
FIG. 6 shows the product of manufacturing step 5 in plan.
FIG. 7 shows the product of FIG. 6 in side elevation.
FIG. 8 shows the product of FIG. 6 in end elevation.
FIG. 9 shows the product of manufacturing step 7 in plan.
FIG. 10 is a cross-section of FIG. 9 on line 10 - 10 .
FIG. 11 shows the product of FIG. 9 in end elevation.
FIG. 12 shows a cell according to the invention in plan.
FIG. 13 shows the call of FIG. 12 in side elevation.
FIG. 14 shows the cell of FIG. 12 in end elevation.
FIG. 15 shows a scrap portion of a second embodiment of the invention in enlarged section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The construction of a thin layer electrochemical cell will now be described by way of example of the improved method of manufacture.
Step 1: A sheet 1 of Melinex® (a chemically inert, and electrically resistive Polyethylene Terephthalate [“PET”]) approximately 13 cm×30 cm and 100 micron thick was laid flat on a sheet of release paper 2 and coated using a Number 2 MYAR bar to a thickness of 12 microns wet (approximately 2-5 microns dry) with a water-based heat activated adhesive 3 (ICI Novacoat system using catalyst:adhesive). The water was then evaporated by means of a hot air dryer leaving a contact adhesive surface. The sheet was then turned over on a release paper and the reverse side was similarly coated with the same adhesive 4 , dried, and a protective release paper 5 applied to the exposed adhesive surface. The edges were trimmed to obtain a sheet uniformly coated on both sides with tacky contact adhesive protected by release paper.
Step 2: The sheet with protective release papers was cut into strips 7 , each about 18 mm×210 mm ( FIGS. 1-3 ).
Step 3: A strip 7 of adhesive-coated PET from step 2 with release paper 2 , 5 on respective sides, was placed in a die assembly (not shown) and clamped. The die assembly was adapted to punch the strip with a locating hole 10 at each end and with for example 37 circular holes 11 each of 3.4 mm diameter at 5 mm centres equi-spaced along a line between locating holes 10 . The area of each hole 11 is approximately 9 square mm.
Step 4: A sheet 12 of Mylar® PET approximately 21 cm square and 135 microns thick was placed in a sputter coating chamber for palladium coating 13 . The sputter coating took place under a vacuum of between 4 and 6 millibars and in an atmosphere of argon gas. Palladium was coated on the PET to a thickness of 100-1000 angstroms. There is thus formed a sheet 14 having a palladium sputter coating 13 .
Step 5: The palladium coated PET sheet 14 from Step 4 was then cut into strips 14 and 15 and a die was used to punch two location holes 16 in each strip, at one end ( FIGS. 6 , 7 and 8 ). Strips 14 and 15 differ only in dimension strips 14 being 25 mm×210 mm and strips 15 being 23 mm×210 mm.
Step 6: A spacer strip 7 prepared as in step 3 was then placed in a jig (not shown) having two locating pins (one corresponding to each locating hole 10 of strip 7 ) and the upper release paper 2 was removed. A strip 14 of palladium coated PET prepared as in step 5 was then laid over the adhesive layer, palladium surface downwards, using the jig pins to align the locating holes 16 with the underlying PET strip 7 . This combination was then passed through a laminator comprising a set of pinch rollers, one of which was adapted to heat the side bearing a palladium coated PET strip 14 . The roller on the opposite side of the strip 7 was cooled. By this means, only the adhesive between the palladium of strip 14 and PET strip 7 was activated.
Step 7: PET strip 7 was then turned over and located in the jig with the release coating uppermost. The release coating was peeled off and second palladium coated strip 15 was placed palladium side down on the exposed adhesive surface using the locating pins to align the strips. this assembly was now passed again through the laminator of step 6, this time with the hot roll adjacent the palladium coated Mylar® added in step 7 so as to activate the intervening adhesive ( FIGS. 9 , 10 and 11 ).
Step 8: The assembly from step 7 was returned to the die assembly and notches 17 punched in locations so as to extend between the circular holes 11 previously punched in the Melinex® PET and the strip edge 17 . Notches 16 extend so as to intercept the circumference of each circular cell. The strip was then guillotined to give 37 individual “sensor strips”, each strip being about 5 mm wide and each having one thin layer cavity cell ( FIGS. 12 , 13 and 14 ).
There is thus produced a cell as shown in FIG. 12 , 13 or 14 . The cell comprises a first electrode consisting of PET layer 12 , a palladium layer 13 , an adhesive layer 3 , a PET sheet 1 , a second adhesive layer 4 , a second electrode comprising palladium layer 13 , and a PET layer 12 . Sheet 1 defines a cylindrical cell 11 having a thickness in the cell axial direction corresponding to the thickness of the Melinex® PET sheet layer 1 together with the thickness of adhesive layers 3 and 4 . The cell has circular palladium end walls. Access to the cell is provided at the side edge of the cell where notches 16 intersect cell 11 .
In preferred embodiments of the invention, a sample to be analysed is introduced to the cell by capillary action. The sample is placed on contact with notch 16 and is spontaneously drawn by capillary action into the cell, displaced air from the cell venting from the opposite notch 16 . A surfactant may be included in the capillary space to assist in drawing in the sample.
The sensors are provided with connection means for example edge connectors whereby the sensors may be placed into a measuring circuit. In a preferred embodiment this is achieved by making spacer 1 shorter than palladium supporting sheets 14 , 15 and by making one sheet 15 of shorter length than the other 14 . This forms a socket region 20 having contact areas 21 , 22 electrically connected with the working and counter electrodes respectively. A simple tongue plug having corresponding engaging conduct surfaces can then be used for electrical connection. Connectors of other form may be devised.
Chemicals for use in the cell may be supported on the cell electrodes or walls, may be supported on an independent support contained within the cell or may be self-supporting.
In one embodiment, chemicals for use in the cell are printed onto the palladium surface of the electrode immediately after step 1 at which stage the freshly-deposited palladium is more hydrophilic. For example, a solution containing 0.2 molar potassium ferricyanide and 1% by weight of glucose oxidase dehydrogenase may be printed on to the palladium surface. Desirably, the chemicals are printed only in the areas which will form a wall of the cell and for preference the chemicals are printed on the surface by means of an ink jet printer. In this manner, the deposition of chemicals may be precisely controlled. If desired, chemicals which are desirably separated until required for use may be printed respectively on the first and second electrodes. For example, a GOD/ferrocyanide composition can be printed on one electrode and a buffer on the other. Although it is highly preferred to apply the chemicals to the electrodes prior to assembly into a cell, chemicals may also be introduced into the cell as a solution after step 6 or step 8 by pipette in the traditional manner and the solvent subsequently is removed by evaporation or drying. Chemicals need not be printed on the cell wall or the electrodes and may instead be impregnated into a gauze, membrane, non-woven fabric or the like contained within, or filling, the cavity (eg inserted in cell 11 prior to steps 6 or 7). In another embodiment the chemicals are formed into a porous mass which may be introduced into the cell as a pellet or granules. Alternatively, the chemicals maybe introduced as a gel.
In a second embodiment of the invention a laminate 21 is first made from a strip 14 as obtained in step 5 adhesively sandwiched between two strips 7 as obtained from step 3. Laminate 20 is substituted for sheet 1 in step 5 and assembled with electrodes as in steps 6 and 7.
There is thus obtained a cell as shown in FIG. 15 which differs from that of FIGS. 9 to 11 in that the cell has an annular electrode disposed between the first and second electrode. This electrode can for example be used as a reference electrode.
It will be understood that in mass production of the cell, the parts may be assembled as a laminate on a continuous line. For example, a continuous sheet 1 of PET could be first punched and then adhesive could be applied continuously by printing on the remaining sheet. Electrodes (pre-printed with chemical solution and dried) could be fed directly as a laminate onto the adhesive coated side. Adhesive could then be applied to the other side of the punched core sheet and then the electrode could be fed as a laminate onto the second side.
The adhesive could be applied as a hot melt interleaving film. Alternatively, the core sheet could first be adhesive coated and then punched.
By drying chemicals on each electrode prior to the gluing step the electrode surface is protected from contamination.
Although the cell has been described with reference to Mylar® and Melinex® PET, other chemically inert and electrically resistive materials may be utilised and other dimensions chosen. The materials used for spacer sheet 1 and-for supporting the reference and counter electrodes may be the same or may differ one from the other. Although the invention has been described with reference to palladium electrodes, other metals such as platinum, silver, gold, copper or the like may be used and silver may be reacted with a chloride to form a silver/silver chloride electrode or with other halides. The electrodes need not be of the same metal.
Although the use of heat activated adhesives has been described, the parts may be assembled by use of hot melt adhesives, fusible laminates and other methods.
The dimensions of the sensor may readily be varied according to requirements.
While it is greatly preferred that the electrodes cover the cell end openings, in other embodiments (not illustrated) the electrodes do not entirely cover the cell end openings. In that case it is desirable that the electrodes be in substantial overlying registration.
Preferred forms of the invention in which the electrodes cover the apertures of cell 11 have the advantages that the electrode area is precisely defined simply by punching hole 11 . Furthermore the electrodes so provided are parallel, overlying, of substantially the same area, and are substantially or entirely devoid of “edge” effects.
Although in the embodiments described each sensor has one cell cavity, sensors may be provided with two or more cavities. For example, a second cavity may be provided with a predetermined quantity of the analyte and may function as a reference cell.
As will be apparent to those skilled in the art from the teaching herein contained, a feature of one embodiment herein described may be combined with features of other embodiments herein described or with other embodiments described in our co-pending application. Although the sensor has been described with reference to palladium electrodes and a GOD/ferrocyanide chemistry, it will be apparent to those skilled in the art that other chemistries, and other materials of construction may be employed without departing from the principles herein taught. | A biosensor for use in determining a concentration of a component in an aqueous liquid sample is provided including: an electrochemical cell having a first electrically resistive substrate having a thin layer of electrically conductive material, a second electrically resistive substrate having a thin layer of electrically conductive material, the substrates being disposed with the electrically conductive materials facing each other and being separated by a sheet including an aperture, the wall of which aperture defines a cell wall and a sample introduction aperture whereby the aqueous liquid sample may be introduced into the cell; and a measuring circuit. | 6 |
BACKGROUND OF THE INVENTION
Plastic shutters that are used to decorate the exterior of a house are normally formed in a single mold. Because of this molding process, standard sizes are manufactured at a reasonable cost. Occasionally, non-standard-sized shutters are required.
It is too expensive to have molds for every possible size. Therefore, manufacturers have developed customizable shutters. These products require cutting portions of the shutter parts and various assembly techniques.
In many of these customizable shutters, separate stiles are employed which connect to slats. Caps are positioned on the top and bottom. An example of this is disclosed in Vagedes U.S. Pat. No. 5,924,255. Others simply cut off the portions of the top and bottom of a preformed shutter and add an end cap. Such shutters are disclosed in Gandy U.S. Pat. No. 5,617,688 and Vagedes U.S. Pat. Nos. 5,530,986 and 5,347,782.
It is very important that customized shutters have the appearance of a standard molded shutter. In other words, it is important not to be able to detect cut edges. It is also important that the assembly process not be labor intensive and, of course, the overall product must be aesthetically appealing.
SUMMARY OF THE INVENTION
The present invention is premised on the realization that a customizable shutter can be formed wherein only straight cuts at 90 degree angels are made at the top and bottom of a preformed shutter body that includes both stiles. Such cuts are easily made with available equipment. A special end cap is formed that includes legs that fit into the hollow interior of the stiles with an end cap body portion that has a generally stepped configuration allowing the ends of the stiles to butt up against the end cap, giving the appearance of a finished shutter. Provision is also made to allow the inside wall of the stile to be concealed by the end cap. This can be used for both slatted shutters as well as raised panel shutters.
The objects and advantages of the present invention will be further appreciated in light of the following detailed description and drawings in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the present invention;
FIG. 2 is an exploded view of the present invention;
FIG. 3 is an exploded perspective view of the present invention with portions cut away;
FIG. 4 is a plan view of the present invention;
FIG. 5 is a cross sectional view taken at lines 5 - 5 of FIG. 4 ;
FIG. 6 is a cross sectional view taken at lines 6 - 6 of FIG. 4 ;
FIG. 7 is a perspective view of an alternate embodiment of the present invention;
FIG. 8 is an exploded view of the embodiment in FIG. 6 ;
FIG. 9 is an exploded view of the embodiment shown in FIG. 6 with portions cut away;
FIG. 10 is a plan view of the embodiment shown in FIG. 6 ;
FIG. 11 is a cross sectional view taken at lines 11 - 11 of FIG. 10 ; and
FIG. 12 is a cross sectional view taken at lines 12 - 12 of FIG. 10 .
DETAILED DESCRIPTION
As shown in FIG. 1 , a customizable shutter 10 includes a body portion 12 , a first end cap 14 and a second end cap 16 . The body portion 12 includes first and second stiles 20 and 22 , each with hollow interior portions 24 and 26 . The body portion 12 further includes a central portion 28 which is formed integrally with the first and second stiles 20 and 22 . As shown in FIG. 1 , shutter 10 is a raised panel shutter, which also includes first and second panels 30 and 32 with peripheral inner bevel portion 36 and side bevel portions 38 . Separating the panels 30 and 32 is a cross member 40 which extends from stile 20 to stile 22 .
The body portion 12 has a top edge 42 and a bottom edge 44 . As can be seen, these edges are simply straight cuts that extend at a 90 degree angle from either of the two parallel stiles.
The end caps 14 and 16 both include first and second legs 52 and 54 and a body portion 56 , which is perpendicular to legs 52 and 54 and has a narrow portion or width approximately equal to the width of stiles 22 and 20 . The body portion 56 includes a front surface 58 , an outer surface 60 and an inner surface 62 . The inner surface 62 is designed to mate with the profile of the raised panels 30 or 32 , and conceal the cut edge 42 or 44 , respectively. As such, each of these inner surfaces 62 include a first and second wing portion 64 and 66 which are adapted to mate with the beveled side portions 38 . Extended between the two winged portions is a narrow strip 68 which is adapted to contact and rest on the central panels 30 or 32 . The wings 64 and 66 each have an outer edge 69 which is adapted to butt against an inner side wall 71 of the stiles 20 and 22 . Thus, small channels 70 and 72 are provided between the legs 52 and 54 and the outer edges 69 of the wings 64 and 68 .
As is shown in FIG. 2 , the legs 52 and 54 have a cross sectional configuration adapted to mate with the interior surface of stiles 20 and 22 with the outer edges 73 of the stiles butted against stepped portions 75 in the end caps 14 and 16 at the juncture of the legs with the body portion 56 . Inner edges 77 of the inner walls 71 of the stiles rest in channels 70 and 72 respectively.
To assemble these shutters, the body portion 12 is simply cut at 90 degree angles relative to the stiles 20 and 22 at the top and bottom to achieve a desired length. The legs 52 and 54 of the end caps are then inserted into the hollow interior of the stiles so that the outer edges of the stiles abut the stepped portions 75 of the end caps 14 and 16 with the inner walls 71 of the stiles located in channels 70 and 72 respectively. The interior wall 68 of the body 56 of the end caps cover the outer cut edges of the raised panel with the wing portions 64 and 66 resting immediately on the beveled portions and the edge 68 resting on the panel surface 28 . Thus, the entire cut edges 42 and 44 on the top and bottom of the body portion 12 either abut stepped portions on the end cap or are concealed by the interior wall 68 of the end cap. The legs 52 and 54 can then be welded, adhered, or fastened to the stile surface to provide a unitary custom-sized shutter.
FIG. 7 to 12 show an alternate embodiment of the present invention and specifically a customizable slatted shutter 80 .
As shown in FIG. 8 , shutter 80 includes a body portion 82 with first and second integral stiles 84 and 86 and a central slatted portion 88 and first and second end caps 90 and 92 . Top and bottom edges 96 and 98 of the body portion 82 are cut edges, which extend 90 degrees relative to the two stiles to provide the desired size.
The end caps 90 and 92 include first and second legs 100 and 102 with a central body portion 104 that extends 90 degrees from the legs. The body portion includes a front surface 106 , an outer surface 108 and an inner surface 110 which faces the slatted portion. The inner wall 110 is a very thin rectangular panel which extends from side to side and includes side edges spaced from legs 100 and 102 providing side channels 122 and 124 . The legs 100 and 102 are sized to mate with the interior surface of the stiles 84 and 86 which, as shown, each includes an outer wall 116 , an inner wall 118 and a top wall 120 . The edges 134 and 136 of the top and outer walls 120 and 116 of the stiles abut against the stepped portions 112 and 114 between the legs 100 , 102 and the body portion 104 of end caps 90 , 92 . Edges 138 of the inner wall 118 of stiles 84 and 86 rest in channels 122 and 124 .
As with the raised panel shutter, the slatted shutter is formed by simply cutting body portion 82 and inserting the end caps 90 and 92 . The legs 100 and 102 can then be welded, adhered, or fastened to the body portion at the interior surfaces of the stiles. The inner wall 110 of the caps will cover the edges 96 , 98 of the body portion 82 . The edges of the stiles will butt against the stepped portions 112 and 114 of the end caps 90 and 92 to provide a neat, clean appearance which will basically be identical to the pre-molded unitary shutters.
The present invention can, of course, be modified without departing from the scope of the invention. As an example, the leg portions of the end caps can be modified so that they do not take the exact configuration of the interior surface of the stiles, but can simply be a single tab or two tabs, as opposed to the three-walled structure shown in the present invention. As long as they can mate along one or more surfaces of the stiles, they can provide the needed stability for the assembled product.
This has been a description of the present invention along with the preferred method of practicing the present invention. However, the invention itself should only be defined by the appended claims, | A custom shutter includes a central body portion and first and second end caps. The central body portion includes two stiles and a central portion all of which are formed integrally as one piece. The top and bottom end caps include first and second legs and a central connecting body portion. The legs are designed to be inserted within the hollow interior of the stiles with the top edges of the stiles resting against the stepped portions of said end cap and wherein an inner surface of said end cap covers any exposed edge of the central portion of the shutter body. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to multimedia communications. More particularly, this invention relates to a method and an apparatus for indexing multimedia communications.
[0003] 2. Description of Related Art
[0004] Multimedia communications used, for example, in a conference call, may be saved for future review by conference call participants or other interested parties. That is, the audio, video and data communications that comprise the conference call may be stored for future retrieval and review. An individual may desire to see the entire conference call replayed, or may want to review only selected portions of the conference call. The individual may want to have participants identified to determine what they said and when they said it or to determine who is saying what. For example, the individual may want to review only the audio from one particular conference call participant.
[0005] However, some conference calls include more than one participant at a given location or end point. The audio, for example, for all the participants at a given location may be recorded and retained for future review. When a large number of participants are involved in the conference call, separating out individual audio tracks, for example, is difficult due to limitations of current systems to differentiate between the participants. This situation can arise when there are a large number of participants at all the locations or when there are a large number of participants at one particular location. Therefore, a more efficient and reliable method for indexing multimedia communications is needed.
SUMMARY OF THE INVENTION
[0006] The invention provides a reliable and efficient method and apparatus for indexing multimedia communications so that selected portions of the multimedia communications can be efficiently retrieved and replayed. The invention uses distinctive features of the multimedia communications to achieve the indexing. For example, the invention provides a combination of face recognition and voice recognition features to identify particular participants to a multicast, multimedia conference call. Data related to the identities of the particular participants, or metadata, may be added, as part of a multimedia data packet extension header, to multimedia data packets containing the audio and video information corresponding to the particular participants, thus indexing the multimedia data packets. The multimedia data packets with the extension headers may then be stored in a database or retransmitted in near real-time (i.e., with some small delay). Then, multimedia data packets containing, for example, audio from a particular individual, can be readily and reliably retrieved from the database by specifying the particular individual.
[0007] Other features, such as background detection and key scene changes can also be used to index the multimedia communications. Data related to these features is also added to multimedia data packet extension headers to allow reliable retrieval of data associated with these features.
[0008] In a preferred embodiment, the participants to the multimedia communications are connected via a local area network (LAN) to a multicast network. An index server within the multicast network receives the multimedia communications from different locations, manipulates/alters the communication and simultaneously broadcasts, or multicasts, the altered multimedia communications to all other locations involved in the multimedia communications. Alternately, the locations can be connected to the multicast network using plain old telephone service (POTS) lines with modems at individual locations and at the multicast network or using ISDN, xDSL, Cable Modem, and Frame Relay, for example.
[0009] These and other features and advantages of the invention are described in or are apparent from the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention is described in detail with reference to the following drawings, in which like numerals refer to like elements, and wherein:
[0011] [0011]FIG. 1 is a block diagram of a multicast network according to the present invention;
[0012] [0012]FIG. 2 is a block diagram of a server platform of the invention;
[0013] [0013]FIG. 3 is a block diagram of representative equipment used by multimedia conference call participants;
[0014] [0014]FIG. 4 is an alternate equipment arrangement;
[0015] [0015]FIG. 5 is a logical diagram of an index server;
[0016] [0016]FIG. 6 is an alternate arrangement for a multicast network;
[0017] [0017]FIG. 7 is a logical diagram of an index used in the multicast network of FIG. 6;
[0018] [0018]FIG. 8 is a representation of a multimedia data packet;
[0019] [0019]FIG. 9 is a logical representation of an index table;
[0020] [0020]FIG. 10 is a flowchart representing the multicast operation; and
[0021] [0021]FIGS. 11A and 11B show a flowchart representing operation of the indexing process.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] Multimedia communications can be provided with metadata that can be recorded along with the multimedia communications and possibly rebroadcast along with the original communications in near real time. Metadata is simply information about data. That is, metadata is information that can be used to further define or characterize the data. A paradigm example of metadata is a time stamp. When multimedia communications are recorded, a time of production may be associated with the communications. A time stamp can be added to the multimedia communications to provide an indexing function. However, a time stamp is often not an adequate method for indexing, multimedia communications.
[0023] One method for indexing multimedia communications is provided in U.S. Pat. Number 5,710,591, “Method and Apparatus for Recording and Indexing Audio and Multimedia Conference,” which is hereby incorporated by reference. However, when the multimedia communications originate from several different locations a multicast feature must be included to provide optimum conference performance.
[0024] Accordingly, this invention provides a method and an apparatus to allow indexing of multicast, multimedia communications that is based on distinguishing features such as the identity of participants to the multimedia communications and other features associated with the locations where the multimedia communications originate. The participants in the multimedia communication can view a slightly time-delayed version of the original communication that now includes the metadata. The indexing then allows subsequent users of a multimedia communications service to easily and efficiently search for and replay audio, video and data communications of a particular individual, for example.
[0025] For example, the invention uses voice and image feature/object recognition in conjunction with RTP packet protocol information to identify specific speakers at a given location. Information that identifies the specific speakers is then inserted into RPT packets, and the RTP packets are rebroadcast/multicast to other participants in a multimedia communication. The thus-modified RTP packets may be stored and later retrieved on demand.
[0026] In one example of the invention, the indexing feature is provided for a multicast, multimedia conference call. However, the invention can be used with any multimedia communications.
[0027] [0027]FIG. 1 shows an example of an apparatus for completing the multicast, multimedia conference call. In FIG. 1, a multicast network 10 receives multimedia communications from locations, or sources, S 1 , S 2 and S 3 , that are engaged in a multimedia conference call. Each of the sources S 1 , S 2 and S 3 includes one or more conference call participants. Thus, participants P 1 , P 2 , P 3 and P 4 are at the source S 1 ; participants P 5 and P 6 are at the source S 2 ; and participants P 7 and P 8 are at the source S 3 in this example. However, the invention is not limited to three sources and eight participants, and any number of sources with any number of participants may be engaged in the multimedia conference call.
[0028] In FIG. 1, the sources S 1 , S 2 and S 3 connect to the multicast network 10 over a local area network such as an Ethernet or any local area network (e.g. ATM) capable of providing sufficient bandwidth. The multimedia conference call could also be completed over existing telephone lines using asymmetric digital subscriber line (ADSL) or integrated services digital network (ISDN) connectors. The method for providing the multimedia conference call could also operate over the public Internet in conjunction with Internet Protocols (IP) . Finally, the method could also be applied to a public switched telephone network (PSTN), for example. The communications may use Real Time Protocols (RTP), Internet Protocols (IP) and User Datagram Protocols (UDP).
[0029] Communications from the sources S 1 , S 2 and S 3 are received at routers R located in the multicast network 10 . The routers R ensure that the communications from each of the sources and from the multicast network 10 are sent to the desired address. The multicast network 10 connects to an index server 20 . The index server 20 participates in the multimedia conference call among the sources S 1 , S 2 and S 3 .
[0030] As shown in FIG. 2, the index server 20 may be a multimedia communications device such as a multicast server or a bridge. If a bridge is used, the bridge may repeatedly transmit the multimedia communications, one transmission for each source connected to the multimedia conference call. The multicast server may transmit the multimedia communications simultaneously to each of the sources. In the discussion that follows, the index server 20 participates in a multimedia conference call among the sources S 1 , S 2 and S 3 . The index server 20 receives multimedia communications from all the sources and simultaneously retransmits the multimedia communications to all the sources. For example, the index server 20 receives multimedia including audio, video and data from sources S 1 , S 2 and S 3 . The index server 20 then simultaneously retransmits, or multicasts, the multimedia communications from sources S 2 and S 3 to source S 1 , the multimedia communications from sources S 1 and S 2 to source S 3 , and the multimedia communications from sources S 1 and S 3 to source S 2 .
[0031] Also as shown in FIG. 2, the index server 20 includes a buffer 22 and a database 23 . The buffer 22 temporarily stores data that is to be processed by an index process module 21 . The buffer 22 is needed because of slight time delays between receipt of the multimedia communications and subsequent index processing. The buffer 22 is also necessary because feature recognition modules (to be described later) contained in the index process module 21 may require several milliseconds of data in order to correctly identify a distinguishing feature. However, the multimedia communications are received at the multicast server in multimedia data packets that may contain as few as 10 μsec of data. Thus, the buffer 22 may store the multimedia data packets temporarily until a sufficient amount of data is available to allow processing by the index process module 21 .
[0032] The database 23 is used to store indexed multimedia communications for subsequent playback, and to store certain information related to the sources and to the participants in the multimedia communications. For example, all the communications received at the multicast network 10 include a time stamp. The time stamp, in addition to serving an indexing function, allows synchronization of the different multimedia communications. That is, the time stamp allows for synchronization of video and data communications from the source S 1 and for synchronization of communications from the sources S 1 and S 2 , for example. For indexing, the time stamp can be used to segment the multimedia conference call according to time, and an individual can replay selected portions of the multimedia conference call corresponding to a set time period. The time stamp information is stored in the database 23 along with the multimedia communications.
[0033] The index server 20 allows for indexing of the multimedia conference call. Specifically, the index server 20 may index the multimedia communications received from the sources S 1 , S 2 and S 3 . The indexing adds metadata to the multimedia conference call data. The metadata could include information that identifies a particular participant, for example. In the preferred embodiment, speaker identification and face recognition software determines the identity of the participant. Once the participant is identified, the index server 20 creates an index table that becomes an index to the multimedia conference call. The indexing process will be described in more detail later. Furthermore, the invention is not limited to distinguishing between live persons. Any object may be distinguished according to the invention including animals, plants and inanimate objects.
[0034] [0034]FIGS. 3 and 4 show examples of a communications device available at the sources S 1 , S 2 and S 3 . FIG. 3 shows a video phone 60 that is an example of a communication device that the participants may use to communicate multimedia information. FIG. 4 shows a computer 40 that is another example of a multimedia communications device that the participants may use in accordance with the invention. The computer 40 includes a data entry device such as a keyboard 41 and a mouse 42 , a central processor unit (CPU) 43 , a visual display 44 , speakers 45 , a video camera 46 and a microphone 47 . The computer 40 connects to the multicast network 10 through LAN connectors 48 . The computer 40 may be a personal computer, a portable computer, a workstation or a main frame computer. The microphone 47 captures and transmits the audio portion of the multimedia conference call. An analog to digital converter or sound card (not shown) converts the analog speech into a digital representation. The video camera 46 captures and transmits an image of each participant. The video camera 46 may be an analog or a digital camera. If an analog camera is used, the video signal from the video camera 46 is first sent to a codec (not shown) for conversion to a digital signal before it is transmitted to the multicast network 10 . Furthermore, the video camera 46 may be voice activated so that the video camera 46 slews, or rotates, to capture the image of a speaker. The speakers 45 provide audio signals to the participants. The display 44 may display images of the participants. The display 44 may also display information related to the multimedia call such as a call label and toolbars that allow the participants to interact with the index server 20 in the multicast network 10 .
[0035] The computer 40 is provided with a specific application program that allows the participants to interface with the index server 20 and other network components. The keyboard 41 and the mouse 42 function as data input devices that allow participants to send commands to the index server 21 , for example. The computer 40 includes a packet assembler (not shown) that compresses and assembles the digital representations of the multimedia communications into discrete packets. The CPU 43 controls all functions of the computer 40 .
[0036] As noted above, at least two ways are available to identify individual conference call participants. Face recognition software such as FACEIT® automatically detects, locates, extracts and identifies human faces from live video. FACEIT® requires a personal computer or similar device and a video camera and compares faces recorded by the video camera to data stored in a database such as the database 23 , using statistical techniques. FACEIT® is described in detail at http://www.faceit.com.
[0037] FACEIT® uses an algorithm based on local feature analysis (LFA) which is a statistical pattern representation formalism that derives from an ensemble of examples of patterns a unique set of local building blocks that best represent new instances of these patterns. For example, starting with an ensemble of facial images, LFA derives the set of local features that are optimal for representing any new face. Equipped with these universal facial building blocks, FACEIT® automatically breaks down a face into its component features and compares these features to stored data such as data stored in the database 23 . Therefore, to use FACEIT®, each multimedia conference call participant's face must first be registered with the multimedia service so that the facial features can be stored in the database 23 . Then, during subsequent multimedia conference calls, FACEIT® can be used to identify a face from all the faces being captured by the video cameras 46 . Although the above discussion refers to FACEIT®, it should be understood that the present invention is not limited to use of this particular facial identification system.
[0038] In addition to face recognition, the preferred embodiment includes a speech recognition feature in which a participant is identified based on spectral information from the participant's voice. As with the face recognition feature, the multimedia conference call participant must first register a speech sample so that a voice model is stored in the database 23 . The speech recognition feature requires an input, a processor and an output. The input may be a high quality microphone or microphone array for speech input and an analog to digital conversion board that produces digital speech signals representative of the analog speech input. The processor and output may be incorporated into the multicast network 10 . A speech recognition system is described in detail in U.S. Pat. No. 5,666,466, which is hereby incorporated by reference.
[0039] By using both speech recognition and face recognition systems, the preferred embodiment can reliably and quickly identify a particular multimedia conference call participant and thereby allow precise indexing of the multimedia conference call. That is, in a multimedia conference call involving several different sources with numerous participants at each source, identifying a particular participant out of the total group of participants is difficult to achieve with current systems. However, this invention can locate an individual to a particular source, such as source S 1 , based on source address and in addition, applies speech and face recognition, only among specific individuals at a particular location. The index process module 21 then compares participant face and speech patterns contained in the database 23 to audio information and video information being received at the multicast network 10 during the multimedia conference call. By using both face recognition and speech recognition systems, the invention is much more likely to correctly identify the particular participant than a system that uses only speech recognition, for example.
[0040] Other metadata may be used in addition to face and speech recognition data to index the multimedia conference call. For example, if the background changes, the index process module 21 can detect this event and record the change as metadata. Thus, if the video camera 46 that is recording the video portion of the multimedia conference call at a source, such as source S 1 , slews or rotates so that the background changes from a blank wall to a blackboard, for example, the index process module 21 may detect this change and record a background change event. This change in background can then be used for subsequent searches of the multimedia conference call. For example, the individual reviewing the contents of a multimedia conference call may desire to retrieve those portions of the multicast, multimedia conference call in which a blackboard at the source S 1 is displayed. As with face and speech recognition, the index process module 21 may have stored in the database 23 , a representation of the various backgrounds at the sources S 1 , S 2 and S 3 , that are intended to be specifically identified. Similarly, a change in key scene features may be detected and used to classify or index the multimedia conference call. Key scene feature changes include loss or interruption of a video signal such as when a source, such as source S 1 , purposely goes off-line, for example.
[0041] [0041]FIG. 5 shows the index process module 21 in detail. A control module 31 controls the functions of index process module 21 . When multimedia communications are transmitted to the multicast network 10 , a multicast module 32 in the index process module 21 receives and broadcasts the multimedia communications. In parallel with broadcasting the multimedia communications, a speech recognition module 33 compares data received by the multicast module 32 to speech models stored in the database 23 to determine if a match exists and outputs a speech identifier when the match exists. In addition, a face recognition module 34 , which incorporates face recognition software such as FACEIT®, compares the data to face models stored in the database 23 and outputs a face identifier when a match is determined between video data comprising the multimedia communications and facial models stored in the database 23 . Finally, a scene recognition module 35 compares scenes captured by the video camera 46 to scenes stored in the database 23 to determine if any background or key scene changes occurred. The scene recognition module 35 outputs a scene change identifier when a background change, for example, is detected. When any of the above recognition modules determines that a match exists, a header function module 36 receives the inputs from the face, speech and scene recognition modules 33 , 34 and 35 , respectively. The header function module 36 , based on the inputs, creates an multimedia extension header, attaches the multimedia extension header to the multimedia data packet, and applies certain information, or data, to the multimedia extension header, based on the inputs received from the speech, face and scene modules 33 , 34 and 35 , respectively. The multimedia data packets with the modified headers are then retransmitted/multicast into the network. The multimedia extension header is described below.
[0042] As noted above, the present invention is able to provide indexing of multimedia communications because the multimedia data streams are divided into multimedia data packets, and each multimedia data packet contains at least one multimedia header. The conversion of the data into digital format is performed at the source, such as source S 1 . Specifically, a processor, such as the computer 40 , receives the audio and video data in an analog format. For example, with the audio data, audio analog wave forms are fed into a sound card that converts the data into digital form. A packet assembler (not shown) then assembles the digitized audio data into multimedia data packets. The multimedia data packets include a segment that contains the digital data and a segment, or multimedia header, that contains other information, such as the source IP address and the destination IP address, for example. The multimedia header is also used by the index process module 21 to hold the data needed to provide the indexing function.
[0043] [0043]FIG. 6 shows an alternate arrangement of an apparatus for indexing multimedia communications. In FIG. 6, source S 4 with participants P 10 and P 12 connects to a multicast network 80 via a computer system 70 and a local indexer 72 . Source S 5 , with participants P 9 and P 11 , connects to the multicast network 80 via a computer system 71 and a local indexer 73 . The computer systems 70 and 72 (or 71 and 73 ) contain all the components and perform all the functions as the apparatus shown in FIG. 3.
[0044] Multimedia communications from the sources S 4 and S 5 are received at routers R located in the multicast network 80 . The multicast network 80 connects to a server 81 that may be a multicast server or a bridge. Multimedia communications from the sources S 4 and S 5 may be stored in a database 82 .
[0045] The apparatus of FIG. 6 differs from that of FIG. 1 in that the indexing function occurs locally at the sources S 4 and S 5 . That is, face recognition and speech recognition functions, for example, are performed by the indexers 72 and 73 at the sources S 4 and S 5 , respectively.
[0046] [0046]FIG. 7 is a logical diagram of the indexer 72 . The description that follows applies to the indexer 72 . However, the indexer 73 is identical to the indexer 72 ; hence the following description is equally applicable to both indexers. An interface module 90 receives multimedia data packets from the computer system 70 . A buffer 91 temporarily stores the multimedia data packets received at the interface module 90 . A database 92 stores face, speech and background models for the source S 4 . A speech recognition module 93 compares audio received by the interface module 90 to speech models stored in the database 92 to determine if a speech pattern match exists. The speech recognition module 93 outputs a speech identifier when the speech pattern match exists. A face recognition module 94 compares video data received at the interface module 90 to face models stored in the database 92 to determine if a face pattern match exists, and outputs a face identifier when the face pattern match exists. A scene recognition module 95 compares scenes captured by the computer system 70 to scene models stored in the database 92 , and outputs a scene identifier when a scene match exists. A header function module 96 creates a multimedia extension header, attaches the multimedia extension header to the multimedia data packet, and applies specific data to the multimedia extension header, based on the inputs from the speech, face and scene recognition modules 93 , 94 and 95 , respectively. The local indexer 72 may also incorporate other recognition modules to identify additional distinguishing features for indexing the multimedia communications.
[0047] [0047]FIG. 8 shows a multimedia data packet 100 . In FIG. 8, a data segment 110 (payload) contains the data, such as the audio data, for example, that was transmitted from the source S 1 . A multimedia data packet header segment 120 contains additional fields related to the multimedia communications. An extension field 121 may be used to indicate that the multimedia data packet 100 contains a multimedia extension header. A payload type field 122 indicates the type of data contained in the data segment 110 . A source identifier field 123 indicates the source of the multimedia data packet. The header segment 120 may contain numerous additional fields.
[0048] Returning to the first embodiment, a header extension segment 130 may be added to allow additional information to be carried with the multimedia data packet header segment 120 . When indexing a particular packet, the index process module 21 records the appropriate metadata in the header extension segment 130 . In this case, a bit is placed in the extension field 121 to indicate the presence of the header extension segment 130 . Once the multimedia data packet 100 arrives at the multicast network 10 , the index process module 21 compares the data contained in the data segment 110 to face and speech models contained in the database 23 . If a match is achieved, the control module 31 in the index process module 21 directs the header function module 36 to add to the multimedia data packet header segment 120 , the header extension segment 130 , which includes the speech or face identifiers, as appropriate. When the data in the data segment 110 indicates a background change or a key scene event, the index process module 21 adds a corresponding indication to the header extension segment 130 .
[0049] In the preferred embodiment, the multimedia data packet 100 is then stored in the database 23 . Alternately, the data in the data segment 110 may be separated from the multimedia data packet header segment 120 . In that case, the index process module 21 creates a separate file that links the data in the multimedia data packet header segment 120 to the data contained in the data segment 110 .
[0050] [0050]FIG. 9 is a logical representation of an index table for a multimedia conference call. In FIG. 9, the index process module 21 is receiving the multimedia conference call described above. When a participant such as participant P 1 is speaking, the header function module 36 adds to the multimedia data packet, a header extension segment 130 that includes an index/ID for participant P 1 . The index process module 21 then stores the resulting multimedia data packet in the database 23 . Thus, as shown in FIG. 9, for participant P 1 at location S 1 , the database 23 stores a speaker ID model VO-102 and a video model VI-356. Then, by specifying the participant P 1 (associated with VO-102 and VI-356), the corresponding data packets can be retrieved from the database 23 and their contents reviewed.
[0051] To identify a particular participant based on information in a multimedia data packet, such as the multimedia data packet 100 , the index process module 21 first retrieves the multimedia data packet 100 from the buffer 22 . The index process module 21 reads the payload type field 122 in the data packet header segment 120 to determine if the multimedia data packet 100 contains audio data. If the multimedia data packet 100 contains audio data, the index process module 21 determines if there is a multimedia data packet from the same source with a corresponding time stamp that contains video data. With both video and audio multimedia data packets from the same source with approximately the same time stamp, the index process module 21 can then compare the audio and video data to the speech and face models contained in the database 23 . For example, the face recognition module 34 , containing FACEIT®, compares the digitized video image contained in the multimedia data packets 100 to the face models stored in the database 23 . The speech recognition module 32 compares the digitized audio in the multimedia data packets 100 to the speech models stored in the database 23 . By using both speech and face recognition features, the index process module 21 may more reliably identify a particular participant.
[0052] [0052]FIG. 10 is a flowchart representing the process of indexing multimedia communications in accordance with the multicast network 10 shown in FIG. 1. The index process module 21 starts with step S 100 . In step S 110 , the index process module 21 queries all participants to register their face and speech features. If all participants are registered, the index process module 21 moves to step S 150 . Otherwise, the index process module 21 moves to step S 120 . In step S 120 , individual participants register their face and speech features with the index process module 21 . The index process module 21 then moves to step S 150 .
[0053] In step S 150 , the index process module 21 stores the multimedia communications from the sources S 1 , S 2 and S 3 in the buffer 22 . That is, the index process module 21 stores the multimedia data packets containing the audio, video and data communications from the sources S 1 , S 2 and S 3 . The index process module 21 then moves to step S 160 and the multimedia communications end.
[0054] [0054]FIGS. 11A and 11B show processing of the multimedia data packets which were stored in the buffer 22 (of FIG. 2) during the multimedia communications of FIG. 10, using the multicast network of FIG. 1. In FIG. 11A, the index process module 21 processes each multimedia data packet to identify participants by face and speech patterns. The index process module 21 starts at step S 200 . In step S 210 , the index process module 21 selects a multimedia data packet for indexing. The index process module 21 then moves to step S 220 . In step S 220 , the index process module 21 reads the payload type field 122 and source identifier field 123 . The index process module 21 thus determines the source of the multimedia data packet and the type of data. If the multimedia data packet contains audio data, the index process module 21 moves to step S 230 . Otherwise the index process module 21 jumps to step S 280 .
[0055] In step S 230 , the index process module 21 notes the time stamp of the multimedia data packet and determines if there are any corresponding video multimedia data packets from the same source with approximately this time stamp. If there are, the index process module 21 moves to step S 240 . Otherwise, the index process module 21 jumps to step S 250 . In step S 240 , the index process module 21 retrieves the corresponding video multimedia data packet identified in Step S 230 . The index process module 21 then moves to step S 250 .
[0056] In step S 250 , the index process module 21 compares the audio and video data contained in the multimedia data packets to face and speech models for the sources as identified by the source identifier field of FIG. 8 stored in the database 23 . The index process module 21 then moves to step S 260 . In step S 260 , the index process module 21 determines if there is a pattern match between the audio and video data contained in the multimedia data packets and the face and speech models. If there is a match, the index process module 21 moves to step S 270 . Otherwise the index process module 21 moves to step S 300 .
[0057] In step S 270 , the index process module 21 creates a variable length header extension segment and attaches the segment to the multimedia data packet header. The index process module 21 places a bit in the extension field 122 to indicate the existence of the header extension segment. The index process module 21 also populates the header extension segment with data to indicate the identity of the participant. The index process module 21 then stores the multimedia data packet in the database 23 (as detailed in FIG. 11B). The index process module 21 then moves to step S 280 .
[0058] In step S 280 , the index process module 21 determines if the multimedia data packet selected in step S 210 contains video data. If the multimedia data packet contains video data, the index process module 21 moves to step S 290 . Otherwise the index process module 21 process moves to step S 300 . In step S 290 , the index process module 21 determines if the multimedia data packet contains background change or key scene change data. If the multimedia data packet contains the data, the index process module 21 moves to step S 310 . Otherwise the index process module 21 moves to step S 300 .
[0059] In step S 310 , the index process module 21 creates a variable length header extension segment and attaches the segment to the multimedia data packet header. The index process module 21 places a bit in the extension field 122 to indicate the existence of the header extension segment. The index process module 21 also populates the header extension segment with data to indicate the identity of the change event. The index process module 21 then stores the multimedia data packet in the database 23 . The index process module 21 then moves to step S 320 .
[0060] In step S 300 , the index process module 21 stores the multimedia data packet in the database 23 without the header extension segment and without the bit in the extension field. The index process module 21 then returns to step S 210 .
[0061] In step S 320 , the index process module 21 determines if all the multimedia data packets for the multimedia communication have been indexed. If all multimedia data packets have not been indexed, the index process module 21 returns to step S 210 . Otherwise the index process module 21 moves to step S 330 . In step S 330 , the index process module 21 creates an index table that associates the identity of each participant with corresponding multimedia data packets and indicates for each multimedia data packet, the appropriate face and speech model for the participant. For multimedia data packets that contain background and scene change data, the index table includes a reference to the change event. The index process module 21 then moves to step S 340 and ends processing of the multimedia data packets.
[0062] In the illustrated embodiments, suitably programmed general purpose computers control data processing in the multicast network 10 and at the sources. However, the processing functions could also be implemented using a single purpose integrated circuit (e.g., an ASIC) having a main or central processor section for overall, system-level control, and separate circuits dedicated to performing various specific computational functional and other processes under control of the central processor section. The processing can also be implemented using separate dedicated or programmable integrated electronic circuits or devices (e.g., hardwired electronic or logical devices). In general, any device or assembly of devices on which a finite state machine capable of implementing the flowcharts of FIGS. 10, 11A and 11 B can be used to control data processing.
[0063] The invention has been described with reference to the preferred embodiments thereof, which are illustrative and not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims. | A network based platform uses face recognition, speech recognition, background change detection and key scene events to index multimedia communications. Before the multimedia communication begins, active participants register their speech and face models with a server. The process consists of creating a speech sample, capturing a sample image of the participant and storing the data in a database. The server provides an indexing function for the multimedia communication. During the multimedia communication, metadata including time stamping is retained along with the multimedia content. The time stamping information is used for synchronizing the multimedia elements. The multimedia communication is then processed through the server to identify the multimedia communication participants based on speaker and face recognition models. This allows the server to create an index table that becomes an index of the multimedia communication. In addition, through scene change detection and background recognition, certain backgrounds and key scene information can be used for indexing. Therefore, through this indexing apparatus and method, a specific participant can be recognized as speaking and the content that the participant discussed can also be used for indexing. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to defect inspection apparatus and a defect inspection method which are used in a manufacturing line of a semiconductor device, liquid crystal device, magnetic head or the like, and particularly relates to a calculation technique of size of a detected defect.
Inspection of a semiconductor wafer is described as an example.
In a semiconductor manufacturing process in the related art, foreign substances on a semiconductor substrate (wafer) may cause inferiority such as imperfect insulation or a short circuit. When a fine foreign substance exists in a semiconductor substrate of a semiconductor element which is significantly miniaturized, the foreign substance may cause imperfect insulation of a capacitor or breakdown of a gate oxide film. The foreign substances may be contaminated in various ways due to various reasons, such as contamination from a movable portion of a carrier device, contamination from a human body, contamination from reaction of a process gas in treatment equipment, and previous contamination in chemicals or materials. Similarly, in a manufacturing process of a liquid crystal display device, contamination of a foreign substance on a pattern, or formation of some defects disables the device as a display device. The same situation occurs in a manufacturing process of a printed circuit board, that is, contamination of the foreign substance leads to a short circuit of a pattern or imperfect connection.
It is now increasingly important to detect a defect such as foreign substance causing inferior products and take the measure for causes of the defect and thus keep a certain yield of products for stably producing a semiconductor element or a flat display device represented by the liquid crystal display device, which are expected to be further miniaturized even more in the future.
To keep the yield of products, it is necessary to determine whether a detected defect such as foreign substance has influence on the yield or not, and it is important to obtain information of a position where the defect such as foreign substance was detected, and information of size of the detected defect.
As a technique for calculating size of a defect detected by defect inspection apparatus, as described in JP-A-5-273110, a method is disclosed, in which a laser beam is irradiated to an object, and then scattering light from a particle on the object or a crystal defect therein is received and then subjected to image processing, thereby size of the particle or the crystal defect is measured. In “Yield Monitoring and Analysis in Semiconductor Manufacturing” mentioned in digest of ULSI technical seminar, pp 4-42 to 4-47 in SEMIKON Kansai in 1997, a yield analysis method using a defect by a foreign substance detected on a semiconductor wafer is disclosed.
SUMMARY OF THE INVENTION
As described above, inspection apparatus in the related art for various fine patterns including a pattern in a semiconductor device is now hard to satisfy detection accuracy of defect size required for detection of a defect on an increasingly miniaturized pattern. Therefore, it is desirable to accurately calculate size of a detected defect.
Defect inspection apparatus according to embodiments of the invention includes a unit for classifying defects into a plurality of classes based on feature quantity of the defects at detection, and modifying a size calculation method of a defect for each of classes.
That is, in embodiments of the invention, defect detection apparatus for detecting a defect of an object is configured to have an illumination unit for illuminating light to the object; a detection unit for detecting scattering light from the object; a defect detection unit for detecting the defect by processing a detection signal of the scattering light detected by the detection unit; a size measuring unit for calculating size of the defect detected by the defect detection unit; a size correction unit for correcting the size of the defect detected by the size measuring unit depending on separately obtained information of feature quantity or a type of the defect; a data processing unit for processing a result corrected by the size correction unit; and a display unit for displaying information of a result processed by the data processing unit.
According to embodiments of the invention, size of a detected defect can be accurately calculated, and for example, only defects having a size larger than a size to be managed can be extracted in semiconductor manufacturing. Thus, since a defect having higher influence on a production yield can be preferentially managed, productivity is improved in semiconductor manufacturing.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings.
FIG. 1 is a block diagram showing a schematic configuration of defect inspection apparatus according to embodiments of the invention;
FIGS. 2A to 2B are graphs showing examples of defect detection signals, wherein FIG. 2A shows a case of large signal intensity, and FIG. 2B shows a case of small signal intensity;
FIGS. 3A to 3B are views showing processing for each region, wherein FIG. 3A shows an example of dividing the inside of a die (chip), and FIG. 3B shows an example of dividing a front face of a wafer;
FIGS. 4A to 4B are scatter diagrams of defect size, wherein FIG. 4A shows an example of large dispersion, and FIG. 4B shows an example of small dispersion;
FIGS. 5A to 5B are views showing examples of representative values of defect size, wherein FIG. 5A shows an example of X or Y size, and FIG. 5B shows an example of L size;
FIG. 6 is a flowchart of setting a correction factor of size calculation;
FIG. 7 is a flowchart of inspection and output;
FIGS. 8A to 8C are views showing examples of size correction using defects of which the size is known, wherein FIG. 8A shows a condition that the defects of which the size is known are disposed on a wafer, FIG. 8B shows a condition that size measured by SEM does not comparatively correspond to size detected and calculated by the defect inspection apparatus in a scatter diagram of defect size, and FIG. 8C shows a condition that the calculated size comparatively corresponds to the size measured by SEM by changing a slope of a graph by changing a factor when size of a defect detected by the defect inspection apparatus is calculated, in the scatter diagram of defect size;
FIG. 9 is a flowchart of calculating a correction factor of size;
FIGS. 10A to 10C are views showing correction examples when a defect signal is saturated, wherein FIG. 10A is a graph showing a condition that the defect signal is not saturated,
FIG. 10B is a graph showing a condition that the defect signal is saturated, and FIG. 10C is a view showing a method of predicting a peak value of a signal when a detection signal is saturated;
FIGS. 11A to 11B are scatter diagrams of defect size, wherein FIG. 11A shows a condition that size measured by SEM does not comparatively correspond to size detected and calculated by the defect inspection apparatus, and FIG. 11B shows a condition that size, which was calculated with performing correction to a defect detected by the defect inspection apparatus based on feature quantity of the defect, comparatively corresponds to the value measured by SEM;
FIG. 12 is a block diagram showing a relationship between a manufacturing process and inspection apparatus;
FIG. 13 is a graph showing a relationship between yield and the number of detected defects;
FIGS. 14A to 14B are graphs showing examples of a method of extracting a defect signal and feature quantity, wherein FIG. 14A shows a case of using a threshold obtained by a normal threshold setting method, and FIG. 14B shows a case of setting a threshold lower than a normal threshold;
FIG. 15 is a front view of a display screen showing a screen display example of the defect inspection apparatus; and
FIGS. 16A to 16B are view of an example of an illumination optical system, wherein FIG. 16A is a front view, and FIG. 16B is a side view.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an example of a configuration of inspection apparatus according to embodiments of the invention (hereinafter, mentioned as defect inspection apparatus).
The defect inspection apparatus is configured to have an illumination system 100 , a stage system 200 , a detection system 300 , a Fourier transform surface observation system 500 , a signal processing section 400 , an observation optical system 600 , and a control section 2 .
Defect detection using the defect inspection apparatus shown in FIG. 1 is performed according to the following procedure. The illumination system 100 illuminates a wafer 1 set in the stage system 200 , and the detection system 300 acquires an image of the illuminated wafer 1 . The illumination system 100 adjusts output of a light source 101 by an illumination controller 103 according to an instruction value of the control section 2 . As the light source 101 , a laser light source is used, which emits laser in an ultraviolet region having a wavelength of 400 nm or less. The illumination system 100 includes a unit (not shown) for reducing coherency of the laser emitted from the laser light source. Illumination light is shaped into an appropriate form on the wafer 1 by an optical system 102 . The stage system 200 includes a rotation stage 201 , a Z stage 202 , an X stage 203 , and a Y stage 204 , and moves with respect to the detection system 300 so that the detection system 300 can scan the whole surface of the wafer 1 .
The detection system 300 includes a Fourier transform lens 301 , spatial filter 302 , focusing lens 303 , and sensor 304 . Here, the spatial filter 302 is to shield a diffraction light pattern caused by diffraction light from a repetitive pattern on the wafer 1 , and set on the Fourier transform surface of the Fourier transform lens 301 . A light shielding pattern of the spatial filter 302 is set such that a diffraction pattern of the wafer 1 is shielded, the diffraction pattern being observed by the Fourier transform surface observation system 500 having a structure that can be inserted and removed into/from an optical path of the detection system 300 . That is, the system 500 is inserted into an optical path of the detection system 300 while removing the spatial filter 302 , and then the optical path is branched by a beam splitter 501 , and an image on the Fourier transform surface of the Fourier transform lens 301 is taken by a camera 503 via a lens 502 and observed. The light shielding pattern of the spatial filter 302 can be set for each type of an object or each of steps. The light shielding pattern of the spatial filter 302 may be fixed during wafer scan, or may be changed in real time depending on a region under scanning.
An image acquired by the detection system 300 is subjected to AD conversion and then transferred to the signal processing section 400 , wherein the image is processed to detect a defect. The defect inspection apparatus further includes CPU 2 , a display device 3 , an input unit 4 , and a storage device 5 , thereby it can set any optional condition for inspection, and can store and display an inspection result or an inspection condition. Moreover, the defect inspection apparatus can be connected to a network 6 , thereby the inspection result, layout information of the wafer 1 , a lot number, the inspection condition, or an image of a defect observed by an observation device or data of a defect type can be shared over the network 6 . Moreover, the defect inspection apparatus includes the wafer observation system 600 in order to allow observation of the detected defect or an alignment mark integrally formed on the wafer 1 for alignment of a pattern formed on the wafer 1 . Furthermore, while not shown, it includes an automatic focusing unit, so that a region where an image is taken in using a sensor when the wafer is scanned on the stage system 200 is within the depth of focus of the detection system 300 .
FIGS. 2A to 2B show three-dimensional display of examples of signal detection of two types of defects A and B respectively. FIGS. 2A to 2B exemplify defects having different signal intensity detected by the defect inspection apparatus while having the same size. A vertical direction represents signal intensity, showing intensity for each pixel. Even if defects (foreign substances) have the same size in SEM (scanning electron microscope) observation, detection signals in the defect inspection apparatus may be varied depending on a defect type, defect position, and surface pattern or surface material of the wafer 1 . Thus, size of defects obtained through detection by the defect inspection apparatus according to embodiments of the invention are corrected based on information of the defect type, defect position, and surface pattern or surface material of the wafer 1 , thereby size calculation accuracy of defects can be improved.
Moreover, to improve the size calculation accuracy of a defect, it is important to modify a detection condition depending on a position of the defect. Thus, in the defect inspection apparatus according to embodiments of the invention, grouping is carried out depending on fineness of a pattern in a detection portion of the wafer 1 or each of many dies (chips) formed on the wafer 1 , so that a detection condition of the defect can be modified.
FIGS. 3A to 3B show examples of grouping for each of regions in the wafer or die (chip). FIG. 3A shows an example of grouping the inside of the die depending on a type of a circuit pattern. A reference 3001 shows a region where awiring pattern is random in the die, and a reference 3002 shows a region where the wiring pattern is repeated at a constant pitch. FIG. 3B shows an example of grouping of the whole surface of the wafer 1 . A reference 3003 indicates a central portion of the wafer 1 , and a reference 3004 indicates the outer circumferential portion of the wafer. A reference 3005 indicates a die. In the case of a fine pattern, interference of illumination light may occur due to a pattern near a defect and the defect, and thus a detection signal of a defect may be different from that in the case of detecting a defect near a coarse pattern, and therefore grouping is carried out depending on regions. Moreover, when thickness is uneven in a wafer surface due to deposition, etching, or polishing, since a detection signal of a defect may be varied due to interference of light as well, grouping is carried out.
FIGS. 4A to 4B show an evaluation method of dimension accuracy of a defect. A graph is displayed on a screen, in which measured values of size by defect observation apparatus such as SEM are plotted as a horizontal axis, and calculated values of size by the defect inspection apparatus are plotted as a vertical axis, which allows visual expression of calculation accuracy of defect size. FIG. 4A shows an example of large dispersion of defect distribution, that is, low dimension accuracy. FIG. 4B shows an example of small dispersion of defect distribution compared with the example of FIG. 4A , that is, high dimension accuracy.
FIGS. 5A to 5B are views for illustrating a way of defining a measured value when defect size is measured by the defect observation device such as SEM. X and Y are coordinate axes used in observation of a defect by SEM. In a way of expressing the defect size, projected length in an X-axis direction (X size), projected length in an Y-axis direction (Y size), diameter of a circumscribed circle of a defect (L; major axis size), √(X+Y), or √(X 2 +Y 2 ) can be used as a representative value. In yield management, one of the diameter of the circumscribed circle of the defect (L; major axis size), √(X+Y), and √(X 2 +Y 2 ), or a combination of them is used.
FIG. 6 shows a condition setting flow for correcting size of a defect detected by the defect inspection apparatus. In embodiments of the invention, a correction factor that was determined and stored according to the flow of FIG. 6 is used, and size of a defect on the wafer, which was inspected and detected by the defect inspection apparatus according to a flow shown in FIG. 7 , is calculated, and then inspection data added with size is registered into a defect management server.
A flow of FIG. 6 is described below. Inspection is performed using the defect inspection apparatus in S 601 , and defects to be observed by the defect observation apparatus such as SEM are selected from defects detected using the defect inspection apparatus in S 602 . When the number of defects is small, for example, about 100, the whole number of them may be selected. When the number of defects is large, while they may be randomly extracted, if defects to be observed are extracted using SSA (Spatial Signature Analysis) based on a distribution condition in a wafer plane, several types of defects in a wafer can be evenly extracted. After defects as objects are selected in S 602 , size or a type (convex defect, concave defect, planar defect or the like) of the defect as object selected by the defect observation apparatus such as SEM is obtained in S 603 . After that, based on information of the size or type of the defect, a size calculation result of the defect inspection apparatus is compared with a measurement result of the defect observation apparatus such as SEM to create a scatter diagram as shown in FIG. 4 in S 604 , then a correction factor is determined depending on the size or type of the defects in S 605 , and then stored in S 606 .
Comparison between the size calculation result of the defect inspection apparatus and the measurement result of the defect observation apparatus such as SEM in S 604 can be carried out by the defect inspection apparatus, SEM, a separated personal computer or the like. Since creation of the scatter diagram in S 604 is intended to be for reference when a user adjusts a condition, in the case that the correction factor is automatically calculated, it need not always be shown diagrammatically. In correction in S 605 , linear correction (y=ax+b): (x is defect size calculated by the defect inspection apparatus, y is size after correction, a is a correction factor, and b is an offset value) may be used, or a higher-order transformation equation may be used for the correction. Regarding a way of determining the correction factor a or the offset value b, one of a value previously registered into the defect inspection apparatus, a value adapted for each treatment step in wafer manufacturing, and a value corresponding to a defect type or feature quantity of a defect, or a combination of them may be used.
After the correction factor has been calculated in S 605 , the correction factor is stored in S 606 , consequently condition setting for size calculation is completed.
FIG. 7 shows a flow of inspection and output. A wafer is inspected (S 701 ), then classification of defects is performed based on a defect type or feature quantity of a defect (S 702 ). Defect size is calculated in S 703 , and then size is corrected for each defect class using the correction factor previously set according to the flow described using FIG. 6 in S 704 . A size calculation result S 705 after correction is added to the defect detection result, then data of them are transferred to a defect management server (S 706 ).
FIGS. 8A to 8C show a method of size calibration using a defect having known size. FIG. 8A shows a standard wafer in which the defects having known size are integrally formed, or a product wafer, dummy wafer, or mirror wafer on which standard particles are scattered, wherein defects 901 (size A (nm)), 902 (size B (nm)), and 903 (size C (nm)) having known size are integrally formed.
FIG. 8B shows an aspect that the size detected and calculated by the defect detection apparatus is different from the size measured by SEM depending on a surface condition or surface material of a wafer due to an adjustment condition of the defect detection apparatus or difference in machine, indicating a relationship between actual size of the defects 901 , 902 and 903 having known size, which were measured using SEM, and size of the defects detected and calculated by the defect detection apparatus. A reference 904 indicates an approximate curve. Based on the approximate curve of 904 , a factor in size calculation is changed so that a slope of a graph is corrected to be approximately 45 degrees ( FIG. 8C ), thereby a value of the defect size detected and calculated by the defect detection apparatus can be calibrated.
FIG. 9 shows a flow of obtaining a factor for correcting size. First, a wafer is inspected to detect a defect using the defect inspection apparatus according to embodiments of the invention (S 901 ), then a sum signal of detection signals in the whole region of the detected defect is calculated (S 902 ). Since part of the detected defects may be beyond a dynamic range of the sensor 304 , saturating signal correction (S 903 ) is performed, and size is temporarily calculated (S 904 ). In this time point, since the calculated size may be different from actual size measured by SEM, an approximate formula is then calculated (S 905 ), and then a correction factor is calculated according to the approximate formula (S 906 ). For correction, linear correction (y=ax+b): (x is defect size calculated by the defect inspection apparatus, y is size after correction, a is a correction factor, and b is an offset value) may be used, or a higher-order transformation equation may be used.
FIGS. 10A to 10C show a specific example of the saturating signal correction of the step S 903 in FIG. 9 . FIG. 10A shows an example of a defect of which the signal is not saturated, wherein d 01 indicates a signal peak. FIG. 10B shows signal intensity (d 02 ) of a defect of which the signal is partially beyond a dynamic range of a sensor during detection of a defect signal and thus saturated. As shown in FIG. 10C , a portion where a defect signal is lacked because of saturation is approximated by an appropriate function, so that a signal of a lacked portion is estimated, thereby a saturating signal can be corrected. For example, when a defect signal is approximated by Gaussian curve, a value of the number of saturated pixels (d 03 ) and broadening of Gaussian distribution (standard deviation) are supposed, thereby a peak (d 04 ) of the defect signal can be estimated.
FIGS. 11A to 11B show correction based on feature quantity of a defect. A correction factor is obtained according to a procedure shown in FIG. 6 for each defect type (convex defect, concave defect, planar defect or the like), then a correction factor of defect size is modified based on feature quantity of a defect according to a procedure of FIG. 7 , thereby dimension accuracy can be improved. FIG. 11A is a scatter diagram of defect size, showing a condition that size measured by SEM does not comparatively correspond to size detected and calculated by the defect inspection apparatus. On the contrary, FIG. 11B is a scatter diagram of defect size in a condition that size, which was calculated with performing correction based on feature quantity of a defect (for example, defect size) to a defect defected by the defect inspection apparatus, comparatively corresponds to size measured by SEM. Size may be calculated by obtaining the correction factor for each defect type (convex defect, concave defect, planar defect or the like), rather than the feature quantity of a defect.
While a procedure of temporarily obtaining size before correction is shown here, size may be calculated at a time during size calculation using information such as feature quantity of a defect or the defect type. For this purpose, information on defects such as feature quantity of a defect or a defect type can be treated as a variable in a size calculation formula in size calculation.
FIG. 12 shows a relationship between the defect inspection apparatus according to embodiments of the invention and a semiconductor manufacturing process. A wafer after passing through a particular step is inspected by the defect inspection apparatus according to embodiments of the invention. In a manufacturing process 810 , for example, inspection is carried out after a photolithography step ( 810 ). After the inspection, a defect is observed by review apparatus 1001 or 1002 , so that a cause of the defect is estimated from a type, size, or a shape of the defect to find a step where the defect is caused, thereby a manufacturing device in the relevant step is managed. When the cause of the defect is not found only by defect observation, element analysis by an analyzer 1003 or observation of a section profile of the defect is performed for further detailed investigation to search the cause of the defect. As described above, a yield of the semiconductor device is improved by repeating inspection and measures, consequently reliable semiconductor device can be manufactured.
FIG. 13 shows a relation between the number of defects and a yield of a semiconductor product. A reference 906 indicates transition of the yield of the semiconductor product, a reference 907 indicates transition of total detection number of defects in a particular step. A reference 908 indicates transition of the number of a particular type of defects (in this case, short-circuit defect). While the yield 906 is significantly decreased in a hatched period in FIG. 13 , the total detection number 907 is increased only slightly. When the detected defects are classified, and the number of short-circuit defects is noticed, it is known that the short-circuit defects are increased in the period where the yield is decreased. In addition to the total number of defects, defects are classified, and the number is monitored for each defect type, thereby information in correlation with the yield of the semiconductor product can be obtained. The number of defects of which the size is at least management size may be noticed and managed by using a defect size calculation value rather than the defect type. The management size is determined based on a wiring rule in an inspection step. While not shown, criticality of the defect may be calculated from the defect size, defect type, and wiring rule to monitor the number of defects having at least a certain value of criticality.
FIGS. 14A to 14B are conceptual diagrams of defect detection thresholds T 01 , T 02 and a feature-quantity extraction threshold T 03 . FIG. 14A shows an example where the defect detection threshold T 01 is equal to the feature-quantity extraction threshold T 03 . In inspection of a semiconductor wafer, the defect detection threshold T 01 is normally set high to suppress false detection of a normal portion. Therefore, in FIG. 14A , only a part of defect signals can be used. Thus, as shown in FIG. 14B , the feature quantity is extracted with a threshold (T 04 ) lower than the defect detection threshold T 02 , thereby more effective extraction of the feature quantity can be performed.
FIG. 15 shows a display example of a defect detection result. A reference 801 indicates an example of a display screen. In a defect map ( 802 ), display is classified depending on whether defect size is at least a defect management size determined at setting of inspection conditions or not, thereby trouble occurrence and a level of influence on the yield can be instinctively determined. Moreover, defect display is clicked by a mouse, thereby defect ID, size (calculation value of the defect inspection apparatus), a defect type and the like can be shown ( 803 ).
Moreover, a graph showing frequency of defect occurrence is displayed for each defect size ( 807 ), thereby the trouble occurrence and the level of influence on the yield can be also instinctively determined.
On the screen, a region 804 for displaying the total number of detected defects or the number of the defects for each size, a region 805 for displaying an operational panel, a region 806 for setting a inspection condition, a region 808 for displaying a defect list are also provided. The display regions may be displayed on one screen at the same time, or may be displayed on separated screens respectively, or several regions of them may be displayed in a combined manner.
FIG. 16 shows an example of the illumination optical system 102 in the configuration of the defect inspection apparatus shown in FIG. 1 . Here, an example where the light source 101 is a laser light source is shown. Laser 1011 emitted from the laser light source 101 is diverged at a certain divergence angle, and made into parallel light by a lens 1021 , and then shaped to be one-sided condensing illumination by a cylindrical lens 1022 and then irradiated to a wafer surface. An illumination pattern is linear on the wafer surface, and used in a combined manner with scan of the stage, thereby a certain area of the wafer surface can be collectively detected. In this case, for the sensor 304 , a linear sensor corresponding to the illumination area or a TDI sensor (Time Delay Integration Sensor) is preferably used. When the TDI sensor is used for the sensor 304 , a signal detected by the TDI sensor is outputted in parallel from a plurality of taps of the TDI sensor, and the signals outputted in parallel are subjected to signal processing in parallel in the signal processing section 400 , thereby defect detection speed can be improved. When the illumination pattern is a dot-like pattern, AOM, AOD, a galvanometer mirror or the like is used in the illumination optical system to allow scan by the dot-like illumination, and movement of the stage is combined therewith, thereby the whole surface of the wafer can be inspected.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is 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 equivalency of the claims are therefore intended to be embraced therein. | When size of a defect on an increasingly miniaturized pattern is obtained by defect inspection apparatus in the related art, a value is inconveniently given, which is different from a measured value of the same defect by SEM. Thus, a dimension value of a defect detected by defect inspection apparatus needs to be accurately calculated to be approximated to a value measured by SEM. To this end, size of the defect detected by the defect inspection apparatus is corrected depending on feature quantity or type of the defect, thereby defect size can be accurately calculated. | 6 |
BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to a method and an apparatus for joining separated blocks of dough, and for supplying a continuous sheet of dough formed from the joined dough blocks. In particular, the present invention relates to a method and apparatus for joining a first kneaded dough block to a subsequently-provided kneaded dough block such that the gel structures of the dough blocks are integrally joined to form a continuous dough sheet on a production line.
2. Prior Art
In a conventional apparatus, a plurality of dough sheets are formed by pressing individual kneaded dough blocks, and then portions of each dough sheet are cut away to produce, for example, bread products. Each dough sheet has a volume corresponding to the volume of the kneaded dough block from which it was formed. The entire dough sheet is used in one production lot, or each part of the dough sheet is used in a production lot. When one dough sheet is used in a production lot, production time is lost between the adjacent dough sheets when they are fed by a conveyor. Also, fragments which remain after portions of the dough sheet are cut away are not used during production.
In a conventional apparatus, if necessary, adjacent dough sheets are joined to each other by a manual operation. That is, a rear end of a dough sheet is piled on a front end of a subsequently-formed dough sheet, and then the piled ends are manually pressed such that they adhere to each other. There is no apparatus to perform this sheet joining operation. Thus, the operation must be manually performed whenever a gap appears between sequentially-formed dough sheets, so that a significant amount of manual labor is needed to perform the joining operation. In bread production lines, unmanned production is usually performed to make bread from dough sheets that have the same conditions in their degree of composition and kneading, because technology to make a thin dough sheet has been improved and is now broadly used. However, when many kinds of breads that have several shapes and additional ingredients, such as fillings, are made on the same production line, much manual work is needed to join sequentially-formed dough sheets.
A gel structure is formed in a dough mass during a mixing operation. When the dough mass is cut to form individual dough blocks, the gel structure of each dough block is separated from the dough mass and from all previously-formed dough blocks. Thus, in order to join two separated dough blocks, it is necessary to join their gel structures. Currently, there is no apparatus for automatically joining the gel structures of two dough blocks.
SUMMARY OF INVENTION
An object of the present invention is to overcome the disadvantages of the prior art.
In accordance with the present invention, a method and apparatus are provided for automatically joining a first dough block to a subsequently-formed dough block, so that a very long and continuous dough sheet is automatically made, and so that unmanned production over a 24 hour period is achieved.
The present invention allows gel structures of dough blocks to be automatically joined to each other. This invention also allows several kinds of breads to be produced during a non-stop production process. In a conventional apparatus there are many production lots corresponding to the mixing operations of the dough. This invention allows a continuous dough sheet corresponding to one production lot to be made. Thus, this invention allows segmentation of douch sheets to be minimized. Also, this invention minimizes the time between the processing of subsequently-formed dough sheets.
One object of the present invention is to provide a method and apparatus for joining dough blocks to each other. The apparatus comprises horizontally and oppositely-positioned pairs of rollers provided in a plurality of tiers. The rollers are arranged such that the distances between the roller pairs in the upper tiers are sequentially greater than the distances between the roller pairs in the lower tiers, thereby forming a “V” shaped space for receiving the dough blocks. Each pair of rollers is rotated in an opposite direction such that a surface of each roller facing the “V” shaped space pushes the dough blocks downward. In addition, the distances between the roller pairs are alternately increased and decreased, thereby causing a pressure applied to the dough blocks by the rollers to alternately increase and decrease to produce a vibrations in the dough blocks as the dough blocks are impelled downward. The resulting thixotropic effect in the dough produced by these vibrations accelerates the growth of gluten and the joining of gel structures of the dough blocks, and a continuous belt-like dough sheet is thereby formed.
The method uses horizontally and oppositely positioned pairs of rollers provided in a plurality of tiers. The rollers are arranged such that the distances between the roller pairs of the upper tiers are sequentially greater than the distances between the roller pairs of the lower tiers, thereby forming a “V” shaped space for receiving the dough blocks. The method includes rotating the rollers of each pair in opposite directions while alternately increasing and decreasing the distances between the rollers of each pair such that a pressure applied by the rollers to the dough blocks is alternately increased and decreased, thereby impelling the dough blocks downward. The resulting vibrations in the dough produced by this pressing and releasing action accelerates the growth of gluten and the joining of gel structures of the dough blocks, and a continuous belt-like dough sheet is thereby formed from the dough blocks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a bread production apparatus that includes a first embodiment of an apparatus for joining dough blocks according to the present invention.
FIG. 2 is an enlarged schematic side view of the apparatus shown in FIG. 1 .
FIG. 3 is a schematic side view for explaining operation steps of the apparatus shown in FIG. 2 .
FIG. 4 is a schematic side view for explaining operation steps of the apparatus shown in FIG. 2 .
FIG. 5 is a schematic side view of a second embodiment of the apparatus for joining dough blocks according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a bread-making apparatus that includes an apparatus 1 for joining dough blocks in accordance with a first embodiment of the present invention. A bowl 2 mixes and kneads materials to make a dough mass 4 . The dough mass 4 is supplied from the bowl 2 onto a conveyor or a dough feeder 3 . The dough feeder 3 feeds the dough mass 4 to a set of rotatable cutter blades 5 , which separates dough blocks 6 from the dough mass 4 . The dough blocks 6 are then supplied to the joining apparatus 1 in response to signals from a sensor 21 (shown in FIG. 2 and discussed below). The joining apparatus 1 joins dough blocks to each other to provide a continuous belt-like dough sheet 7 which is deposited from a lower opening of the joining apparatus 1 onto a first conveyor 8 . The dough sheet is continuous (i.e., not separated by gaps). The first conveyor 8 feeds the dough sheet 7 to a dough-extending apparatus 9 . The extending apparatus 9 presses and extends the dough sheet 7 to make a pressed dough sheet 10 having a predetermined thickness and width required for making desired bread products. The dough-extending apparatus 9 feeds the pressed dough sheet 10 to a second conveyor 11 . A depositing apparatus 12 is located above the second conveyor 11 so as to supply a filling, such as jam or meat, onto the pressed dough sheet 10 . A cutting apparatus 13 is positioned over the second conveyor 11 . The cutting apparatus 13 moves vertically to cut the pressed dough sheet 10 into pieces 14 , each piece 14 having a desired length and width. Also, the cutting apparatus 13 may provide desired shapes to the pieces 14 . Then resulting dough pieces 14 are continuously output from the cutting apparatus 13 .
FIG. 2 is an enlarged view of a part of the bread-making apparatus shown in FIG. 1. A hopper 22 is positioned at the forward end of the dough feeder 3 .
The rotatable cutter blades 5 are positioned at a bottom opening of the hopper 22 . The joining apparatus 1 is located under the opening of the hopper 22 and the rotatable cutter blades 5 . A sensor 21 is positioned near an upper opening of the joining apparatus 1 , and senses whether an amount of dough in the joining apparatus 1 decreases to such an extent that the upper surface of the dough is below a predetermined level in the joining apparatus 1 . When the sensor 21 senses the surface of the dough in the joining apparatus 1 is below a predetermined level, it outputs a signal. In response to this signal, the dough feeder 3 is driven to feed the dough mass 4 into the hopper 22 . Simultaneously, the dough cutter blades 5 are rotated. When the dough mass 4 is supplied from the dough feeder 3 to the hopper 22 , a dough block 6 is cut from the dough mass 4 by the blades 5 , which are located at the bottom opening of the hopper 22 , thereby causing the dough block 6 to have a predetermined volume. The cut dough block 6 drops into the upper opening of the joining apparatus 1 . As a result, the amount of dough in the joining apparatus 1 is increased such that an upper surface of the dough is above the predetermined level.
The joining apparatus 1 includes a first roller group 20 including rollers 23 , 24 , 25 and 26 , and a second roller group 20 ′ including rollers 23 ′, 24 ′, 25 ′ and 26 ′. In the embodiment shown in FIG. 2, each roller of the first and second groups 20 and 20 ′ is cylindrical, and is shown in end-view in FIG. 2 . The rollers 23 - 26 are parallel and aligned in a first row, and the rollers 23 ′- 26 ′ are also parallel and aligned in a second row. The first and second rows of rollers are arranged to form a “V” shaped space for receiving the dough blocks 6 cut by the blades 5 . Each roller of the first group is arranged opposite to a corresponding roller of the second group in a horizontal plane or tier. For example, rollers 23 and 23 ′ are arranged in an uppermost tier and are separated by a first horizontal gap forming the upper opening of the joining apparatus 1 . Likewise, rollers 26 and 26 ′ are arranged in a lowermost tier and are separated by a second horizontal gap forming the lower opening of the joining apparatus 1 . The first horizontal gap is greater than the second horizontal gap. The remaining opposing roller pairs (that is, 24 and 24 ′, and 25 and 25 ′) in the respective intermediate tiers are spaced apart to form the “V” shaped space. In addition, the rollers of the first group 20 are rotated in an opposite direction from the rollers of the second group 20 ′ by a suitable driving means (not shown) such that the dough blocks therebetween are pushed downward. For example, as indicated in FIG. 2, the rollers of the first group 20 are rotated clockwise, while the corresponding rollers of the second group are rotated counter-clockwise. In addition to rotating, each roller reciprocally swings or linearly moves toward and away from its opposing roller. Thus, the rollers in an opposite roller pair are alternately moved toward and away from each other in a horizontal plane, so that the gaps between them are repeatedly increased and decreased. When the opposing rollers move toward each other, pressure on the dough therebetween is increased. When the opposing rollers move away from each other, the pressure is decreased. The rate of movement of the opposing rollers is selected such that the repeated increase and decrease in pressure applied to the dough produces vibrations which create a thixotropic effect in the dough. As a result, the gluten in the dough increases and the gel structures of the dough blocks are joined to each other.
The circumferential speeds of the lower rollers of the groups are lower than those of the upper rollers of the groups. However, the circumferential speeds of all of the rollers may be the same. Also, the speeds of the rollers of one group may differ from those of the rollers of the other group.
FIG. 3 shows the joining apparatus 1 , in which the circumferential speeds of the lower rollers of the groups are lower than those of the upper rollers. For example, the speeds of the rollers 25 , 25 ′, and 26 , 26 ′ are lower than those of the rollers 23 , 23 ′ and 24 , 24 ′. Parts of the surfaces of each dough block 6 that contact the upper rollers 23 , 23 ′, and 24 , 24 ′ are drawn downward as the rollers rotate. Then, these parts and/or other parts of the surface of each dough block 6 that contact the lower rollers 25 , 25 ′, and 26 , 26 ′ are drawn to the lower opening of the joining apparatus 1 . Thus, the parts of the dough block 6 that contact the upper rollers flow faster than those that contact the lower rollers.
However, parts of each dough block 6 located in the middle of the “V” shaped space between the opposite roller pairs (that is, parts which do not contact any roller) flow faster than the parts that contact the rollers. This occurs because the pressure applied by the opposing roller pairs to each dough block 6 when the opposing rollers approach each other forces the dough blocks downward toward the lower opening, rather than the dough blocks being drawn by the rotations of the rollers 23 , 23 ′, 24 , 24 ′, 25 , 25 ′, 26 , and 26 ′. Thus, as shown in FIG. 3, parts of each dough block 6 that do not contact the rollers and that are generally positioned at the middle between each opposing roller pairs flow faster than those that contact the rollers.
In detail, a lower surface of a dough block 6 is generally flat (horizontal) when the dough block is supplied from the hopper 22 onto the top surface of a previously-supplied dough block located in the joining apparatus 1 . As the dough block is drawn downward into the joining apparatus 1 , the lower surface of the dough block 6 that contacts the upper surface of the previously-supplied dough block descends at a higher rate at the mid-point between the opposing roller pairs such that the dough block becomes V-shaped. This V-shaped layer is gradually elongated as the dough block 6 descends further into the joining apparatus 1 , so that the surface areas of adjacent dough blocks that contact each other are increased. Then, the layer extends longitudinally. Simultaneously, the roller pairs move toward and away from each other to press the dough block and release the pressure from the dough block, so that the contacted surfaces are vibrated by the motions of the rollers. As a result, the adhesion between the contacted surfaces of the adjacent dough blocks is increased. Also, the receding and approaching movements of the rollers function as a tapping motion on the dough blocks, resulting in generating a thixotropic effect. Thus, the flowage of the dough is increased and the joining of the gluten in the dough is accelerated. Finally, the joining apparatus 1 supplies a continuous and belt-like dough sheet 7 through the lower opening onto the first conveyor 8 .
FIG. 4 shows the joining apparatus 1 , in which the circumferential speeds of the rollers of one group differ from those of the rollers of the other group. That is, the circumferential speeds of the rollers 23 , 24 , 25 , and 26 of the group 20 are faster than those of the rollers 23 ′, 24 ′, 25 ′, and 26 ′ of the group 20 ′. As a result, as shown in this figure, the parts of each dough block 6 that contact the rollers 23 , 24 , 25 , and 26 are drawn down faster by these rollers than the parts of each dough block 6 that contact the rollers 23 ′, 24 ′, 25 ′, and 26 ′. Thus, each separated dough block 6 is modified to form long continuous dough layers. The movements of the rollers toward and away from each other increases adhesion between the dough layers. Then, the joining apparatus 1 supplies a continuous and belt-like dough sheet 7 to the first conveyor 8 .
FIG. 5 shows another embodiment, namely, 1 ′, of the joining apparatus 1 as in FIG. 1 . It includes a group 50 of rollers 51 , 52 , 53 , and 54 and the group 20 ′ of the rollers 23 ′, 24 ′, 25 ′, and 26 ′. The cross-sectional shape of each roller of the group 50 is hexagonal. These hexagonal rollers impel the dough with a stronger force than the cylindrical rollers, so that each separated dough block 6 is modified more effectively into long continuous dough layers along the longitudinal direction of the flow of the dough. The long continuous dough layers extending in the longitudinal direction of flow of the dough have large contact surfaces. Thus, the resulting thixotropic effect unites the gel structures of the dough layers.
Polygonal rollers may be used for the sectional shape of the rollers. Also, polygonal rollers may be used for the upper rollers of the joining apparatus 1 in FIG. 1, so that the same effects as is the case as in FIG. 4 can be generated.
In the above embodiments, either or both of the group 20 ′ of the rollers 23 ′, 24 ′, 25 ′, and 26 ′ and the group 20 of the rollers 23 , 24 , 25 , and 26 or either or both of the group 20 ′ of the rollers 23 ′, 24 ′, 25 ′, and 26 ′ and the group 50 of rollers 51 , 52 , 53 , and 54 is/are reciprocally swung or linearly and reciprocally moved. However, this invention is not limited to these configurations. For example, the distances between the opposite roller pairs may be changed so that their pressing movements are sequentially generated between them from above downwards. Also, the distances between the opposite roller pairs may be alternately changed in the vertical direction such that the pressing movements between the opposite roller pairs are alternately effected in the vertical direction.
By this invention gel structures in respective dough blocks are joined to each other by repeatedly providing pressing and vibrating operations to the dough blocks, so that the dough blocks are deformed and piled upon each other to form layers. Thus, a continuous belt-like dough web is formed. | An apparatus for joining dough blocks to form a continuous dough sheet. The dough blocks are cut from a dough mass and drop into a space between first and second groups of rollers. The first and second groups of rollers include horizontally-paired rollers arranged in tiers and forming a substantially V-shaped space for receiving the dough blocks, with the uppermost pair of rollers being separated by a first horizontal gap which is wider than a second horizontal gap separating the lowermost pair of rollers. The first group of rollers are rotated in a direction (e.g., clockwise) which is opposite to that of the second group of rollers. In addition, the first group of rollers is alternately moved toward and away from the second group of rollers, thereby applying vibrations to the dough blocks. The combined rotation and vibrations of the rollers impels the dough blocks downward toward the second gap between the lowermost pair of rollers and increases gluten growth and a joining of the gel structures to produce a continuous dough sheet. | 0 |
PRIOR APPLICATION
This is a U.S. Divisional patent application that claims priority from U.S. patent application Ser. No. 12/198,815, filed 27 Aug. 2008.
TECHNICAL FIELD
The present invention relates to a continuous digester system.
BACKGROUND AND SUMMARY OF THE INVENTION
In the pulping of comminuted cellulosic fibrous material, preferably but not excluded to wood chips, in a continuous digester the material is first treated to remove air bound in the cellulosic fibrous material. Typically, the cellulosic fibrous material is steamed to remove the material of air while simultaneously increasing the temperature to about 80-100° C. The steaming process will normally release the natural acidity of the wood material and the pH value in any drained steam condensate could easily reach 4-5. The steamed cellulosic fibrous material is thereafter slurried or impregnated in an impregnation or slurrying liquid with sufficient amount of chemicals, i.e. alkali and sulfidity in case of a kraft process.
The slurried cellulosic fibrous material is transported as slurry to the pressurized digester or impregnation vessel using high pressure pumps or a high pressure sluice feeder, and with a top separator arranged in the top of the pressurized impregnation vessel or in the top of the digester. The typical digester pressure is more than 5 bar (>0.5 MPa).
In conventional systems these steaming and slurrying systems have been installed as a system preceding the pressurized impregnation vessel or the pressurized digester vessel. The systems preceding the pressurized vessel have included expensive and energy consuming machines.
For a typical digester system, following systems and machines have been used;
Chip bins, Steaming vessels Slurrying chutes High pressure sluice feeder and/or high pressure pumps Impregnation vessels
Only to transport the slurried chips to the pressurized impregnation or digester vessel requires some 400 kW per ADT pulp produced. In a digester with a capacity of some 5000 ADT per day is thus required and a pumping system with an installed power available in the order of some 2 MW.
These systems and associated equipment and building structure are a large part of the total investment costs of a continuous digester system. Also, the operating costs of these systems and machines take a large part of the production costs for the pulp produced.
U.S. Pat. No. 3,303,088 disclosed already in mid 1960-ties a process using a single hydraulic digester, but with separate chip bin, steaming vessel, slurring tank and high pressure pumps ahead of the single hydraulic digester.
U.S. Pat. No. 5,635,025 disclosed an effort to patent the concept of a single vessel for the entire pre-treatment of chips, including the functions of a chip bin, a steaming vessel and the chip chute. This single pre-treatment vessel was located ahead of the transfer system including the high pressure sluice feeder. The corresponding Swedish application was abandoned as the concept with a common chip bin, steaming vessel and chip chute was anticipated by U.S. Pat. No. 3,532,594 from the mid 1960-ties.
A further improvement of the pre-treatment systems in a single impregnation vessel is disclosed in U.S. Pat. No. 7,381,302, where the impregnation vessel is held substantially at atmospheric pressure, and impregnation liquids at successively higher temperatures where added at successively increasing depth in the liquid volume established in the impregnation vessel. Still, the conventional high pressure sluice feeder was located after this impregnation vessel for feeding the impregnated chips to the pressurized digester. This type of atmospheric impregnation vessel, called the IMPBIN™ system guarantees that the chips are both steamed and impregnated at low temperature, resulting in easy cooking at low reject volumes and high pulp quality. The IMPBIN concept has been installed in a number of new digester systems throughout the world, in mills having capacities in the order of 3000-6000 ADT per day and has proven to be a success. One further advantage with the IMPBIN system is that this could be operated with “cold top” control, i.e. avoiding blow trough of steam, which reduce energy losses in gas handling systems needed as the amount of hot gases driven off from the chips and needing condensation is dramatically reduced.
The fait of the IMPBIN™ system has been challenged as the conventional approach has been using excessive steaming systems in chip bins and steaming vessels, and this excessive steaming has been perceived as a necessity in order to purge all air from chips and be able to establish a correct column movement of the chips in the digester.
However, excessive steaming in pre-treatment establish a high chip temperature and in subsequent impregnation stages is the cooking chemicals consumed as they penetrate the chips, preventing cooking chemicals from penetrating into the core of the chips and as a consequence causing high reject volumes.
The IMPBIN™ system has in spite of this proven to be fully sufficient in establishing the necessary impregnation of the chips and a smooth column movement inside the digester.
The present invention is related to a further improvement and simplification of the digester system, where both the installation costs, i.e. investment costs, and operating costs are dramatically reduced.
In view of the success of the IMPBIN™ system, this general impregnation concept could be integrated with the actual digester, and a true “single vessel” digester system would be obtained. By this integration are several major advantages obtained, such as;
No need to classify the digester vessel as a pressure vessel; and Guaranteed low temperature impregnation, and No power losses in chip transfer to a pressurized digester; and No high pressure transfer systems, and No expensive top separator mounted at the top of the digester; and No need for chip bins, steaming vessels, and chip chutes etc.
In following parts are an atmospheric vessel referred to, and this implies a vessel not qualified as a pressure vessel and associated required testing and certification for a pressure vessel. According to European legislation a vessel must be classified as a pressure vessel if the pressure applied in the vessel is exceeding 0.5 bar. Thus, the atmospheric vessel could thus have a pressure established in the top substantially at atmospheric pressure, i.e. 0 bar (g), or a slight positive pressure of up to 0.5 bar (g) or slight negative pressure of down to −0.5 bar (g). The small deviation from a perfect atmospheric pressure is most often wanted for a controlled venting of the atmospheric phase in the top of the vessel as air may enter into the vessel with the raw material, i.e. chips, and a small leakage flow of malodorous gases could escape from the underlying chip volume. Preferably only an incremental positive pressure or negative pressure in the order of 0.1-0.2 bar is implemented, but still qualifying the vessel as an atmospheric vessel. The actual pressure established is controlled by the venting system, and parallel safety valves in form of reliable water-locks.
The establishment of a single vertically oriented atmospheric vessel enables a successive implementation of hotter treatment zones throughout the digester, and no need for a pressurized digester vessel is at hand, nor any separate pre-treatment systems, nor any high pressure transfer devices. The principle applied is similar to that one shown for the impregnation vessel IMPBIN™ as shown in U.S. Pat. No. 7,381,302, but now applied to the entire cooking process. The possible temperature profiling throughout the vessel is given by following table;
T LIQ
Sat. P
ΔH atm
ΔH +0.5
ΔH −0.5
(° C.)
(kPa)
(meter)
(meter)
(meter)
105
120.8
>2
—
>7
110
143.3
>4.3
—
>9.3
115
169.1
>6.9
>1.9
>11.9
120
198.5
>9.8
>4.8
>14.8
125
232.1
>13.2
>8.2
>18.2
130
270.1
>17.0
>12
>23
135
313.0
>23.3
>18.3
>28.3
140
361.3
>26.1
>21.1
>31.1
145
415.4
>31.5
>26.5
Where;
T LIQ is the possible temperature of the liquid in vessel
Sat. P is the saturation pressure at the actual temperature
ΔH atm /ΔH +0.5 / ΔH −0.5 are minimum depths under liquid level at atmospheric/+0.5 bar/−0.5 bar pressures in vessel top.
According to the present invention a continuous digester system is used that has only a single generally vertically oriented atmospheric vessel having a top and a bottom for receiving comminuted cellulose fibrous raw material and within the vessel steaming, slurrying, impregnating and digesting the fibrous material before feeding out digested fibrous material from the bottom of the vessel.
In the inlet of the vessel is any suitable metering means installed for continuously feeding the fibrous raw material into the vessel from the top thereof. The metering means could be a conventional chip meter having a rotor with pockets of a predefined volume.
The vessel also has means for establishing a first level of fibrous raw material in the vessel. This level could be monitored by any suitable conventional chip level meter available in the field.
In order to control the atmospheric pressure in the top of the vessel also the vessel has means for establishing a pressure in the top of the vessel at substantially atmospheric pressure in the range of +0.5 to −0.5 bar (g). The vessel also has means for establishing a second level of liquid in the vessel. The second level is below the first level thus creating a fibrous raw material volume in a pile above a total liquid volume in the vessel.
This pile of raw material volume provides a triple function, as
condensation surfaces for any steam penetrating upwards, and a location for steaming action from underlying hotter liquids, purging air from chips, and a thrust force for the chips downward into the liquid volume.
The vessel also includes means for supplying impregnation liquids to a first end of a first upper volume of liquid in the total liquid volume held by the vessel, and also means for supplying cooking liquids to a first end of a second lower volume of liquid in the total liquid volume held by the vessel.
For heating to cooking temperature the vessel also has means for heating at least the cooking liquids in the second lower volume of liquid in the total liquid volume held by the vessel.
The first upper volume of liquid containing the impregnation zone has preferably a height of at least 17 meters, and preferably in the range of 17-40 meters, and more preferably in the range of 20-30 meters, which will enable typical cooking temperatures in the subsequent second lower volume of liquid containing the cooking zone.
The second lower volume of liquid containing the cooking zone has preferably a height of at least 30 meters, and more preferably at least 40-50 meters, which will enable sufficient retention time in the cooking zone at normal cooking temperatures, resulting in the required H-factor for successful delignification process.
The total height of the vessel, containing the impregnation and cooking zones is thus preferably at least 70 meters high, and preferably in the range of 75-90 meters, but should not result in a total height of liquid in the vessel exceeding 100 meters or a height of comminuted cellulose fibrous raw material exceeding 120 meters, as to high chip column may impede operation of the digester circulations due to compacting effects in the bottom of the digester. The total height should more preferably be 75-90 meters, but should not result in a total height of liquid in the vessel exceeding 100 meters or a height of comminuted cellulose fibrous raw material exceeding 120 meters. The required heights of liquids are controlled by controlling the net liquid flows entering and leaving the vessel in a conventional manner.
The vessel also has means for withdrawing spent cooking liquid from the end of the second lower volume of liquid. The vessel preferably also includes a final zone for cooling and washing the processed material. Finally, the vessel has means for continuously withdrawing slurry of digested fibrous raw material from adjacent the bottom of the vessel and feeding the slurry to subsequent post cooking systems.
Typically the digested fibrous raw material is sent to post cooking systems such as brown washing, screening, mechanical refining or any chemical pre-bleaching stages such as oxygen delignification, ozone bleaching or similar first pre-bleaching stages, all depending on the subsequent use of the digested pulp.
According to the present invention now described will the atmospheric vessel be the only handling vessel where the fibrous raw material is purged from air, impregnated and digested to an extent that the digested fibrous raw material is delignified and reaching a kappa number below 120.
High yield pulp typically used for liner is digested to a kappa number in the order of 60-90, but other pulps used for bleached grades of paper are typically digested to a kappa number in the order of 15-30.
In a preferred embodiment, the present invention has the means for heating the cooking liquids comprising a first liquid circulation conduit having a screen in the wall of the vessel in first end of the circulation conduit and an outlet pipe in the centre of the vessel at the second end of the circulation conduit, and a pump in the circulation conduit, wherein the liquid in the circulation conduit is passing a heater for heating the liquid circulated in the circulation conduit and wherein the first and second end of the first circulation conduit is located in the second lower volume of liquid.
In the most simplified form of the present invention all or the overwhelming part of the heating could be made to the cooking stage, and preceding stages could be heated by sending hot liquids from cooking stage in counter current flow upwards in the vessel. Either in a displacement function, where the hotter liquid is displacing the colder liquid, or using the heat in the liquids in heat exchangers.
In a further preferred embodiment of the present invention the means for supplying cooking liquids, preferably in form of white liquor, has a second liquid circulation conduit having a screen in the wall of the vessel in first end of the circulation conduit and an outlet pipe in the center of the vessel at the second end of the circulation conduit, and a pump in the circulation conduit, wherein the liquid in the circulation conduit receives fresh cooking chemicals to the liquid circulated in the circulation conduit and wherein the first and second end of the second circulation conduit are located in the second lower volume of liquid. Alternatively cooking liquids could be used such as white liquor, kraft black liquor, green liquor, or sulfite cooking liquor.
In the simplest embodiment of the present invention the first and second liquid circulation conduits used for heating and supplying cooking chemicals, could be one and the same liquid circulation conduit.
The means for heating the cooking liquids includes preferably a heater in the form of an indirect heat exchanger, where the heating medium used is steam. Indirect heating is preferred as the clean condensate obtained from any such indirect heaters could be used again in the clean steam production systems, and further dilution of cooking liquors with water is avoided.
In a yet a further preferred embodiment, the present invention has means for supplying impregnation liquids using as a liquid source at least partly a liquid withdrawn from the cooking zone in the second lower volume of liquid. Preferably a semi-spent cooking liquor is used, which still has a relatively high residual alkali content, well over 6 g/l and typically in the range of 6-12 g/l. Such semi-spent cooking liquor is also typically having a high sulfidity level which is advantageous for the impregnation process. The means for supplying impregnation liquids could also use as liquid source at least partly fresh cooking chemicals, preferably white liquor. This additional charge of fresh cooking liquors could be made to establish a sufficient neutralization of the wood acidity released from the original raw material, and establishment of sufficient level of alkali throughout the impregnation process, avoiding precipitation of lignin on the raw material if spent or semi-spent cooking liquor, i.e. black liquor, is used in impregnation.
In some vessels, depending on type of raw material and cooking process, it could also be preferable that the vessel has means for withdrawing spent impregnation liquids from the other end of the first upper volume of liquid. This reduces the level of dissolved lignin in the subsequent cooking stage, thus promoting further dissolution of lignin in the raw material.
An early withdrawal of impregnation liquid and condensate could also preferably be made at a position in the vessel close to the liquid surface and hence could a large part of the acidic condensate released from the steamed chips be withdrawn, reducing need for charging alkali for neutralization purposes. Such early withdrawal will also reduce harmful content of calcium, which metal is dissolved in acidic conditions and may cause scaling problems in the digester.
An early withdrawal of impregnation liquid at lower temperature also improves the overall heat economy as less mass volumes needs heating in subsequent stages.
One of the primary objects of the present invention is to provide for a simplified continuous digester, with a true single vessel system, having less investment costs as well as less operating costs, but still capable of producing pulp at commercial grades.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 , shows a first embodiment of the single vessel digester system of the present invention;
FIG. 2 , shows a second embodiment of the single vessel digester system of the present invention;
FIG. 3 shows a third embodiment of the single vessel digester system of the present invention;
FIG. 4 shows a prior art digester system with an IMPBIN™ ahead of the digester, used for comparison; and
FIG. 5 shows an embodiment of the present invention replacing the system shown in FIG. 4 .
DETAILED DESCRIPTION
Instead of the conventional pre-treatment systems such as chip bins, steaming vessels, chip chutes, and high pressure transfer device as well as preceding impregnation vessel, a single atmospheric vessel 30 is provided according to the present invention.
The vessel, as shown in FIG. 1 , is a single generally vertically oriented atmospheric vessel having a top and a bottom for receiving comminuted cellulose fibrous raw material CH. Within the vessel 30 are all the stages in digestion of the raw material performed, such as steaming, slurrying, impregnating and digesting the fibrous material before feeding out digested fibrous material from the bottom 10 of the vessel 30 .
The raw material CH, preferably in the form of chips, is fed to the top of the vessel by any conventional conveyer belt system, and enters an inlet chute 1 having a conventional chip metering rotor 2 for continuously feeding the fibrous raw material into the vessel from the top thereof.
The chips that are fed into the vessel 30 are thus preferably unheated and untreated chips that normally have the same temperature as the ambient temperature.+/−.5° C.
The vessel includes conventional control for establishing a first level (CH LEV) of fibrous raw material in the vessel. This control could use a chip level meter and the in-feed of chips is controlled in order to maintain a predetermined minimum chip level (CH LEV). An alternative chip level control could use conventional gamma or radar radiation systems. In a simple control mode the speed of any conveyer belt system and the chip metering rotor 2 are increased if the chip level detected is decreasing below any set-point.
The pressure in the vessel can be adjusted as necessary through a control valve 13 arranged in a valve line 4 at the top of the vessel, possibly also in combination with control of the steam ST via input lines 5 . When atmospheric pressure is to be established, this valve line can open out directly to the atmosphere. It is preferable that a pressure is established at the level of atmospheric pressure, or a slight negative pressure by the outlet 4 of magnitude −0.5 bar (−50 kPa), or a slight positive pressure of magnitude up to 0.5 bar (50 kPa). A parallel safety valve (not shown) could also preferably be implemented, such as a water seal with a 1-3 dm height of water, to ensure the establishment of the intended atmospheric pressure.
Input of a ventilating flow, SW_AIR (sweep air), can be applied at the top as necessary, which ensures the removal of any excess air or gases present. When impregnation primarily easily cooked types of wood, such as eucalyptus and other annual plants, additional steaming can be essentially avoided. The steam that penetrates the chip pile from the underlying liquid volume is in many cases fully sufficient for effective steaming. Fresh steam is thus not added to the chip pile above the fluid level established in the vessel during normal steady-sate operation. The present invention can also be applied even if coniferous and deciduous wood (softwood and hardwood) are used as raw material, giving a markedly reduced need for using fresh steam ST.
When treating primarily wood raw material that is difficult to cook, coniferous and deciduous wood, and in operational cases with extremely low temperature of the chips, (in cold seasons), the chips that lie above the fluid level established by the impregnation fluid can be heated by the addition to the impregnation vessel of external steam such that a temperature of the chips of at least 20 degrees C. and up to 80 degrees C. at the most is obtained on the chips before the chips reach the fluid level that has been established by the impregnation fluid.
A maximum liquid level LIQ_LEV is established in the vessel under the chip level CH_LEV in the vessel. Control of the level occurs by adjusting the balance between the addition of liquids to the vessel and withdrawal of liquids from the vessel by any appropriate control system. The liquid level must thus be established such that it lies under the chip level CH_LEV in the vessel. The second level of liquid (LIQ LEV) in the vessel establish a total liquid volume (Z 1 & Z 2 ) in the vessel.
The level CH_LEV of the chips above the level LIQ_LEV of the liquid, i.e, the distance marked H 0 in figure, is preferably at least 2 meters and more preferably at least 5 meters when impregnating eucalyptus. In the case of wood raw material of lower density, for example, softwood, which has a density that is up to 30% lower, a corresponding increase in the height of the pile of chips over the surface of the fluid is established. This height is important in order to provide an optimal chip column movement in the vessel.
In order to establish appropriate conditions for the first impregnation stage impregnation liquids are supplied by a central pipe CP 1 to a first end, in FIG. 1 the upper end, of a first upper volume of liquid Z 1 in the total liquid volume at a position preferably slightly below the liquid level, i.e. the distance marked H 1 in figure. Here is the impregnation liquids supplied via pump P 3 and central pipe CP 1 as a mixture of semi spent cooking liquor withdrawn from screen S 3 in the cooking zone, and preferably with addition liquids in form of fresh cooking chemicals WL S and possible dilution liquid LIQ 1 , the latter preferably alkaline filtrates from subsequent washing or bleaching stages. The supply of impregnation liquids thus uses as a liquid source at least partly a liquid withdrawn from the cooking zone in the second lower volume of liquid. The supply of impregnation liquids preferably also uses as liquid source at least partly fresh cooking chemicals, preferably white liquor. The impregnation stage is thus established in a concurrent impregnation stage in the upper liquid volume Z 1 down to the screens S 2 .
As the hot semi-spent cooking liquor is added to the chips ascending down from the pile, a mixed temperature is obtained lying between that of the chips and that of the semi-spent cooking liquor. The temperature established in the liquid surface is preferably close to or slightly above 100° C., such that this liquid may provide a small release of steam upwards into the ascending chip pile, where it condenses. In an alternative embodiment the central pipe CP 1 could end slightly above the liquid surface, such that the impregnation liquid will flash off steam at the very release into chip pile in the vessel.
The atmospheric conditions in the top of the vessel will guarantee that no excessive temperature is established in this first upper part of the impregnation zone Z 1 , as steam would flash upwards against the descending chip pile.
In order to establish appropriate chemical conditions for the subsequent cooking stage cooking liquids are supplied to a first end, in FIG. 1 the upper end, of a second lower volume of liquid Z 2 in the total liquid volume. Here is the liquid a mixture of fresh cooking chemicals WL M , added to a circulation with screen S 2 , pump P 2 and a central pipe CP 2 ending above screen S 2 .
In order to establish appropriate temperature conditions for the subsequent cooking stage in the second lower volume Z 2 of liquid in the total liquid volume heating is performed by heater HE in the same first liquid circulation, having a screen S 2 in the wall of the vessel in first end of the first circulation conduit and an outlet pipe CP 2 in the center of the vessel at the second end of the circulation conduit, and a pump P 2 in the circulation conduit, wherein the liquid in the circulation conduit is passing the heater HE for heating the liquid circulated in the circulation conduit.
As shown in the table in preceding part of the description a cooking temperature of 140° C. could easily be implemented if this circulation, i.e. the outlet of central pipe CP 2 , ends up more than 26 meters below the second liquid level if pressure in vessel top is held at 0 bar (g), i.e. at the total distance H 1 +H 2 in the figure.
The means for heating the cooking liquids includes preferably a heater in form of an indirect heat exchanger, where the heating medium used is steam. This indirect heater is also suitable for cooling purposes in case of unplanned stops in the operations, as the indirect heater instead could use cold water instead of steam. By this forced cooling could heat merger upwards trough the chip column be prevented.
The first and second end, i.e. screen S 2 and central pipe CP 2 respectively, of the first circulation conduit is located in the second lower volume of liquid Z 2 , and in FIG. 2 at the very start of this lower liquid volume Z 2 . The cooking stage is thus established as a concurrent cooking stage in the lower liquid volume Z 2 down to the screens S 3 and S 4 .
When the cooking stage is ended at screens S 4 spent cooking liquor, i.e. black liquor, is withdrawn from the other end, in FIG. 1 the lower end, of the second lower volume Z 2 via screens S 4 . The withdrawn spent cooking liquor could be sent directly or indirectly to recovery REC, preferably via recovery of the heat energy in the liquors by heat exchange against other liquids or flashing off steam in a flash tank and using the flashed steam in heat exchangers or chip steaming ST.
In FIG. 1 some wash or displacement liquid LIQ 2 is also added via a central pipe CP 3 in order to improve displacement and withdrawal of the spent cooking liquor. This kind of wash or displacement liquid LIQ 2 could also be added via conventional vertical and/or horizontal supply nozzles (not shown) located in the lower cupped gable of the vessel below the screens S 4 .
Finally, in the bottom of the vessel are installed means for continuously withdrawing slurry of digested fibrous raw material from adjacent the bottom of the vessel and feeding the slurry to a subsequent post cooking systems BW via line 11 . The withdrawal and feeding means is typically of a conventional outlet design, with an outlet bucket 10 and associated bottom scraper (the latter not shown) and where dilution liquid LIQ 3 is added to the outlet bucket in order to facilitate feed out of the digested raw material. Dilution liquid LIQ 3 could also in part be liquid supplied via conventional vertical and/or horizontal supply nozzles (not shown) located in the lower cupped gable of the vessel, or integrated with the bottom scraper.
By the embodiment shown in FIG. 1 the atmospheric vessel 30 is the only handling vessel where the fibrous raw material is impregnated and digested to an extent that the digested fibrous raw material is reaching a kappa number below 120.
In FIG. 2 is an alternative embodiment of the invention shown having the same features as shown in FIG. 1 , but for an additional withdrawal screen S 1 in the lower part of the impregnation zone Z 1 . Here the vessel has means for withdrawing spent impregnation liquids from the other end of the first upper volume of liquid, which in FIG. 2 is the lower end of the first upper volume. This withdrawal screen is preferably located at a position in the vessel that lies above the position for addition of cooking liquid via central pipe CP 2 , and a displacement flow of the spent impregnation liquid towards screen S 1 is established, in the lower part of the fluid-filled zone Z 1 in the vessel 30 .
In FIG. 3 yet another alternative embodiment of the present invention is shown that have the same features as shown in FIG. 1 , but for;
separate liquid circulations for adding cooking chemicals, i.e. S 2 ′—P 2 ′—CP 2 ′; separate liquid circulations for heating, i.e. S 2 ″—P 2 ″—HE-CP 2 ″; and early withdrawal of impregnation liquid and condensate via screen S 5 and pump P 5 .
In FIG. 3 the means for supplying cooking liquids, preferably in form of white liquor, has a second liquid circulation conduit having a screen S 2 ′ in the wall of the vessel in first end of the circulation conduit and an outlet pipe CP 2 ′ in the center of the vessel at the second end of the circulation conduit, and a pump P 2 ′ in the circulation conduit. The liquid in the circulation conduit is passing a mixer for adding fresh cooking chemicals WL M to the liquid circulated in the circulation conduit and wherein the first and second end of the second circulation conduit is located in the second lower volume of liquid Z 2 , which in FIG. 3 is the upper end of the lower volume of liquid.
The early withdrawal of impregnation liquid and condensate is made via screen S 5 located close to the liquid surface and pump P 5 . By this location of the screen S 5 could a large part of the acidic condensate released from the steamed chips be withdrawn, reducing need for charging alkali only for neutralization purposes.
Comparative Examples
In FIG. 4 a state of the art digester system is shown with an IMPBIN™ located ahead of the digester. In FIG. 5 a comparative example of the present invention is shown applied for the same process. In both examples shown in FIGS. 4 and 5 the screens with similar functions are given similar reference numbers, such as S 5 for the early withdrawal screen close to the liquid surface, S 3 for the withdrawal of semi-spent cooking liquor, and S 4 for the final spent cooking liquor drawn from the digester and subsequently sent to recovery, together with liquor from the early withdrawal from S 5 . The figures also show a fiber filter FF in the stream of spent liquors, which sifts out fiber residues in the liquor streams and circulates these fiber residues back to appropriate positions in the digester system. In FIG. 4 is the conventional high-pressure sluice feeder 41 is also in the transfer system from the low pressure part, i.e. the IMPBIN 20 , and the digester.
The system shown in FIG. 4 is a typical implementation of the Compact Cooking™ G2 Process for cooking Eucalyptus (Hardwood) pulp, having a production capacity of 1500 ADMT/day.
The IMPBIN™ 20 has a diameter of 5.2 meters and a height of 40.5 meters, reaching a total volume of 550 m 3 . The digester 40 has a diameter of 7.4 meters and a height of 49 meters, reaching a total volume of 1950 m 3 . The total volume in the system thus, i.e. IMPBIN™ 20 plus digester 40 , amounts to 2500 m 3 .
The total installed available power amounts to 1950 kW, and the power consumption per ton of pulp amounts to 21.8 kW/ADT. This system needs a total heat exchanger area of 600 m 2 and the MP (Medium Pressure) steam consumption amounts to 400 kg/ADT. The process needs a total alkali charge of 18% EA.
The system shown in FIG. 5 is an implementation of the present invention using the principles of the Compact Cooking™ G2 Process for cooking Eucalyptus (Hardwood) pulp and has the same production capacity of 1500 ADMT/day at a total alkali charge of 18% EA. The single vessel system according to the present invention has a digester having a diameter of 7.4 meters and a height of 82 meters, reaching a total volume of 2700 m 3 .
However, the total installed available power amounts to only 1400 kW, and the power consumption per ton of pulp amounts to only 15.7 kW/ADT, which corresponds to savings in the order of 28%. The large part of the savings is obtained from lack of pumps for pressurizing and feeding the impregnated slurry to the digester top (i.e. sluice feeder and/or pumps), lack of any top separator and lack of any bottom scraper in IMPBIN. The only increase in power consumption is the extended height of operation of the existing chip conveyer, which additional power requirement, is negligible in comparison to the power consumption of deleted machines. This system needs a total heat exchanger area of 650 m 2 and the MP (Medium Pressure) steam consumption amounts to the same order of 400 kg/ADT.
The difference in heating in the systems shown is that the cooking temperature in the system shown in FIG. 4 is established largely in part by direct steam heating in digester top, resulting in that clean steam condensate is diluting the cooking chemicals and putting extra capacity requirement in the evaporation process. In the system shown in FIG. 5 cooking temperature is reached only by using liquor circulations and indirect steam heating, which enables a recovery of the clean steam condensate, thus decreasing net thermal energy usage. In both systems it is possible to mix different liquors, i.e. total liquor flows or parts thereof, to reach any desired temperature profiling and heat economy.
It will thus be seen that according to the present invention a simplified digester system is provided which would require far less investment costs and lower operation costs. The operating costs are of ever increasing interest in order to save energy and obtain an environmental friendly system.
The embodiments shown are principle designs utilizing the inventive concept of the present invention, and it will be apparent to those skilled in digester operations that many modifications can be made within the scope of the present invention.
As examples of modifications are changes of the impregnation or digester zones or both to counter current operation, in parts or the entire zone. More circulations could also be implemented in order to modify the concentration of cooking chemicals or amount of dissolved lignin or total dissolved organic material or dissolved amount of metals such as calcium, which need for additional circulations is depending upon the type of cellulose fibrous raw material fed to the vessel.
While the present invention has been described in accordance with preferred compositions and embodiments, it is to be understood that certain substitutions and alterations may be made thereto without departing from the spirit and scope of the following claims. | In a continuous digester system the digester system is greatly simplified by using a single vertical atmospheric vessel, replacing the conventional chip bin, steaming vessel, chip chute, high pressure pumping or sluice feeders, impregnation vessels and top separator. Chips are simply fed to the top of the atmospheric vessel, and a chip level is established in the vessel. Treatment liquids are added to the vessel such that a total liquid volume (Z 1 +Z 2 ) with a liquid level (LIQ LEV) is established under the chip level (CH LEV). Impregnation stage and subsequent cooking stages are implemented in the atmospheric vessel at successively increasing temperature and depths into the total liquid volume, thus preventing boiling in the stages and preferably reducing steam blow trough of the chip surface in the top of the vessel. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to a pad for connecting electronic devices. More specifically, the present invention relates to a connection pad under control of a smart host.
BACKGROUND OF THE INVENTION
[0002] By “storage” we mean tangible computer-accessible electronic storage.
[0003] By a “communication system” we mean a combination of hardware devices and logic in software and/or hardware for electronically communicating data in digital form. A communication system might include, for example, a wide-area network such as the Internet; a local-area network (e.g., within a home, business, or school); and/or a personal-area network (e.g., a network implemented with Bluetooth or Infrared Data Association). The term “communication system” is hierarchical, and any combination of communication systems used to transmit data between two smart devices is a communication system. A communication system is assumed to include at least a hardware interface.
[0004] By “logic”, we mean some combination that includes tangible electronic hardware, and may include software, whereby a processing system executes tasks and makes decisions.
SUMMARY OF THE INVENTION
[0005] A universal smart connection pad allows a slave device, such as a mobile electronic device, to be conveniently connected to a host device, such as a computer. Orientation of a connector of the slave upon the pad may be assisted by magnetization. Through the pad, the host may provide services needed by the slave, such as power and communication. The host may adapt the connection to accommodate changing needs of the slave. The host may facilitate recovery and reconnection of a slave that becomes disconnected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a conceptual diagram illustrating a host device and a slave device adapter connected e an exemplary universal smart connection pad (USCP), viewed from its connecting surface.
[0007] FIG. 2 is a side view illustrating a host device that has an integrated USCP.
[0008] FIG. 3 illustrates an arrangement of pins in a rectangular slave adapter.
[0009] FIG. 4 illustrates an arrangement of pins in an elliptical slave adapter.
[0010] FIG. 5 is a side view illustrating a slave device with an integrated slave adapter.
[0011] FIG. 6 illustrates an arrangement of magnetic polarities of pins in a USCP.
[0012] FIG. 7 illustrates an alternative configuration of magnetic polarities of pins in a USCP.
[0013] FIG. 8 illustrates an exemplary cross section through a slave adapter mated with a USCP.
[0014] FIG. 9 is a conceptual diagram illustrating a host device and multiple slave devices connected through an exemplary USCP.
[0015] FIG. 10 is a block diagram illustrating exemplary types of connections whereby a host device or a slave device might access a USCP.
[0016] FIG. 11 is a block diagram illustrating exemplary functions of host connection manager logic in an exemplary USCP.
[0017] FIG. 12 is a block diagram illustrating exemplary components of a host connection manager in an exemplary USCP.
[0018] FIG. 13 is a block diagram illustrating exemplary functions of slave connection manager logic for a slave that is compatible with a USCP.
[0019] FIG. 14 is a block diagram illustrating exemplary components of a slave connection manager for a slave that is compatible with a USCP.
[0020] FIG. 15 is a sequence diagram illustrating exemplary mating module logic in an exemplary USCP.
[0021] FIG. 16 is a sequence diagram illustrating exemplary recovery module logic in an exemplary universal smart connection pad.
[0022] FIG. 17 is a sequence diagram illustrating exemplary pin reassignment module logic in an exemplary universal smart connection pad.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0023] This description provides embodiments of the invention intended as exemplary applications. The reader of ordinary skill in the art will realize that the invention has broader scope than the particular examples described here. It should be noted from the outset that the drawings, and the elements depicted by the drawings, are intended to illustrate concepts, and may not be to scale. Generally, reference numbers are keyed to the drawing of first appearance. For example, reference number 220 would appear first in FIG. 2 ; and 460 , in FIG. 4 . Each such reference will be described at least once, ordinarily in connection with the figure of first appearance. For clarity, a given reference number that appears in a second figure will not necessarily be described a second time.
[0024] FIG. 1 is a conceptual diagram illustrating a host 110 device and a slave 120 device connected through an exemplary universal smart connection pad (USCP) 100 and an exemplary slave adapter 121 . The host 110 and slave 120 are both electronic devices. A host 110 might be, for example, a laptop computer or a tablet computer. A slave 120 might be, for example, a mobile device, a camera, a video recorder, or a computer. More generally, a host 110 might be any type of electronic device; similarly, for a slave 120 . The connection through the USCP 100 between the host 110 and the slave 120 facilitates transfers between them. A transfer might be power or “data”. By data, we mean anything that has information content, such as text, audio, video, instructions, signals, or software, whether in analog or digital form, alone or in combination. Data includes any handshaking done between host 110 and slave 120 regarding a transfer. Multiple transfers might be occurring over a given interval. Transfers are done between pins 104 of the pad 100 that are mated with slave pins 310 of the slave adapter 121 .
[0025] In the type of embodiment shown in FIG. 1 , pad 100 is in a separate housing from host 110 . In FIG. 1 , host 110 connects to pad 100 with a cable 131 . This cable 131 might connect to the host 110 with a pair of mating connectors, making the cable 130 convenient for a user to disconnect from the host 110 ; alternatively, the end of the cable 131 might be integrated into the host 110 , designed to prevent separation. Similarly, the connection between the cable 131 and the pad 100 might be integrated into the pad 100 or be separable using a pair of mating connectors of the pad 100 and cable 131 . Mating-pair and integrated types of connectors are illustrated by FIG. 8 , which is described in more detail below.
[0026] The slave 120 connects to the pad 100 with a slave adapter 121 . Similar to connections between the cable 131 and the host 110 , connections between the cable 132 and the slave 120 might be integrated into the slave 120 , or use mating pairs of connectors; likewise, for connections between the cable 132 and the slave adapter 121 .
[0027] FIG. 2 shows a side view of an embodiment, in which the pad 100 is integrated into the housing of a host 110 , exposed along a surface. In such embodiments, an external cable linking the host 110 and pad 100 is not required. Analogously, as illustrated by FIG. 5 , a slave adapter 121 might be integrated into a slave 120 , eliminating the need for a slave external connecting cable.
[0028] A slave adapter 121 makes physical contact with the pad 100 to electrically connect the slave 120 to the host 110 . As shown in FIG. 1 , the pad 100 has pins 104 exposed on one of its surfaces. The pins 104 might protrude slightly beyond the surface of the pad 100 , as illustrated by FIG. 2 . Alternatively, the exposed ends of the pins 104 might be recessed slightly, or flush with the surface. Preferably, all pins 104 will be uniform in their elevation relative to the connecting surface. Similarly, as illustrated by FIG. 5 , the slave adapter 121 has slave pins 310 exposed on one of its surfaces; such slave pins 310 might be raised, lowered, or flush with respect to that connecting surface. Preferably, all slave pins 310 will be uniform in this regard.
[0029] Preferably, the pad 100 will have a rectangular shape as illustrated by FIG. 1 . In this case, the pins 104 are equally-spaced in two dimensions in a rectangular grid. With some pad 100 shape other than a rectangle, the grid is still rectangular, but will be truncated by the shape of the pad 100 . The pins 104 shown in FIG. 1 are preferably circular when viewed from above the surface, but they might have other shapes, such as diamond, square, or hexagon. Like the pins 104 , the slave pins 310 are also arranged into a rectangular grid, with the same equal spacing as the FIG. 1 . FIG. 3 illustrates a view of a pin-surface grid of a rectangular slave adapter 121 ; FIG. 4 , an elliptical slave adapter 121 , in which the rectangular grid is truncated by the overall shape of the slave adapter 121 . Preferably, the pad 100 will have at least 4 pins in each direction.
[0030] Rows of pins 104 in the pad 100 in FIG. 1 are labeled with letters; columns, with numerals. Labeled pin 104 ‘B 7 ’ exemplifies this system. Magnetism is used to automatically orient the slave adapter 121 into a functional position, as facilitated by the same equal spacing of slave pins 310 and pins 104 . Both pins 104 and the slave pins 310 are magnetized. Magnetism of the pins 104 might be either natural magnetism, or magnetism induced electronically by the host 110 . The slave pins 310 are preferably naturally magnetized, but in some embodiments, their magnetism might be induced by the slave 120 .
[0031] Magnets in the pad 100 orient the slave adapter 121 into an optimal position for transfer of power and/or data between the host 110 and the slave 120 . FIG. 6 shows an illustrative arrangement of polarities of a grid of pins 104 in a USCP 100 . Filled pins 104 have positive polarity; empty ones, negative. Polarities alternate between adjacent pins 104 . FIG. 7 shows a reversed arrangement of the same pad 100 . In FIG. 6 , pin B 7 604 is positive; in FIG. 7 the same pin, pin B 7 604 , is negative. As shown in FIG. 8 , which is a cross-section through a pad 100 and a slave adapter 121 , positive slave pins 310 will be attracted to and align with negative pins 104 , and conversely. The cross-sectional view of FIG. 8 illustrates how positively-charged pins 104 connect with negatively-charged slave pins 310 .
[0032] In both FIG. 1 and FIG. 8 , pins 104 either connected to corresponding slave pins 310 or not. Preferably, all the slave pins 310 are connected slave pins 106 , but in some embodiments, the slave adapter 121 might straddle a boundary of the pad 100 and still have enough connected slave pins 106 for the connection to work. Preferably, the pin grid of the pad 100 is sufficiently large so that a slave adapter 121 might be attached to the pad 100 at a variety of locations, as shown in FIG. 1 and FIG. 8 . In other words, the pin-dimensions of the pad 100 should as a minimum be larger than those of the largest slave adapter 121 that the pad 100 is intended to accommodate. The locations unused by a first slave 120 can be used so that the host 110 can mate with other slave 120 devices. FIG. 9 shows a second slave 920 , connected to the pad 100 by cable 922 and adapter 921 .
[0033] The connected slave pins 106 fall into two categories--they are either mated slave pins 107 or reserved slave pins 108 . The mated slave pins 107 (shown as filled in FIG. 1 ) are actively participating in the connection, exchanging power or data. The reserved slave pins 108 (shown as hollow) are inactive, either because they are presently unneeded to transfer data, or because they are defective or have failed. During a given interaction or exchange between a host 110 and a slave 120 , host connection management logic 1100 and/or slave connection management logic 1300 might change the role of a given slave pin 310 from mated to reserved, or conversely. Moreover, the position of the slave adapter 121 on the pad 100 can change during an interaction.
[0034] In the embodiment illustrated by FIG. 1 , the pad 100 is in a hardware housing separate from both the host 110 and the slave 120 . The host 110 is connected to the pad 100 by a cable 130 ; specifically, cable 131 . The slave 120 is connected to the slave adapter 121 by a cable 130 ; specifically, cable 132 . In other embodiments, the pad 100 may be integrated into the host 110 ; and/or the slave adapter 121 may be integrated into the slave 120 . FIG. 10 , which is a block diagram illustrating exemplary types of connections whereby a host 110 device or a slave 120 device might access a USCP 100 . The host 110 may be either connected with an integrated connection 1010 , or through an external port 1020 of the host 110 and a corresponding cable; similarly, for the slave 120 . Such an external port 1020 might be, for example, a USB port 1021 , a SD port 1022 , a SATA port 1023 , or an eSATA port 1024 . Other examples include Ethernet, HDMI, analog audio/video, digital audio/video, COAX, Lightening, Thunderbolt, and FireWire.
[0035] The smart connection between the host 110 and the slave 120 through the pad 100 is managed for the host 110 by host connection management logic 1100 , illustrated by FIG. 11 . For the slave 120 , the connection is managed by slave connection management logic 1300 , illustrated by FIG. 13 . Functionality, and corresponding hardware/software, of host connection management logic 1100 may be split in any combination between the host 110 and the pad 100 . Placing more functionality in the pad 100 means that one pad 100 might be compatible with many hosts. On the other hand, a host 110 with a processing system may be able to easily accommodate a relatively passive and unintelligent pad 100 , possibly with a simple software application installation on the host 110 . Analogously, functionality, and corresponding hardware/software, of slave connection management logic 1300 may be split in any combination between the slave 120 and the slave adapter 121 ; in this case, placing as much functionality on the slave adapter 121 as possible is preferable.
[0036] In the illustrative embodiment of FIG. 8 , the pad 100 has module 860 where some or all of the host connection management logic 1100 might be housed. Similarly, the slave adapter 121 has module 840 where some or all of the slave connection management logic 1300 might be housed. As a minimum, module 860 provides electrical connections between the pins 104 and the cable 131 ; similarly, module 840 provides electrical connections between the slave pins 310 and the cable 132 .
[0037] The host connection management logic 1100 may include an action selection module 1110 . The action selection module 1110 considers, given the current state of the pad 100 , whether each of the possible other action modules should be executed, and if so, initiates execution of that module. The host connection management logic 1100 may include a pin orientation module 1115 that manages magnetization of pins 104 , causing an attached slave 120 device to assume a workable orientation. The host connection management logic 1100 may include a mating module 1120 , a power module 1130 , a pin assignment module 1140 , a function expansion module 1150 , a function reduction module 1160 , a recovery module 1170 , and/or a handshaking module 1180 . Exemplary logic of a mating module 1120 and a pin assignment module 1140 is illustrated by FIG. 15 . Exemplary logic of a pin assignment module 1140 , a handshaking module 1180 , and a recovery module 1170 is illustrated by FIG. 16 . Exemplary logic of a pin assignment module 1140 , a function expansion module 1150 , a function reduction module 1160 , and a 17 is illustrated by FIG. 17 .
[0038] The modules of the slave connection management logic 1300 are required to collaborate with their counterparts to facilitate the transfers. The slave connection management logic 1300 may include an action selection module 1310 , a mating module 1320 , a power module 1330 , a pin assignment module 1340 , a function expansion module 1350 , a function reduction module 1360 , a recovery module 1370 , and/or a handshaking module 1380 . 15 - FIG. 17 illustrate applications of these modules in initiating interactions with the host 110 , and responding to interactions initiated by the host 110 .
[0039] FIG. 12 is a block diagram illustrating exemplary components of a host connection manager 1200 in an exemplary USCP 100 . The host connection manager 1200 executes the host connection management logic 1100 . The processing system 1210 includes at least one processor, housed in either the host 110 , the pad 100 , or one or more in each. Similarly, storage 1220 may be housed in either the host 110 , the pad 100 , or in each. The processing system 1210 , storage 1220 , and the four interfaces all include hardware electronic components; the host connection management logic 1100 may include hardware components and may include software instructions, some or all of which might be accessed from the storage 1220 . The host communication interface 1230 is an interface between the host 110 and the pad 100 through which the host 110 may communicate electronically with the slaves 120 and with the pad 100 itself. The host power interface 1240 is an interface through which the host 110 may provide power to the pad 100 , and in some embodiments, to slaves 120 . The host transfer-control interface 1250 is an interface through which the host 110 communicates with the slave 120 , through the pad 100 and slave adapter 121 , to coordinate and monitor transfers of power and/or data, including handshaking.
[0040] FIG. 14 is a block diagram illustrating exemplary components of a slave connection manager 1400 in an exemplary USCP 100 . The slave connection manager 1400 executes the slave connection management logic 1300 . The processing system 1410 includes at least one processor, housed in either the host 110 , the pad 100 , or one or more in each. Similarly, storage 1420 may be housed in either the host 110 , the pad 100 , or in each. The processing system 1410 , storage 1420 , and the four interfaces all include hardware electronic components; the slave connection management logic 1300 may include hardware components and may include software instructions, some or all of which might be accessed from the storage 1420 . The slave communication interface 1430 is an interface between the host 110 and the pad 100 through which the host 110 may communicate electronically with the slaves 120 and with the pad 100 itself. The slave power interface 1440 is an interface through which the host 110 may provide power to the pad 100 , and in some embodiments, to slaves 120 . The slave communication interface 1430 is an interface through which slaves 120 may communicate electronically with the host 110 and with the pad 100 itself. The slave power interface 1440 is an interface through which slaves 120 may receive power from the pad 100 , and in some embodiments, ultimately from the host 110 . The slave transfer-control interface 1450 is an interface through which the slave 120 communicates with the host 110 , through the slave adapter 121 and pad 100 , to coordinate and monitor transfers of power and/or data, including handshaking. Preferably, as much of the slave connection manager 1400 as possible is housed in the slave adapter 121 , and as much of the slave connection management logic 1300 as possible is executed by the slave adapter 121 . Preferably, the slave 120 itself is unaware of the details of the connection.
[0041] The handshaking module 1180 and the handshaking module 1380 may communicate regularly to monitor the status of any transfers of power or data, and to initiate any appropriate corrective action. Such handshaking might be done using one or more otherwise unassigned slave pins 310 , a dedicated slave pin 310 , or might be piggybacked on a data or power transfer pin.
[0042] FIG. 15-17 are sequence diagrams (also known as swim lane diagrams) that illustrate exemplary host connection management logic 1100 of an exemplary USCP 100 . FIG. 15 is typical of these swim-lane diagrams. Across the top of the diagram, system components are depicted in boxes; in FIG. 15 , the components are the host 110 , the pad 100 , and the slave 120 . As indicated by notation 1500 , time increases down the page. Under each box representing a respective component is a timeline; in FIG. 15 , the timelines are host timeline 1501 , pad timeline 1502 , and slave timeline 1503 . An arrow between two timelines indicate interactions between the corresponding system components, where the component transfers something to, communicates with, or senses something from other component. A single-headed arrow indicates a one-way interaction; a double-headed arrow, two-way. An arrow from a timeline to itself indicates an action taken by the corresponding system component at that point in the sequence.
[0043] FIG. 15 is a sequence diagram illustrating exemplary mating module 1120 logic in an exemplary USCP 100 . In FIG. 15 , when the pad 100 has no active connections, host 110 still provides 1510 a low level of power to the pad 100 . This power might be required for a slave adapter 121 to respond to contact, or for the host 110 to detect presence of a slave adapter 121 . Magnetic attraction of the pins 104 to the slave pins 310 causes 1520 the slave adapter 121 of the slave 120 to attain a workable orientation. The host 110 detects 1530 contact with the slave adapter 121 , and establishes 1540 with the slave 120 through the slave adapter 121 . The slave 120 then identifies 1550 itself to the host 110 . Such identification may include type of the slave 120 , the type of the slave adapter 121 , and the number of connections available. The slave 120 then requests 1555 what it needs from the host 110 , such as the types of connections, the power requirements, assignments of slave pins 310 and their duties, which pins are reserved, and how handshaking will occur. The host 110 responds 1565 , choosing pin assignments. The slave 120 complies 1565 by assigning slave pins 310 as directed. The host 110 places 1570 unused slave pins 310 on standby. The host 110 establishes 1575 the power connection. The host 110 establishes 1580 the data connection. At this point, interaction begins 1585 between the host 110 and the slave 120 .
[0044] FIG. 16 is a sequence diagram illustrating recovery from a connection failure. Initially, the host 110 and slave 120 are interacting 17 , as in the last step of FIG. 15 . Something disturbs the system; for example, a user 150 might bump 1603 the slave adapter 121 . The host 110 detects 1607 the connection failure at the pad 100 . The remaining steps ( 1625 - 1685 ) follow their counterparts ( 1520 - 1585 ) in FIG. 15 , except that here there is an additional step of recovery 1675 from interruption of the data transfer.
[0045] FIG. 17 is a sequence diagram that deals with changes to the system once interaction 1585 between the host 110 and slave 120 has already been taking place. In the embodiment shown, the slave 120 determines for itself 1704 that a change in the interaction is needed. (In other embodiments, a needs change might be initiated by the pad 100 , by the host 110 , or by the slave adapter 121 .) The slave 120 requests 1712 a change. The remainder steps ( 1560 - 1585 ) follows their counterparts ( 1660 - 1685 ) in FIG. 16 . The optional recovery step 1782 might or might not be needed, depending upon circumstances of the change.
[0046] Of course, many variations of the above method are possible within the scope of the invention. The present invention is, therefore, not limited to all the above details, as modifications and variations may be made without departing from the intent or scope of the invention. Consequently, the invention should be limited only by the following claims and equivalent constructions. | The present invention is a pad for connecting a host device to a slave device through a slave adapter. The host may provide services to the slave, including power and data connections. Pins in the pad magnetically align the slave adapter. The host and slave may collaborate on which pins are assigned to connections. The system handles various usage modifications including, for example, dislocation of the slave adapter, and changes in pin assignments. | 6 |
FIELD OF THE INVENTION
The present invention relates generally to masonry tools and more particularly to a masonry grout bag having an integral semi-rigid tip formed by immersing the tip in a liquid rubber coating compound. The liquid rubber cures to form a semi-rigid layer upon the external surface of the tip. The grout bag is used for applying grout to masonry, such as tile floors, during the installation process.
BACKGROUND OF THE INVENTION
Grout bags for applying grout to floor tiles and the like during their installation are well known. Such grout bags typically comprise a flexible fabric cone having a semi-rigid tip. The cone of contemporary grout bags is typically formed of a vinyl laminated fabric which is formed into a cone and sewn or glued at the seam in the fashion of a cake decorating bag. A semi-rigid insert is glued or sewn into the tip of the cone to provide structural rigidity so that the tip may be forced into the void between adjacent tiles where grout is to be applied. The insert is commonly made of plastic. It may be either preformed in the shape of a cone or formed from flat stock which is rolled into a cone, glued or sewn at the seam, inserted into the grout bag, and glued or sewn in place.
The vinyl layer of the vinyl laminated plastic forms the inside surface of the grout bag, thereby sealing moisture within the bag. The fabric outer layer provides a non-slip grip for the user.
The masonry grout bag is used by filling it, through the upper opening, with grout, grasping the top portion in one hand to seal the upper opening, and squeezing the grout-filled cone with the other hand to force grout from the tip and into the void between adjacent tiles. This is done in much the same manner as applying decorative icing to a cake with a cake decorating bag.
Forming the grout bag of a vinyl coated fabric and a separate tip insert makes the fabrication process comparatively elaborate and expensive. After the cone is formed, then the insert must also be formed if a preformed insert is not used, and then the insert is inserted and secured within the bag. The use of a preformed insert, while saving labor costs, increases the cost of material. A preformed tip is generally dye cast, thus requiring significant tooling and per unit cost.
Alternatively, the flat stock used to form the insert is comparatively inexpensive, but the process is very labor intensive. Flat stock must be cut to the proper pattern, formed into a cone, sewn or glued at the seam in order to retain its shape, and inserted and secured within the grout bag.
A method of forming a masonry grout bag having a semi-rigid tip but not requiring a separate tip insert is desirable. The separate plastic tip insert of prior art grout bags can crack and become brittle after a period of use. This commonly results in the bag becoming useless for its intended function since the tip can no longer be forced into the void between adjacent tiles. Therefore, a new bag must be purchased. Although the need for an improved masonry grout bag has long been recognized, the solution has heretofore never been addressed.
SUMMARY OF THE INVENTION
The present invention specifically addresses and alleviates the above-mentioned deficiencies associated in the prior art. More particularly, the present invention comprises a masonry grout bag having an integral semi-rigid tip formed by immersing the tip in a liquid rubber-like coating compound. The liquid rubber-like coating cures to form a semi-rigid layer upon the external surface of the tip. The grout bag is used for applying grout to masonry, such as tile and brick floors, during the installation process.
The bag is formed by cutting a sheet of vinyl laminated fabric into substantially the shape of a triangle and forming it into a cone as in the prior art.
The integral semi-rigid tip eliminates the requirement for a separate plastic insert which must be formed into the shape of a cone and inserted into the grout bag and then secured therein. The integral semi-rigid tip is incapable of loosening or becoming detached from the bag.
Forming the tip as an integral part of the masonry grout bag reduces both the labor and materials required for fabrication. Therefore, the masonry grout bag of the present invention can be manufactured at a much lower cost than masonry grout bags of the prior art.
These, as well as other advantages, will be more apparent from the following description and drawings. It is understood that changes in the specific structure shown and described may be made within the scope of the claims without departing from the spirit of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a prior art masonry grout bag;
FIG. 2 is an enlarged cross-sectional view of the tip of a prior art masonry grout bag;
FIG. 3 is a plan view of a sheet of vinyl laminated fabric prior to its being formed into a cone as in the prior art and the present invention;
FIG. 4 is a perspective view of the vinyl laminated fabric formed into a cone as in the prior art and the present invention;
FIG. 5 illustrates the immersion of the tip of the masonry grout bag of the present invention into a liquid coating compound;
FIG. 6 is a perspective view of the masonry grout bag of the present invention; and
FIG. 7 is an enlarged cross-sectional view of the tip of the masonry grout bag of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The masonry grout bag of the present invention is illustrated in FIGS. 3-7 which depict a presently preferred embodiment of the invention and a method for making the same. FIGS. 1 and 2 depict a prior art masonry grout bag.
Referring now to FIGS. 1 and 2, the prior art masonry grout bag comprises a cone 10 and an insert 20. The cone 10 is typically fabricated from vinyl laminated fabric and comprises a tip 14, a first or upper opening 16, and a second or lower opening 18.
The insert 20 is commonly formed of plastic sheet stock which is rolled into a cone and glued together at the seam. It is then inserted into the cone 10, and glued therein. One or more recesses 22 may be formed into the insert 20 to help secure it within the tip 14.
Grout is placed within the masonry grout bag by pouring it in through the first or upper opening 16. The insert 20 causes the tip 14 of the prior art masonry grout bag to be semi-rigid such that the tip 14 can be forced between adjacent tiles and grout can be squeezed through the lower opening 18 of the tip 14 and into the void formed by adjacent tiles and not generally upon the exposed upper surface of the tiles.
Referring now to FIGS. 3-7, the grout bag of the present invention is depicted preferably comprising a sheet of vinyl laminated fabric 44 cut such that it will form a cone when rolled about a mandrel is depicted. The sheet 44 is formed generally in the shape of a triangle having the tip of one corner removed.
FIG. 4 depicts the vinyl laminated fabric sheet 44 after it has been formed into a cone 30. The vinyl laminated fabric sheet 44 may be formed into a cone by wrapping it around a cone-shaped mandrel. The overlapping ends of the sheet 44, which form the seam 32, may be secured together by heat sealing upon a mandrel the abutting vinyl surfaces of the sheet 44, by gluing with a suitable adhesive or by sewing.
Referring now to FIG. 5, the tip 34 of the cone 30 is immersed into a liquid coating compound 44 which, when cured, forms a semi-rigid rubber-like coating upon the inside and outside of the tip 34 of the masonry grout bag. U.S. Pat. No. 4,536,454, issued to Haasl, discloses a suitable coating compound. The Haasl patent utilizes a two-step process wherein a primer coating is first formed upon the material to be coated and then a top coating is applied. Therefore, the use of the method disclosed in the Haasl patent involves immersing the tip 34 of the masonry grout bag into two different coating compounds. However, those skilled in the art will recognize that various single-step coating compounds are available and suitable for use in this invention.
The first or primer-coating of the Haasl process is a thermoplastic resin comprised of methylmethacrylate copolymer, silicon dioxide filler, and a thermoplastic rubber comprising styrene/ethylene/butylene/styrene block copolymer.
The second or top coating is a thermoplastic rubber comprised essentially of a styrene/ethylene/butylene/styrene block copolymer, silicon dioxide filler, and calcium carbonate.
Both coatings are mixed with a solvent, thus keeping them in liquid form. After immersion, the material to be coated is permitted to air dry until the solvent has substantially evaporated.
Referring now to FIGS. 6 and 7, the finished masonry grout bag is depicted. The tip 34 has been coated on both the exterior 40 and interior 42 surfaces. The rubber coating makes the tip 34 semi-rigid, such that it can be forced into the void between adjacent tiles and grout can be forced into the void.
Use of the masonry grout bag of the present invention is the same as in the prior art. However, the masonry grout bag of the present invention will generally last longer since there is no insert to crack or become brittle.
It is understood that the exemplary masonry grout bag described herein and shown in the drawings represents only a presently preferred embodiment of the invention. Indeed, various modifications and additions may be made to such embodiment without departing from the spirit and scope of the invention. For example, the shape of the bag may vary substantially from the cone as disclosed. Also, various materials other than vinyl laminated fabric may be utilized to form the bag. For example, leather, vinyl, and various other flexible plastics may be used. Further, other flexible rubber-like compounds may be utilized on the tip of the bag for rigidifying purposes. Thus, these and other modifications and additions may be obvious to those skilled in the art and may be implemented to adapt the present invention for use in a variety of different applications. | A masonry grout bag having an integral semi-rigid tip formed by immersing the tip in a liquid rubber-like coating compound. The liquid rubber-like coatings cure to form a semi-rigid layer upon the internal and external surfaces of the tip. The grout bag is used for applying grout to masonry structures, such as tile floors, during athe installation process. | 4 |
FIELD OF THE INVENTION
This invention relates to telecommunications networks and more particularly to a method for reducing information error rates of communication channels within telecommunication networks.
DESCRIPTION OF THE RELATED ART
The use of communication networks such as telephony networks and data communication networks (e.g., the Internet) by the general public to convey information has increased significantly in the past several years. The information is represented by analog and/or digital communication signals. A telephony network provides traditional telephony services (e.g., voice communications, facsimile communications, analog data) over such media as twisted metallic wire pairs (e.g., tip/ring pairs), coaxial cables, fiber optic cables, air, free space, and other media. The Public Switched Telephone Network (PSTN) is an established telephony network which is accessible to the general public. A data communication network is a network in which information signals are conveyed throughout the network in digital form. Examples of a data communication network include the public Internet, and computer communication networks (e.g., corporate communication networks, educational communication networks, governmental communication networks).
Often, users of telephony networks, computer communication networks and other communication networks gain access to such networks via local access networks such as a Digital Loop Carrier (DLC) system. An exemplary DLC system is shown in FIG. 1. DLC 10 comprises Remote Terminal (RT) 28 connected to Local Digital Switch (LDS) 20 via communication link 26. Communication signals are exchanged between LDS 20 and communication link 26 via interface 24. LDS 20 is connected to PSTN 12 and Public Internet 14 via communication links 18 and 16 respectively. Remote Terminal 28 is connected to user 1 (34) via communication link 30 and to user 2 (36) via communication link 32. Users 1 and 2 thus have access to Public Internet 14, PSTN 12 and to each other. For the sake of clarity only two users are shown in FIG. 1. In practice, DLC systems connect hundreds or even thousands of users. Moreover, an actual DLC system, such as the one shown in FIG. 1, may provide access to a variety of communication networks in addition to the ones shown.
Communication links 30 and 32 are currently implemented with metallic wires (i.e., tip/ring pairs) through which analog communication signals (e.g., voice, facsimile) are conveyed between the users (34, 36) and Remote Terminal 28. Communication links 30 and 32, when implemented as metallic tip/ring pairs, are part of the well known Plain Old Telephone Service (POTS) telephony system and such links are commonly referred to as POTS lines. POTS lines typically are able to convey analog communication signals within a limited bandwidth spanning the frequency range of 0-4 KHz commonly referred to as Voice Frequencies (VF). The VF range is typically further band limited to a frequency range of 200 Hz-3400 Hz due to additional analog filtering by DLC 10 equipment.
Users who wish to communicate with data communication networks such as the Public Internet typically use modems to transmit and receive analog data signals over the POTS lines. The analog signals from communication links 30 and 32 are converted to digital signals by RT 28 and are conveyed over communication link 26. The digital signals are processed in accordance with a protocol being followed by DLC 10 and are transferred to LDS 20 which transmits such digital signals to either PSTN 12 or Public Internet 14 via communication links 18 or 16 respectively. A protocol is a set of rules and standards that govern the operation of the various equipment of a communication network such as a local access network so as to control, monitor, and/or manage communications between users of the same or different networks and also between equipment of the same or different networks. Part of the protocol information is referred to as signaling information which is used to initiate communication between users, monitor the channel through which information is being conveyed during user communications and terminate communications between users. The signaling information is often generated by the various communication network equipment (e.g., RT 28, LDS 20).
Before users of the same or different networks can communicate with each other, the communication is established in accordance with the protocol. A communication is established when the system has allocated appropriate network resources (e.g., a communication channel) and has followed certain procedural steps defined by the protocol, to allow users to convey communication signals to each other within a communication network or different networks. The communication signals conveyed between users is referred to as user information. Examples of protocols used by local access networks (particularly in North America) and other communication networks include the well known TR-303 Hybrid Signaling protocol and the TR-08 protocol.
Still referring to FIG. 1, LDS 20 also receives user information from either PSTN 12 or Public Internet 14 and transmits such information to RT 28 which converts the information to the proper analog signal for propagation through communication links 30 or 32. The signaling information is extracted by RT 28 and the remaining user information is relayed to the users. It should also be noted that communication links 30 and 32 need not be analog POTS lines but can be other communication links through which digital and/or analog communication signals are conveyed.
The user information conveyed through the various communication links of local access network 10 is packaged and structured in accordance with well defined communication channel formats. An example of a communication channel format used in many local access networks and other communication networks is the well known Digital Signal Zero (DS0) channel format. A DS0 channel is defined as a communication channel with an information capacity of 64 kbps (64 kilobits per second). Part of the information conveyed through the communication channels represents protocol information. Communication links can also be formatted as per a Digital Signal One (DS1) channel structure. A DS1 channel contains 24 DS0 channels.
The digital signals conveyed between RT 28 and LDS 20 over communication link 26 are organized in a particular fashion dictated by the protocol being followed by the local access network.
Referring to FIG. 2, there is shown how digital signals are organized and conveyed over communication link 26 between LDS 20 and RT 28 as per the TR-303 Hybrid Signaling protocol. Communication link 26 is organized as a DS1 channel. Typically, the analog signals from the users are sampled by RT 28 at a rate of 8000 samples per second. RT 28 converts each sample to an 8 bit word which is then placed in a particular DS0 channel within the DS1 channel of communication link 26. In particular, the digital signals are organized as frames (38) with each frame being 125 μsec long (i.e., length of one sample). Each frame (38) comprises 24 DS0 channels (40) where each DS0 channel contains the 8 bits of data representing a sample from a particular user, and a framing bit (43) used as an indicator for separating the frames. Thus, a DS1 channel can serve up to 24 separate users.
The TR-303 Hybrid Signaling protocol allows signaling information to be integrated with user information and both types of information are conveyed through the DS1 channel. Such a technique of integrating user information with signaling information is commonly referred to as in-band signaling (or in-slot signaling). Still referring to FIG. 2, part of each user's information, and in particular, the least significant bit (42) of each DS0 channel of every sixth frame is discarded and replaced with a signaling bit that represents signaling information. The information that replaces the discarded user information is referred to as in-band signaling information. The in-band signaling scheme where the least significant bit of user information is purposely discarded and replaced with signaling information is referred to as Robbed Bit Signaling (RBS). The TR-303 Hybrid Signaling protocol uses the Robbed Bit Signaling scheme.
FIG. 2 discloses a particular form of RBS structured in what is commonly known as a DS1 frame format. In this particular version of RBS, the least significant bit (42) of every DS0 channel within the 6 th frame, the 12 th frame, the 18 th frame, and the 24 th frame etc . . . is replaced with signaling information. For purposes of clarity, only the configuration of the 6 th frame is shown in FIG. 2.
As the popularity of data communication networks such as the Internet increases, there is an ever increasing need by users of local access networks to convey information to and from such networks at higher and higher speeds. At such high speeds and in view of the limited bandwidth of the POTS lines, signal degradation is often a problem. The analog data signals tend to be more susceptible to noise and are more easily distorted by bandwidth limited media such as POTS lines.
It will be readily understood that the use of the RBS scheme, or other in-band signaling schemes, in which part of the user information is sacrificed for signaling information, is another contributor to the signal degradation suffered by local access network 10 and other similar communication networks. The use of in-band signaling schemes often degrades the performance of local access networks and other communication networks because of the increase in the information error rate (e.g., high bit error rates) and /or lowered throughput. Typically, a certain amount of errors occurs in the conveyance of user information at a particular speed for a particular amount time. For a certain time period, the ratio of the amount of errors occurring in conveyed user information to the amount of user information is defined as information error rate. The throughput is defined as the actual amount of information conveyed. Often, subscribers or the local access network equipment must reduce the speed at which information is being conveyed through the local access network in order to lower the information error rates to an acceptable level. For example, many subscribers who use 56 Kb/s, 33.6 Kb/s or even 28.8 Kb/s modems to convey information through communication channels of local access networks have to operate their modems at lower speeds because of the exacerbating effects of in-band signaling such as RBS. As a result, the throughput of these communication channels is decreased.
It is therefore, an object of the present invention to eliminate substantially the adverse effects (e.g., increased information error rate, lowered throughput) of in-band signaling schemes such as RBS during communications between users of local access networks or other communication networks.
SUMMARY OF THE INVENTION
The present invention provides for a method, which when applied to a communication network that uses in-band signaling, suspends the application of in-band signaling for at least a portion of established communication between at least two users of the communication so as to reduce information error rates associated with the established communication. The method of the present invention comprises the steps of establishing communication between at least two users in accordance with a protocol and conveying information free of in-band signaling information so as to reduce information error rates associated with the conveyed user information.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary local access communication network called a Digital Loop Carrier system;
FIG. 2 is a diagram of a data structure for a DS1 frame format for the Robbed Bit Signaling (RBS) scheme;
FIG. 3 is a flowchart of the method of the present invention;
FIG. 4 is a flowchart of the method of the present invention implemented in accordance with the TR 303 hybrid signaling protocol.
DETAILED DESCRIPTION
The present invention provides a method, which when applied to a communication network that uses an in-band signaling scheme, suspends the application of the in-band signaling for at least a portion of established communications between users of the communication network during which the communication network operates in a clear channel mode that serves to reduce information error rates associated with the established communication. The clear channel mode occurs after communication between at least two users is established. In the clear channel mode, no in-band signaling information is conveyed; the user information is conveyed free of signaling information. The duration of the clear channel mode may occur for part or all of the established communication between users.
It will be readily understood that the method of the present invention is applicable to all protocols which use an in-band signaling scheme. It should further be understood that the implementation of the present invention within existing communication networks that comply with an in-band signaling protocol can be made transparent to the operation of such networks. As such, the present invention represents an added feature to protocols with in-band signaling and allows such protocols to operate in the clear channel mode without adversely affecting in any significant manner their standard operation. Furthermore, the method of the present invention will be described in the context of DLC 10. However, it should be readily obvious to one skilled in the art to which this invention belongs that the method of the present invention is applicable to other types of communication networks and is not limited to local access networks such as DLC 10.
FIG. 3 depicts the method of the present invention which starts with step 50 in which communication is initiated by a user of a local access network such as DLC 10 of FIG. 1. For example, referring back to FIG. 1, user 1 may wish to communicate via a modem to a user within Public Internet 14. User 1 does this by placing a call to the user that is part of the Internet. A call is defined as the completion of an established communication and the conveyance of information between at least two users of the same or different networks in accordance with the protocols of the networks. Users can communicate with each other with communicating devices such as modems, telephones, facsimile machines, and computers. User 1 first goes Off Hook which is a condition that is detected by DLC 10, in particular, RT 28. Referring again to FIG. 3, the method of the present invention now moves to step 52.
In step 52, DLC 10 and the communication network associated with the called user take the appropriate steps as per their respective protocols to establish communication between user 1 and the called user. At this point the established communication is using in-band signaling. Once communication is established between user 1 and the called user, the method of the present invention moves to step 54 where inband signaling is suspended. In step 54, DLC 10 enters the clear channel mode in which user information conveyed between RT 28 and LDS 20 has no in-band signaling information thus reducing the information error rates associated with the conveyed user information. In many protocols that use in-band signaling, there exists a separate or out of band channel through which protocol signals such as signaling information are conveyed apart from the user information. For example, the TR-303 Hybrid Signaling protocol has such a channel which is called the Timeslot Management Channel (TMC). The TMC is implemented as a DS0 channel within communication link 26. During the clear channel mode, a communication system that complies with the TR-303 Hybrid Signaling protocol for example, may continue to convey signaling information between RT 28 and LDS 20 via the TMC. DLC 10 remains in the clear channel mode (i.e., suspension of in-band signaling) for a period of time that is equal to or less than the duration of the established communication.
In step 56, the method of the present invention determines whether any condition has occurred within DLC 10 which would warrant a return to in-band signaling. Many communication networks offer various features (e.g., 3-way calling, call waiting) which when activated can be more efficiently implemented with in-band signaling. It should be noted however that the implementation of such features is dependent upon the particular design of the communication network and that such features may not necessarily specifically require the use of in-band signaling. If no such conditions occur during communication between the users, the system may operate in the clear channel mode for the duration of the established communication. In step 62 the method of the present invention has determined that it should return to in-band signaling mode. The method of the present invention remains in the in-band signaling mode until step 64 where at least one of the users has terminated (e.g., user goes On-Hook) communication or DLC 10 signaling terminates the communication. In step 66, the method of the present invention ends the communication in accordance with the particular protocol being followed by the communication system.
Referring back to step 56, when there exists no conditions warranting the return to in-band signaling, the method of the present invention moves to step 58 where the communication system continues to operate in the clear channel mode until communication has been terminated (step 60) in which case the system moves to step 66 or conditions warranting return to in-band signaling occur in which case the communication system operates in the manner described above (i.e., steps 62, 64 and 66).
FIG. 4 depicts an example of a specific version of the method of the present invention implemented in accordance with the TR-303 Hybrid Signaling protocol. More particularly, FIG. 4 depicts a particular procedure (using the TR-303 Hybrid Signaling protocol) of the method of the present invention applied to a feature commonly referred to as the 3-way calling feature. The 3-way calling feature is a well known characteristic provided by many telephony systems which allows three users to communicate with each other simultaneously. The 3-way calling feature is activated in the following manner: (1) User 1 calls User 2; either the calling party (User 1) or the called party can activate the 3-way calling feature. Say, for example, User 1 wishes to add a third party to the call; (2) User 1 performs a flash hook, i.e., User 1 presses and releases the telephone hookswitch; this action is recognized by the communication system as a flash hook; (3) User 1 now hears a dial tone and then proceeds to dial the third party's number; (4) User 1 can now communicate to the third party and after performing another flash hook can communicate with the third party and User 2 simultaneously.
FIG. 4 shows how the method of the present invention can be applied to a specific protocol (TR-303 Hybrid Signaling protocol) to implement a specific feature (i.e., 3-way calling) provided by a communication system such as DLC 10. As such FIG. 4 is simply an illustrative procedure that shows how the method of the present invention can be integrated within a particular protocol being followed by a particular communication system. A similar procedure can be implemented for other features (e.g., call-waiting) and/or other communication systems.
Prior to step 100 of FIG. 4, communication is established between at least two users of a communication system such as DLC 10 in accordance with the TR-303 Hybrid Signaling protocol. The system has provided a DS0 channel from the DS1 channel of communication link 26 for conveying information (user and signaling) between the users. Furthermore, one of the users has called the other and thus communication (exchange of communication signals) between the two users is about to start. The communication system will follow the steps of the method of the present invention while still complying with the TR-303 Hybrid Signaling protocol.
In step 100, LDS 20 transmits a "suspend" message to RT 28 via the TMC. The "suspend" message instructs RT 28 to suspend the use of Robbed Bit signaling. In step 102, RT 28 puts the DS0 channel allocated for the call in a clear channel mode and sends a "suspend acknowledge" message to LDS 20 via the TMC. In step 104 the system enters the clear channel mode. The user information being conveyed through the allocated DS0 channel does not have any embedded signaling information; i.e., there is no in-band signaling. Instead, the signaling information is conveyed through an out of band channel (e.g., the TMC). Preferably DLC 10 enters the clear channel mode within 300 milliseconds from the time communication between User 1 and the called user is established.
In step 106, LDS 20 determines whether the DS0 channel allocated for the call is authorized for the 3-way calling feature. The system moves to step 108 where LDS 20 has determined that the allocated DS0 channel does have the 3-way calling feature, and LDS 20 sends a "flash hook enable" message via the TMC to RT 28. In response, in step 110 RT 28 sends a "flash hook enable acknowledge" message to LDS 20 via the TMC. In step 114, RT detects a flash hook (one of the users has applied a flash hook to initiate 3-way calling as described above) and reports it to LDS 20. In step 116, LDS 20 decides to return to RBS (i.e., in-band signaling) as the 3-way calling feature has been activated. In step 118, LDS 20 sends a "resume" message to RT 28 instructing RT 28 to activate the RBS scheme. In response, in step 120, RT 28 sends a "resume acknowledge" message to LDS 20. The system moves to step 122 in which the RBS scheme is activated. The system continues to operate in the RBS mode until RT 28 detects an On Hook condition and consequently moves to step 124 where RT 28 reports the On Hook condition to LDS 20.
When an On Hook condition is detected the method of the present invention moves to step 126 in which LDS 20 sends a "disconnect" message to RT 28. In step 128 RT 28 sends a "release" message to LDS 20. In step 130, LDS 20 sends a "release complete" message to RT 28. At this point, the established communication is terminated and the allocated DS0 channel is now made available for future communications.
Referring back to steps 106 and 116, the method of the present invention moves to step 112 for features other than 3-way calling (e.g., call-waiting) that are also activated by the application of a flash hook. In such cases, the method of the present invention would certainly apply procedures that are consistent with the protocol being followed by the communication system. It will be readily understood by those skilled in the art to which this invention belongs that the method of the present invention can be modified to apply to any and all features of protocols that use in-band signaling and that FIG. 4 is simply one example of a particular application. | The present invention provides a method for conveying information over a communication network such as a Digital Loop Carrier network free of in-band signaling information for at least a portion of an established communication between at least two users so as to reduce the information error rate associated with the established communication. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from pending U.S. provisional patent application serial No. 60/247,137 filed Nov. 9, 2000; the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates generally to a duplicator for use in woodworking, and more particularly to a duplicator for attachment to a standard radial arm saw. Specifically, the present invention relates to a duplicator that may be attached to a standard radial arm saw while being movable and adjustable in at least five directions.
2. Background Information
Woodworkers often desire to duplicate a three dimensional object. Such objects may includes faces, patterns, sculptured items, etc. These parts could be carved individually, but it is very difficult to make them similar, let alone identical to each other. The time and skill to individually carve them also makes this option undesirable. It is therefore desirable to have a tool which can be used to make duplicate copies of an article. Such a tool would allow the woodworker to hand carve an original work and then quickly and easily duplicate the work so that the duplicates may be sold.
BRIEF SUMMARY OF THE INVENTION
The device of the present invention is a woodworking duplicator which is adapted to be attached to a standard radial arm saw. The device allows a rotating cutting tool and a stylus to be movably supported allowing the user to trace a pattern with the stylus while cutting the pattern into a work piece with the cutter.
The invention provides a duplicator that may be mounted to a radial arm saw wherein the duplicator includes elements that may be moved in five different directions. The invention also provides a duplicator having a stylus and a cutter that may be easily locked into different parallel positions so that the user of the duplicator may more easily trace the item being duplicated. The invention also provides a duplicator that supports the weight of the stylus and cutter tool.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The preferred embodiments of the invention, illustrative of the best modes in which applicant has contemplated applying the principles of the invention, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is a front view of the duplicator shown mounted on a standard radial arm saw.
FIG. 2 is a plan view of the device shown in FIG. 1 .
FIG. 3 is a side view of the device through line 3 — 3 o f FIG. 1, showing the cutting tool contacting a block of wood to be carved.
FIG. 4 is a side view of the device through line 4 — 4 of FIG. 1, showing the stylus contacting an article to be duplicated.
FIGS. 5 and 6 are front views of the duplicator illustrating that the sleeve holding the cutting tool and stylus may be moved in a first horizontal plane.
FIGS. 7 and 8 are side views of the device illustrating the vertical motion of the duplicator, showing that the cutting carriage may be lowered towards or raised away from the table of the radial arm saw.
FIGS. 9 and 10 are side views of the device illustrating that the cutting carriage may be moved in a second horizontal plane toward or away from the post of the radial arm saw.
FIGS. 11 and 12 are partial side views of the device illustrating the vertical rotatability of the cutting tool of the device about the second bar of the duplicator.
FIG. 13 is a partial plan view of the sleeve of the device showing how a first cutting tool and the stylus are mounted on the sleeve.
FIG. 14 is a partial plan view of the sleeve showing a second cutting tool and the stylus, and illustrating how the stylus is adjusted to align with the cutting tool on the sleeve.
FIG. 15 is sectional view taken along line 15 — 15 of FIG. 14 .
FIG. 16 is a front view of the sleeve, with the cutting tool and stylus removed to show the bushings.
FIG. 17 is a front view of the sleeve with the cutting tool and stylus in position for engagement with the block of wood to be carved and the article to be duplicated.
FIGS. 18 and 19 are front views of the sleeve shown in FIG. 17, illustrating the rotatability of the cutting tool and stylus relative to the sleeve.
FIG. 20 is a sectional view taken along line 20 — 20 of FIG. 17 .
FIG. 21 is a view taken along line 21 — 21 on FIG. 20 .
Similar numerals refer to similar parts throughout the specification.
DETAILED DESCRIPTION OF THE INVENTION
The duplicator device 8 of the present invention is adapted to be mounted on a radial arm saw 10 . Radial arm saw 10 includes a horizontal table 12 , a post 14 extending vertically therefrom, an arm 16 extending horizontally from the post 14 and over the table 12 , and a slide 18 mounted on the underside of the arm 16 . Post 14 is adapted to telescope so that arm 16 moves vertically towards and away from table 12 . Slide 18 is adapted to move horizontally along the underside of arm 16 , both towards and away from post 14 .
Duplicator 8 of the present invention is adapted to be secured to radial arm saw 10 when the saw motor and blade have been removed. Duplicator 8 includes a frame that is generally indicated at 20 . Frame 20 is generally rectangular in shape having first and second bars 22 , 24 being disposed at right angles to end bars 26 , 28 . First bar 22 is attached to slide 18 of arm 16 by any suitable mounting arrangement. A spring 30 is disposed between slide 18 and first bar 22 so as to bias frame 20 upwardly towards arm 16 and away from table 12 of saw 10 .
A sleeve 32 is coaxially, slidably, and rotatably disposed on second bar 24 and is adapted to move horizontally along second bar 24 between end bars 26 , 28 (FIGS. 5 & 6 ). A cutting tool 34 and stylus 36 are mounted on sleeve 32 in any suitable manner. As sleeve 32 moves horizontally along second bar 24 , cutting tool 34 and stylus 36 move with it. Cutting tool 34 and stylus 36 thus slide and rotate in concert. Cutting tool 34 is adapted to carve into a workpiece which is typically a block of wood 38 or other substrate and stylus 36 is adapted to engage the article 40 which is to be duplicated into workpiece 38 .
Device 8 can move in a number of directions so that cutting tool 34 can be used to cut a three dimensional copy of article 40 as stylus 36 traces over article 40 . Cutting tool 34 can make the following movements. Firstly, sleeve 32 can slide horizontally in the A-A′ direction along second bar 24 (FIGS. 5 & 6 ). This allows the cutting tool 34 to cut the block of wood 38 in a first horizontal direction. Secondly, frame 20 can rotate vertically about axis B-B′ (FIG. 6 ). This allows the sleeve 32 to be lowered (FIG. 7) or raised (FIG. 8) relative to table 12 , allowing cutting tool 34 to cut workpiece 38 in a vertical direction. Thirdly, because frame 20 is connected to slide 18 , it can slide towards and away from post 14 in the C-C′ direction (FIGS. 9 & 10 ). This moves cutting tool 34 in the second horizontal direction, thereby allowing for cuts to be made in the block of wood 38 in this direction. Fourthly, sleeve 32 is able to rotate about the axis D-D′ (FIGS. 5, 11 & 12 ), allowing for cuts to be made in this direction. Fifthly, frame 20 can rotate about the vertical axis E-E′ (FIG. 7) as arm 16 is rotated about post 14 of radial arm saw 10 . Finally, as best can be seen in FIGS. 17, 18 and 19 , cutting tool 34 and stylus 36 can be rotated about axes F and F′ (FIGS. 20 and 21) in a manner which will be described below. The relative movements and rotatability of cutting tool 34 and stylus 36 in these various directions, allows for any three dimensional object to be duplicated by device 10 .
Stylus 36 is shown in greater detail in FIGS. 15 and 20. Stylus 36 includes a handle 42 at one end and a tracing tip 44 at the other. Tracing tip 44 may be adjustably mounted to stylus 36 in any suitable manner such as being received within a slot and being clamped therein by a clamp 46 . While tracing tip 44 is shown as a removable part of stylus 36 , it may be formed as an integral part thereof. The body of stylus 36 includes a slot for receiving a rod 48 therethrough. A suitable clamp 50 secures rod 48 and stylus 36 together. Rod 48 has a threaded first end 52 and a second end 54 that is inserted first through the bore 55 of a bushing 56 connected to sleeve 32 then through a V-shaped bracket 58 and finally through the slot in stylus 36 . Bushing 56 is connected to sleeve 32 by any suitable connectors such as welds or mechanical connectors. Clamp 50 is then inserted into stylus 36 to secure rod 48 in place.
As can be seen from FIGS. 16 & 21, the front face of bushing 56 which lies proximate bracket 58 is provided with a plurality of grooves 60 for receiving the apex 61 of the V of bracket 58 . An internally threaded handle 62 engages the external threads on first end 52 of rod 48 . When handle 62 is rotated, rod 48 is drawn farther towards or away from handle 62 , thereby decreasing or increasing the distance between sleeve 32 and stylus 36 (see FIGS. 13 and 14 ). If it is desired to alter the angle of stylus 36 relative to sleeve 32 , handle 62 is rotated to the point that apex 61 disengages from groove 60 , bushing 50 is rotated so that a different groove 60 is disposed for engagement with bracket 58 , and then handle 62 is rotated until apex 61 re-engages in the different groove 60 .
Cutting tool 34 is connected to the sleeve 32 in the following manner. A second V-shaped bracket 58 ′ is provided to engage in the grooves 60 ′ of a second bushing 56 ′ in the manner described above. Second bracket 58 ′ is connected to an adjustable clamp 64 by a second rod (not shown). Clamp 64 may include any suitable means of securing the cutting tool within its grasp, such as an expandable band having a lock screw 66 disposed for locking the ends of the band together. A second handle 62 ′ is provided to engage the end of the second rod to allow for release and securing of second bracket 58 ′ in second bushing 56 ′. Cutting tool 34 may be any suitable device such as a rotary cutter or a hand-held router. An electrical outlet 70 and switch 72 are provided on frame 20 so that cutting tool 34 may be conveniently and safely operated. Cord 73 of cutting tool 34 may be connected to outlet 70 . An electrical cord 74 connects outlet 70 to a power source (not shown).
It is desirable that tracing tip 44 of stylus 36 and cutting tip 68 of cutting tool 34 be aligned with each other so that as movements are made with stylus 36 over article 40 to be copied, the same movements are made at the same time and in the same relative position by cutting tip 68 . If cutting tool 34 is exchanged for a larger tool 34 ′ (FIGS. 13 & 14 ), then handle 62 can be adjusted to allow for stylus 36 to move farther away from sleeve 32 . This allows the user to adjust the device so that cutting tip 68 and tracing tip 44 remain aligned.
Similarly, the angle of cutting tool 34 and stylus 36 relative to the sleeve 32 may be adjusted (FIG. 18 & 19 ). This is achieved by changing grooves 60 on the bushings 56 , 56 ′ with which the brackets 58 , 58 ′ engage, as previously described. It may also be desirable to sometimes cut a mirror image of an article 40 . In that event brackets 58 , 58 ′ proximate stylus 36 and cutting tool 34 are engaged in grooves which face in opposing directions.
The device of the present invention is used in the following manner:
Referring to FIGS. 1 & 2, article 40 to be duplicated is secured to table 12 by any suitable means. Similarly block of wood 38 or other desired workpiece is positioned alongside article 40 and is secured to table 12 by a suitable holding mechanism. Frame 20 is pulled downwardly towards table 12 by the user grasping second bar 24 , end 26 , 28 or handle 42 of stylus 36 . The user connects cutting tool 34 to outlet 70 , and switches cutting tool 34 on. The user then manipulates stylus 36 so that tracing tip 44 traces out the shape of article 40 being duplicated. As the user does this cutting tool 34 moves in concert with stylus 36 and cutting tip 68 cuts the identical shape into block of wood 38 . Adjustments are made to the angle of stylus 36 and cutting tool 34 as necessary. When block of wood 38 has been shaped into the desired article, cutting tool 34 is switched off and disconnected from outlet 70 . Frame 20 is released and rises back to its at rest position (shown in FIG. 8 ). The duplicated article is removed from table 12 and a new block of wood 38 may then be secured to the table for the manufacture of another duplicate.
Accordingly, the improved duplicator device for a radial arm saw is simplified, provides an effective, safe, inexpensive, and efficient device which provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art.
In the foregoing description, certain terms have been used for brevity, clearness, and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described.
Having now described the features, discoveries, and principles of the invention, the manner in which the duplicator device is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts, and combinations are set forth in the appended claims. | The invention provides a woodworking duplicator which is adapted to be attached to a standard radial arm saw. The device allows a rotating cutting tool and a stylus to be movably supported allowing the user to trace a pattern with the stylus while cutting the pattern into a work piece with the cutter. The invention provides a duplicator that may be mounted to a radial arm saw wherein the duplicator includes elements that may be moved in five different directions. The invention also provides a duplicator having a stylus and a cutter that may be easily locked into different parallel positions so that the user of the duplicator may more easily trace the item being duplicated. The invention also provides a duplicator that supports the weight of the stylus and cutter tool. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention generally relates to a method for use in subterranean wellbores. More particularly, the invention relates to a method used to measure inflow profiles in subterranean injector wellbores.
2. Description of Related Art
It is important for an operator of a subterranean injector wellbore, such as for an oil or gas well, to determine the inflow profile of the injector wellbore in order to analyze whether all or just certain parts of a specific zone are injecting fluids therethrough. This determination and analysis is useful in vertical, deviated, and horizontal wellbores. In horizontal wellbores, the amount of fluid flowing through a specific zone tends to decrease from the heel to the toe of the well. Often, the toe and sections close to the toe have very little and sometimes no fluid flowing therethrough. An operator with knowledge of the inflow profile of a well can then attempt to take remediation measures to ensure that a more even inflow profile is created from the heel to the toe of the well.
Thus, there exists a continuing need for an arrangement and/or technique that addresses one or more of the problems that are stated above.
BRIEF SUMMARY OF THE INVENTION
The invention comprises a method of determining the inflow profile of an injection wellbore, comprising stopping injection of fluid into a formation, the formation intersected by a wellbore having a section uphole of the formation and a section within the formation, monitoring temperature at least partially along the uphole section of the wellbore and at least partially along the formation section of the wellbore, injecting fluid into the formation once the temperature in the uphole section of the wellbore increases, and monitoring the movement of the increased temperature fluid as it moves from the uphole section of the wellbore along the formation section of the wellbore. The monitoring may be performed using a distributed temperature sensing system.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is more fully described with reference to the appended drawings wherein:
FIG. 1 is a schematic illustration of a wellbore utilizing the present invention;
FIG. 2 is a plot of a geothermal temperature profile along a horizontal wellbore;
FIG. 3 is a plot showing temperature profiles taken along a wellbore at different points in time, including during injection and while the well is shut-in;
FIG. 4 is a plot illustrating the movement of a temperature peak along the wellbore and relevant formation; and
FIG. 5 is a plot of the velocity of the temperature peak of FIG. 4 as it moves along the wellbore and relevant formation.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a general schematic of an injector wellbore utilizing the present invention. A tubing 10 is disposed within a wellbore 12 that may be cased or uncased. Wellbore 12 may be a horizontal or inclined well that has a heel 14 and a toe 16 , or a vertical well. The horizontal section of the well may have a liner, may be open-bole, or may have a continuation of tubing 10 therein. Wellbore 12 intersects a permeable formation 18 such as a hydrocarbon formation. A packer 11 may be disposed around the tubing 10 to sealingly separate the wellbore sections above and below the packer 11 .
Wellbore 12 is an injector wellbore and the tubing 10 thus has injection equipment 20 (such as a pump) connected thereto near the earth's surface 22 . Injection equipment 20 may be connected to a tank 23 containing the fluid which is to be injected into formation 18 . Typically, the fluid is injected by the injection equipment 20 through the tubing 10 and into formation 18 . Tubing 10 may have ports adjacent formation 18 so as to allow flow of the fluid into formation 18 . In other embodiments, a liner with slots disposed in the horizontal section of the well may provide the fluid communication, or the horizontal section may be open hole. Perforations may also be made along formation 18 to facilitate fluid flow into the formation 18 .
A distributed temperature sensing (DTS) system 24 is also disposed in the wellbore 12 . The DTS system 24 includes an optical fiber 26 and an optical launch and acquisition unit 28 .
In the embodiment shown, the optical fiber 26 is disposed along the tubing 10 and is attached thereto on the outside of the tubing 10 . In other embodiments, the optical fiber 26 may be disposed within the tubing 10 or outside of the casing of the wellbore 12 (if the wellbore is cased). The optical fiber 26 extends through the packer 11 and across formation 18 . The optical fiber 26 may be deployed within a conduit, such as a metal control line. The control line is then attached to the tubing 10 or behind the casing (if the wellbore is cased). The optical fiber 26 may be pumped into the control line by use of fluid drag before or after the control line and tubing 10 are deployed downhole. This pumping technique is described in U.S. Reissue Pat. No. 37,283, which is incorporated herein by reference.
The acquisition unit 28 launches optical pulses through the optical fiber 26 and then receives the return signals and interprets such signals to provide a distributed temperature measurement profile along the length of the optical fiber 26 . In one embodiment, the DTS system 24 is an optical time domain reflectometry (OTDR) system wherein the acquisition unit 28 includes a light source and a computer or logic device. OTDR systems are known in the prior art, such as those described in U.S. Pat. Nos. 4,823,166 and 5,592,282, both of which are incorporated herein by reference. In OTDR, a pulse of optical energy is launched into an optical fiber and the backscattered optical energy returning from the fiber is observed as a function of time, which is proportional to distance along the fiber from which the backscattered light is received. This backscattered light includes the Rayleigh, Brillouin, and Raman spectrums. The Raman spectrum is the most temperature sensitive, with the intensity of the spectrum varying with temperature, although Brillouin scattering, and in certain cases Rayleigh scattering, are also temperature sensitive.
Generally, in one embodiment, pulses of light at a fixed wavelength are transmitted from the light source in acquisition unit 28 down the optical fiber 26 . At every measurement point in the optical fiber 26 , light is back-scattered and returns to the acquisition unit 28 . Knowing the speed of light and the moment of arrival of the return signal enables its point of origin along the optical fiber 26 to be determined. Temperature stimulates the energy levels of molecules of the silica and of other index-modifying additives, such as germania, present in the optical fiber 26 . The back-scattered light contains upshifted and downshifted wavebands (such as the Stokes Raman and Anti-Stokes Raman portions of the back-scattered spectrum), which can be analyzed to determine the temperature at origin. In this way, the temperature of each of the responding measurement points in the optical fiber 26 can be calculated by the acquisition unit 28 , providing a complete temperature profile along the length of the optical fiber 26 . In one embodiment, the optical fiber 26 is disposed in a u-shape along the wellbore 12 providing greater resolution to the temperature measurement.
FIG. 2 shows a graph of the geothermal temperature profile 29 of a generic horizontal wellbore. This profile shows at 30 a gradual increase in temperature as the depth of the well increases, until at 32 a stable temperature is reached along the horizontal section of the wellbore. The geothermal temperature profile is the temperature profile existing in the wellbore without external factors (such as injection). After injection or other external factors end, the wellbore will gradually change in temperature towards the geothermal temperature profile.
In one embodiment of this invention, in order to determine the inflow profile of a wellbore 12 , the wellbore 12 must first be shut-in so that no injection takes place. The temperature profile of the wellbore 12 changes if there is injection and throughout the shut-in period. FIG. 3 shows these changes.
Curve 34 is the temperature profile of the wellbore 12 during injection, wherein the temperature is relatively stable since the injected fluid is flowing through the tubing 10 and into the formation 18 .
Curve 36 represents a temperature profile of the wellbore 12 taken after injection is stopped and the well is shut-in. Curve 36 is already gradually moving towards the geothermal profile 29 . However, section 40 of curve 36 is changing at a much slower rate than the uphole part of the curve 36 because section 40 represents the area of the formation 18 which absorbed the most fluid during the injection step. Therefore, since this area is in contact with a substantial amount of fluid already injected in the formation 18 , this area takes a longer time to heat or return to its geothermal norm. Of interest, peak 42 is present on curve 36 because peak 42 is the area of wellbore 12 found directly before formation 18 (and not taking fluids). Therefore, a substantial temperature difference exists between peak 42 and section 40 .
Curve 38 represents a temperature profile of the wellbore 12 taken subsequent to the temperature profile represented by curve 36 . Curve 38 shows that the temperature profile is still heating towards the geothermal norm, but that the difference between peak 44 (peak 42 at a later time) and the section 40 are still apparent.
The object of this invention is to determine the velocity of the fluid being injected across the length of the formation 18 in order to then determine the inflow profile of such formation 18 . The technique used to achieve this is to re-initiate injection after a relatively short shut-in period and track the movement of the temperature peak ( 42 , 44 ) by use of the DTS system 24 .
FIG. 4 shows four curves representing temperature profiles taken over time. Curve 50 is a profile taken during shut-in, curve 52 is a profile taken after injection is re-started, curve 54 is a profile taken after curve 52 , and curve 56 is a profile taken after curve 54 . For purposes of clarity, the entire temperature profile of the wellbore has not been shown. Curve 50 includes a temperature peak 58 A that represents the temperature peak present during shut-in and found directly uphole of formation 18 . Temperature peak 58 A corresponds to temperature peaks 42 and 44 of FIG. 3 . Once injection is restarted, the slug of heated fluid represented by temperature peak 58 A is essentially “pushed” down the wellbore 12 , as is shown by the temperature peaks 58 B-D in time lapse curves 52 , 54 , and 56 . The temperature peak 58 A-D, as expected, decreases over time once injection is restarted.
By tracking the movement of the temperature peak 58 A-D down the wellbore 12 (through use of the DTS system 24 ), an operator can determine the velocity of the temperature peak 58 A-D as it moves down the wellbore 12 and the formation 18 over time. As shown in FIG. 5 , the velocity of the temperature peak 58 A-D is then plotted against depth across the length of the formation 18 . This plot shows a constant velocity at 60 immediately prior to the temperature peak reaching the formation 18 , a gradual decrease of velocity at 62 as the temperature peak moves away from the uphole boundary of the formation 18 , and a very low and perhaps zero velocity as the peak nears the downhole boundary of the formation 18 . From this plot, one can determine that the downhole portion of the formation 18 (that closer to the toe 16 ) is not receiving much fluid during injection in comparison to the uphole portion of the formation 18 . With this information, one can provide injection inflow profiles across the formation 18 , which profiles can be shown in percentage form (percentage of fluid being injected along the length of the formation 18 ) or quantitative form (with knowledge or a measurement of the actual surface injection rate). Thus, by monitoring the velocity of a heated slug (temperature peaks 58 A-D) across a formation 18 , the injection inflow profile of a wellbore 12 across a formation 18 may be determined.
Of importance, the shut-in period required to use the present technique is short in relation to the shut-in periods in some comparable prior art techniques. In some prior art techniques, the area of the formation 18 (see section 40 in FIG. 3 ) and not the area directly uphole of the formation 18 (see peaks 42 and 44 in FIG. 3 ) is monitored during the warmback period (and not, the injection period) to determine the inflow profile. However, in wellbores that have been injecting for a long period of time, the area of the formation 18 (see section 40 ) must be monitored for a substantial period of time before the warmback curves begin to move towards the geothermal gradient and the relevant information can be extracted therefrom. With the present technique, the warmback period can be as short as 24 to 48 hours, since the temperature peaks 42 and 44 (used as previously stated) begin to shift towards the geothermal profile much more quickly. Thus, a process that would take weeks or months to complete using the prior art techniques can now be completed in several days using the present technique.
While the invention has been disclosed with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the scope of the invention. | A method of determining the inflow profile of an injection wellbore, comprising stopping injection of fluid into a formation, the formation intersected by a wellbore having a section uphole of the formation and a section within the formation, monitoring temperature at least partially along the uphole section of the wellbore and at least partially along the formation section of the wellbore, injecting fluid into the formation once the temperature in the uphole section of the wellbore increases, and monitoring the movement of the increased temperature fluid as it moves from the uphole section of the wellbore along the formation section of the wellbore. The monitoring may be performed using a distributed temperature sensing system. | 4 |
[0001] Portions of the present invention were made with support of the United States Government via a grant from the National Institutes of Health under grant numbers HD33531 and NS34568. The U.S. Government therefore may have certain rights in the invention.
BACKGROUND OF THE INVENTION
[0002] Gene transfer is now widely recognized as a powerful tool for analysis of biological events and disease processes at both the cellular and molecular level. More recently, the application of gene therapy for the treatment of human diseases, either inherited (e.g., ADA deficiency) or acquired (e.g., cancer or infectious disease), has received considerable attention. With the advent of improved gene transfer techniques and the identification of an ever expanding library of “defective gen”-related diseases, gene therapy has rapidly evolved from a treatment theory to a practical reality.
[0003] Traditionally, gene therapy has been defined as a procedure in which an exogenous gene is introduced into the cells of a patient in order to correct an inborn genetic error. Although more than 4500 human diseases are currently classified as genetic, specific mutations in the human genome have been identified for relatively few of these diseases. Until recently, these rare genetic diseases represented the exclusive targets of gene therapy efforts. Accordingly, most of the NIH approved gene therapy protocols to date have been directed toward the introduction of a functional copy of a defective gene into the somatic cells of an individual having a known inborn genetic error. Only recently, have researchers and clinicians begun to appreciate that most human cancers, certain forms of cardiovascular disease, and many degenerative diseases also have important genetic components, and for the purposes of designing novel gene therapies, should be considered “genetic disorders.” Therefore, gene therapy has more recently been broadly defined as the correction of a disease phenotype through the introduction of new genetic information into the affected organism.
[0004] Two basic approaches to gene therapy have evolved: (1) ex vivo gene therapy and (2) in vivo gene therapy. In ex vivo gene therapy, cells are removed from a subject and cultured in vitro. A functional replacement gene is introduced into the cells (transfection) in vitro, the modified cells are expanded in culture, and then reimplanted in the subject. These genetically modified, reimplanted cells are reported to secrete detectable levels of the transfected gene product in situ. The development of improved retroviral gene transfer methods (transduction) has greatly facilitated the transfer into and subsequent expression of genetic material by somatic cells. Accordingly, retrovirus-mediated gene transfer has been used in clinical trials to mark autologous cells and as a way of treating genetic disease.
[0005] In in vivo gene therapy, target cells are not removed from the subject. Rather, the transferred gene is introduced into cells of the recipient organism in situ that is, within the recipient. In vivo gene therapy has been examined in several animal models. Several recent publications have reported the feasibility of direct gene transfer in situ into organs and tissues such as muscle, hematopoietic stem cells, the arterial wall, the nervous system, and lung. Direct injection of DNA into skeletal muscle, heart muscle and injection of DNA-lipid complexes into the vasculature also has been reported to yield a detectable expression level of the inserted gene product(s) in vivo.
[0006] Treatment of inherited genetic diseases of the brain remains an intractable problem. An example of such are the lysosomal storage diseases. Collectively, the incidence of lysosomal storage diseases (LSD) is 1 in 12,000 births world wide, and in 58% of cases, there is significant central nervous system (CNS) involvement (Meikle et al., JAMA 281:249-254, 1999). Proteins deficient in these disorders, when delivered intraveneously, do not cross the blood-brain barrier, or, when delivered directly to the brain, are not widely distributed. Injection of viral vectors expressing recombinant lysosomal proteins, a proportion of which is secreted, can result in significant spread of enzyme in murine cerebrum. However, methods to improve the distribution of enzyme following intraventricular injection of recombinant protein, or from transduced cells, are required for approaching therapies in the significantly larger brains of humans. Similar to lysosomal storage diseases, approaching global therapy for degenerative diseases due to polyglutamine repeat expansion or mutations in channels remains a significant problem. Thus, methods to improve the distribution of secreted proteins following transduction of tissues in vivo is required.
SUMMARY OF THE INVENTION
[0007] The present invention provides polynucleotides (DNA or RNA), vectors and polynucleotides encoding a lysosomal enzyme, a secreted protein, a nuclear protein, or a cytoplasmic protein operably linked to a nucleic acid sequence encoding a protein transduction domain (PTD). As used herein, the term “secreted protein” includes any secreted protein, whether naturally secreted or modified to contain a signal sequence so that it can be secreted. Proteins not normally secreted may be modified to contain a secretory signal so that the Tat-protein fusion is secreted out of the cell, where they may then be broadly distributed and contact cellular or intracellular receptors, such as hormone receptors. For example, the secreted protein could be β-glucuruonidase, pepstatin insensitive protease, palmitoyl protein thioesterase. When expressed from the vector the target protein of interest is synthesized in cells, secreted, distributed, and taken up by other cells without a cognate receptor. Soluble lysosomal enzymes are secreted upon overexpression, and can be distributed in vivo when modified to contain the Tat-motif or a similar PTD motif. The PTD can be Tat PTD, and in particular, can be Tat 47-57 . The Tat-PTD fusion protein could also be a cytoplasmic protein (such as a cytotoxic agent), a nuclear protein (such as a transcription factor), a growth factor (such as GDNF, BDNF, NGF, or NT3). For example, a nuclear protein could be engineered to be secreted, be taken up by a neighboring cell, and then target the nucleus of the uptaking cell. Alternatively, Tat-PTD could be fused to proteins with anti-neoplastic activity, such as inhibitors of neovascularization, cell migration, or cell proliferation. The fusion proteins may be produced using conventional recombinant DNA technology.
[0008] Nucleic acid is “operably linked” when it is placed into a functional relationship with another nucleic acid sequence. For example, DNA for a presequence or secretory leader is operably linked to DNA for a polypeptide if it is expressed as a preprotein that participates in the secretion of the polypeptide; a promoter or enhancer is operably linked to a coding sequence if it affects the transcription of the sequence; or a ribosome binding site is operably linked to a coding sequence if it is positioned so as to facilitate translation. Generally, “operably linked” means that the DNA sequences being linked are contiguous, and, in the case of a secretory leader, contiguous and in reading phase. However, enhancers do not have to be contiguous. Linking is accomplished by ligation at convenient restriction sites. If such sites do not exist, the synthetic oligonucleotide adaptors or linkers are used in accordance with conventional practice. Additionally, multiple copies of the nucleic acid encoding enzymes may be linked together in the expression vector. Such multiple nucleic acids may be separated by linkers. The vector may be an adenoviral vector, an adeno-associated virus (AAV) vector, a retrovirus, or a lentivirus vector based on human immunodeficiency virus or feline immunodeficiency virus. Examples of such AAVs are found in Davidson et al., PNAS (2000) 97:3428-3432. The AAV and lentiviruses could confer lasting expression while the adenovirus would provide transient expression.
[0009] The present invention also provides a mammalian cell containing the expression vector described above. The cell may be human, and may be from spleen, kidney, lung, heart, liver or brain. The cell type may be a stem or progenitor cell population.
[0010] The present invention provides a method of treating a genetic disease or cancer in a mammal by administering a polynucleotide, polypeptide, expression vector, or cell described above. The genetic disease or cancer may be a lysosomal storage disease (LSD) such as infantile or late infantile ceroid lipofuscinoses, Gaucher, Juvenile Batten, Fabry, MLD, Sanfilippo A, Late Infantile Batten, Hunter, Krabbe, Morquio, Pompe, Niemann-Pick C, Tay-Sachs, Hurler (MPS-I H), Sanfilippo B, Maroteaux-Lamy, Niemann-Pick A, Cystinosis, Hurler-Scheie (MPS-I H/S), Sly Syndrome (MPS VII), Scheie (MPS-I S), Infantile Batten, GM1 Gangliosidosis, Mucolipidosis type II/III, or Sandhoff disease. Alternatively, the genetic disease may be a neurodegenerative disease, such as Huntington's disease, ALS, hereditary spastic hemiplegia, primary lateral sclerosis, spinal muscular atrophy, Kennedy's disease, Alzheimer's disease, a polyglutamine repeat disease, or focal exposure such as Parkinson's disease.
[0011] In general, the invention relates to polynucleotides, polypeptides, vectors, and genetically engineered cells (modified ex vivo or in vivo), and the use of them. In particular, the invention relates to a method for gene or protein therapy that is capable of both localized and systemic delivery of a therapeutically effective dose of the therapeutic agent.
[0012] According to one aspect of the invention, a cell expression system for expressing a therapeutic agent in a mammalian recipient is provided. The expression system (also referred to herein as a “genetically modified cell”) comprises a cell and an expression vector for expressing the therapeutic agent. Expression vectors of the instant invention include, but are not limited to, viruses, plasmids, and other vehicles for delivering heterologous genetic material to cells. Accordingly, the term “expression vector” as used herein refers to a vehicle for delivering heterologous genetic material to a cell. In particular, the expression vector is a recombinant adenoviral, adeno-associated virus, or lentivirus or retrovirus vector.
[0013] The expression vector further includes a promoter for controlling transcription of the heterologous gene. The promoter may be an inducible promoter (described below). The expression system is suitable for administration to the mammalian recipient. The expression system may comprises a plurality of non-immortalized genetically modified cells, each cell containing at least one recombinant gene encoding at least one therapeutic agent.
[0014] The cell expression system can be formed ex vivo or in vivo. To form the expression system ex vivo, one or more isolated cells are transduced with a virus or transfected with a nucleic acid or plasmid in vitro. The transduced or transfected cells are thereafter expanded in culture and thereafter administered to the mammalian recipient for delivery of the therapeutic agent in situ. The genetically modified cell may be an autologous cell, i.e., the cell is isolated from the mammalian recipient. The genetically modified cell(s) are administered to the recipient by, for example, implanting the cell(s) or a graft (or capsule) including a plurality of the cells into a cell-compatible site of the recipient.
[0015] According to yet another aspect of the invention, a method for treating a mammalian recipient in vivo is provided. The method includes introducing an expression vector for expressing a heterologous gene product into a cell of the patient in situ. To form the expression system in vivo, an expression vector for expressing the therapeutic agent is introduced in vivo into target location of the mammalian recipient by, for example, intraperitoneal injection or injection directly into the brain.
[0016] According to yet another aspect of the invention, a method for treating a mammalian recipient in vivo is provided. The method includes introducing the recombinant PTD-fusion protein into the tissues of the patient in vivo. The therapeutic agent is introduced in vivo into target location of the mammalian recipient by, for example, a pump to provide continuous delivery into brain ventricles.
[0017] The expression vector for expressing the heterologous gene may include an inducible promoter for controlling transcription of the heterologous gene product. Accordingly, delivery of the therapeutic agent in situ is controlled by exposing the cell in situ to conditions, which induce transcription of the heterologous gene.
[0018] The mammalian recipient may have a condition that is amenable to gene replacement therapy. As used herein, “gene replacement therapy” refers to administration to the recipient of exogenous genetic material encoding a therapeutic agent and subsequent expression of the administered genetic material in situ. Thus, the phrase “condition amenable to gene replacement therapy” embraces conditions such as genetic diseases (i.e., a disease condition that is attributable to one or more gene defects), acquired pathologies (i.e., a pathological condition which is not attributable to an inborn defect), cancers and prophylactic processes (i.e., prevention of a disease or of an undesired medical condition). Accordingly, as used herein, the term “therapeutic agent” refers to any agent or material, which has a beneficial effect on the mammalian recipient. Thus, “therapeutic agent” embraces both therapeutic and prophylactic molecules having nucleic acid or protein components.
[0019] According to one embodiment, the mammalian recipient has a genetic disease and the exogenous genetic material comprises a heterologous gene encoding a therapeutic agent for treating the disease. In yet another embodiment, the mammalian recipient has an acquired pathology and the exogenous genetic material comprises a heterologous gene encoding a therapeutic agent for treating the pathology. According to another embodiment, the patient has a cancer and the exogenous genetic material comprises a heterologous gene encoding an anti-neoplastic agent. In yet another embodiment the patient has an undesired medical condition and the exogenous genetic material comprises a heterologous gene encoding a therapeutic agent for treating the condition.
[0020] According to yet another embodiment, a pharmaceutical composition is disclosed. The pharmaceutical composition comprises a plurality of the above-described genetically modified cells or polypeptides and a pharmaceutically acceptable carrier. The pharmaceutical composition may be for treating a condition amenable to gene replacement therapy and the exogenous genetic material comprises a heterologous gene encoding a therapeutic agent for treating the condition. The pharmaceutical composition may contain an amount of genetically modified cells or polypeptides sufficient to deliver a therapeutically effective dose of the therapeutic agent to the patient. Exemplary conditions amenable to gene replacement therapy are described below.
[0021] According to another aspect of the invention, a method for forming the above-described pharmaceutical composition is provided. The method includes introducing an expression vector for expressing a heterologous gene product into a cell to form a genetically modified cell and placing the genetically modified cell in a pharmaceutically acceptable carrier.
[0022] According to still another aspect of the invention, a cell graft is disclosed. The graft comprises a plurality of genetically modified cells attached to a support, which is suitable for implantation into the mammalian recipient. The support may be formed of a natural or synthetic material.
[0023] According to still another aspect of the invention, an encapsulated cell expression system is disclosed. The encapsulated expression system comprises a plurality of genetically modified cells contained within a capsule, which is suitable for implantation into the mammalian recipient. The capsule may be formed of a natural or synthetic material. The capsule containing the plurality of genetically modified cells may be implanted in the peritoneal cavity, the brain or ventricles in the brain, or into the specific disease site.
[0024] According to still another aspect of the invention, a protein delivery method is disclosed. The protein is purified from genetically modified cells and then placed into the mammalian recipient. The purified protein is placed into the brain, into the peritoneum, or into the specific disease site.
[0025] These and other aspects of the invention as well as various advantages and utilities will be more apparent with reference to the detailed description of the invention and to the accompanying Figures.
[0026] As used herein, the term “lysosomal enzyme,” a “secreted protein,” a “nuclear protein,” a “cytoplasmic protein,” or a “Tat protein transduction domain” include variants or biologically active or inactive fragments of these polypeptides. A “variant” of one of the polypeptides is a polypeptide that is not completely identical to a native protein. Such variant protein can be obtained by altering the amino acid sequence by insertion, deletion or substitution of one or more amino acid. The amino acid sequence of the protein is modified, for example by substitution, to create a polypeptide having substantially the same or improved qualities as compared to the native polypeptide. The substitution may be a conserved substitution. A “conserved substitution” is a substitution of an amino acid with another amino acid having a similar side chain. A conserved substitution would be a substitution with an amino acid that makes the smallest change possible in the charge of the amino acid or size of the side chain of the amino acid (alternatively, in the size, charge or kind of chemical group within the side chain) such that the overall peptide retains its spacial conformation but has altered biological activity. For example, common conserved changes might be Asp to Glu, Asn or Gln; His to Lys, Arg or Phe; Asn to Gln, Asp or Glu and Ser to Cys, Thr or Gly. Alanine is commonly used to substitute for other amino acids. The 20 essential amino acids can be grouped as follows: alanine, valine, leucine, isoleucine, proline, phenylalanine, tryptophan and methionine having nonpolar side chains; glycine, serine, threonine, cystine, tyrosine, asparagine and glutamine having uncharged polar side chains; aspartate and glutamate having acidic side chains; and lysine, arginine, and histidine having basic side chains. Stryer, L. Biochemistry (2d edition) W. H. Freeman and Co. San Francisco (1981), p. 14-15; Lehninger, A. Biochemistry (2d ed., 1975), p. 73-75.
[0027] The amino acid changes are achieved by changing the codons of the corresponding nucleic acid sequence. It is known that such polypeptides can be obtained based on substituting certain amino acids for other amino acids in the polypeptide structure in order to modify or improve biological activity. For example, through substitution of alternative amino acids, small conformational changes may be conferred upon a polypeptide which result in increased. Alternatively, amino acid substitutions in certain polypeptides may be used to provide residues, which may then be linked to other molecules to provide peptide-molecule conjugates which, retain sufficient properties of the starting polypeptide to be useful for other purposes.
[0028] One can use the hydropathic index of amino acids in conferring interactive biological function on a polypeptide, wherein it is found that certain amino acids may be substituted for other amino acids having similar hydropathic indices and still retain a similar biological activity. Alternatively, substitution of like amino acids may be made on the basis of hydrophilicity, particularly where the biological function desired in the polypeptide to be generated in intended for use in immunological embodiments. The greatest local average hydrophilicity of a “protein”, as governed by the hydrophilicity of its adjacent amino acids, correlates with its immunogenicity. U.S. Pat. No. 4,554,101. Accordingly, it is noted that substitutions can be made based on the hydrophilicity assigned to each amino acid.
[0029] In using either the hydrophilicity index or hydropathic index, which assigns values to each amino acid, it is preferred to conduct substitutions of amino acids where these values are ±2, with ±1 being particularly preferred, and those with in ±10.5 being the most preferred substitutions.
[0030] The variant protein has at least 50%, at least about 80%, or even at least about 90% but less than 100%, contiguous amino acid sequence homology or identity to the amino acid sequence of a corresponding native protein.
[0031] The amino acid sequence of the variant polypeptide corresponds essentially to the native polypeptide's amino acid sequence. As used herein “correspond essentially to” refers to a polypeptide sequence that will elicit a biological response substantially the same as the response generated by the native protein. Such a response may be at least 60% of the level generated by the native protein, and may even be at least 80% of the level generated by native protein.
[0032] A variant of the invention may include amino acid residues not present in the corresponding native protein or deletions relative to the corresponding native protein. A variant may also be a truncated “fragment” as compared to the corresponding native protein, i.e., only a portion of a full-length protein. Protein variants also include peptides having at least one D-amino acid.
[0033] The variant protein of the present invention may be expressed from an isolated DNA sequence encoding the variant protein. “Recombinant” is defined as a peptide or nucleic acid produced by the processes of genetic engineering. It should be noted that it is well-known in the art that, due to the redundancy in the genetic code, individual nucleotides can be readily exchanged in a codon, and still result in an identical amino acid sequence. The terms “protein,” “peptide” and “polypeptide” are used interchangeably herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] [0034]FIG. 1. β-glucuronidase-Tat expression vectors. (a) Cartoon depicting the orientation of the Tat motifs at the carboxy termini of β-glucuronidase. The β-glucuronidase sequences were cloned into the E1 region of Ad shuttle plasmids, and the shuttles recombined with Ad backbones expressing GFP in the E3 region. The resultant viruses expressed β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 in E1 and GFP in E3. Both trangenes are driven off the RSV promoter. (b-d), β-glucuronidase activity after incubation of A549 cells with the recombinant proteins β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 , respectively. Using the assay conditions described in the Examples below the background levels of β-glucuronidase staining is very low (inset, panel b). The uptake of both native and tat-modified β-glucuronidase (inset, panel d) was notably punctate. (e-g), β-glucuronidase activity after incubation of A549 cells with the recombinant proteins β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 in the presence of D-mannose-6-phosphate. Bars=50 μm.
[0035] [0035]FIG. 2. eGFP and β-glucuronidase activity in sections of murine liver after i.v. injection of vectors expressing native or Tat-modified β-glucuronidase. (a-c), photomicrographs showing representative levels of GFP expression in murine liver following injection of Adβgluc, AdβglucTat 47-57 or AdβglucTat 57-47 , respectively. (d-f), sections from mice transduced with Adβgluc, AdβglucTat 47-57 or AdβglucTat 57-47 , respectively, stained in situ for β-glucuronidase activity. Bar=200 μm.
[0036] [0036]FIG. 3. β-glucuronidase activity in non-hepatic tissues after i.v. injection of mice with vectors expressing native or Tat-modified β-glucuronidase. β-glucuronidase activity was detected in situ ten days after i.v. injection of Adβgluc (a,c,e,g,i) or Adβgluc-Tat 47-57 (b,d,f,h,j). Representative sections from spleen (a,b), kidney (c,d) lung (e,f), heart (g,h) and brain (i,j) are shown. Scale bar is 400 μm. (k), enzyme activity levels in tissue lysates.
[0037] [0037]FIG. 4. GFP and β-glucuruonidase distribution and activity in brain. Mice were injected with Adβgluc (a,c), Adβgluc-Tat 47-57 (b,d) or Adβgluc-Tat 57-47 into straita, and GFP and β-glucuronidase activity evaluated ten days later on full corona sections (a-e) or tissue lysates (f). Equivalent i.u. (and particles) were injected. Sections photomicrographed in c and d are within 60 μm from those shown in a and b, respectively. (e), the volume of brain positive for GFP and β-glucuronidase quantified using NIH Image. (f), enzyme activities for the contralateral (CL) and injected hemispheres (IL) were determined as described in Methods, and expressed as CL/(CL+IL)×100.
[0038] [0038]FIG. 5. Expression of β-glucuronidase or β-glucuronidase-Tat 47-57 from transduced ependyma. Mice were injected with Adβgluc (a,d), Adβgluc-Tat 47-57 (b,e) or Adβgluc-Tat 57-47 (c,f) and brains harvested ten days later for evaluation of GFP (a-c) or β-glucuronidase (d-f) expression. Sections photomicrographed in a-c are within 60 μm from those shown in d-f. The volume of brain (both hemispheres) positive for β-glucuronidase activity was determined using NIH image.
[0039] [0039]FIG. 6. Expression of β-glucuronidase and β-glucurondiase-Tat in the brainstem. Mice were injected with Adβgluc or Adβgluc-Tat 47-57 and animals sacrificed ten days later for evaluation of GFP or β-glucuronidase expression.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Collectively, the prevalence of lysosomal storage diseases is strikingly high. As an example, a 16 year retrospective study in Australia revealed a prevalence between 1 in 6,700 to 1 in 7700 live births (Meikle, et al., (1999) JAMA 281(3):249-254). In 58% of cases, there is significant CNS involvement. Early work in rodent models of the lysosomal storage diseases has shown tremendous promise in addressing the systemic manifestations of these disorders, either by enzyme replacement or bone marrow transplant to adult recipients. However these therapies did not ameliorate or substantially delay progressive neurodegeneration. In the β-glucuronidase deficient mouse, inhibition of cognitive decline required that treatment be initiated in the neonatal period systemically prior to blood-brain barrier (BBB) closure (O'Connor, et al., (1998) J. Clin. Invest. 101:1394-1400), or directly to brain (Frisella, et al., (2001) Mol. Ther. (In Press)).
[0041] Recent work showed that the 11 amino acid motif from HIV Tat known as the protein transduction domain (PTD) improved the biodistribution of recombinant reporter proteins following systemic delivery (Fawell, et al., (1994). Proc. Natl. Acad. Sci. U.S.A. 91:664-668), (Schwarze, et al., (1999) Science 285:1569-1572). When partially denatured, the protein was capable of crossing the blood brain barrier of adult mice (Schwarze, et al., (1999) Science 285:1569-1572). These findings suggest that gene therapy with vectors engineered to express Tat-modified recombinant lysosomal proteins from systemic sources in vivo could be used to improve their biodistribution.
[0042] To test this, fusion proteins of human β-glucuronidase and the 11 amino acid PTD from HIV Tat were engineered in recombinant adenovirus expression vectors (FIG. 1 a ). As peptides representative of the PTDs from Drosophila antenapedea can translocate across cell membranes in either orientation (Derossi, et al., (1996) J. Biol. Chem. 271(30):18188-18193) fusion proteins with the HIV Tat peptide in the 47-57 and 57-47 orientation were generated. We first examined the properties of the modified β-glucuronidase for mannose-6 phosphate (M6P) dependent and independent entry into cells. HeLa cells were infected with 20 infectious units (i.u.)/cell of recombinant vectors expressing unmodified β-glucuronidase (Adβgluc), β-glucuronidase-Tat 47-57 (Adβgluc-Tat 47-57 ) or β-glucuronidase-Tat 57-47 (Adβgluc-Tat 57-47 ). Three days later, supernatants were collected and β-glucuronidase activity quantified. The Tat modification to the COOH-terminus did not inhibit enzyme activity. Equivalent units of β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 were added to the media of A549 cells in the presence or absence of M6P (FIGS. 1 b - g ). While all recombinant proteins entered cells readily (FIGS. 1 b - d ), M6P dramatically inhibited the uptake of native β-glucuronidase (FIG. 1 e ) relative to β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 (FIGS. 1 f,g ) as assayed by an in situ activity stain (Ghodsi, et al., (1998) Hum. Gene Ther. 9:2331-2340). Quantitation of enzyme activity showed that M6P inhibited 100% of uptake of native β-glucuronidase. β-Glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 , were inhibited by 24 and 51%, respectively (FIG. 1 h ). Thus β-glucuronidase modified at the COOH terminus with the PTD of Tat allowed for both M6P dependent and independent entry. Similar results were found when the wild type and Tat-modified β-glucuronidase-containing supernatants were added to cultures of NIH 3T3 cells with or without M6P.
[0043] Earlier studies showed that uptake of Tat-modified proteins occurred by adsorptive endocytosis in cell lines and primary cell cultures (Fawell, et al., (1994) Proc. Natl. Acad. Sci. U.S.A. 91:664-668), (Mann, et al., (1991) EMBO J. 10(7): 1733-1739). Mann and Frankel also showed that entry of [ 125 I] Tat was temperature dependent (Mann, et al., (1991) EMBOJ 10(7):1733-1739). This is distinct from peptides representative of the PTD from antenopedia, which enters cells readily at 4 and 37° C. (Derossi, et al., (1996) J. Biol. Chem. 271(30):18188-18193). Equivalent units of β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 were added to cells and uptake at 4 and 37° C. measured and compared. In all cases, enzyme uptake at 4° C. was dramatically inhibited compared to that occurring at 37° C. These data, and the observation that histochemical staining for enzyme activity at time points early after enzyme addition was punctate (FIG. 1 d , inset), suggests that Tat-modified β-glucuronidase, like native β-glucuronidase, enters cells in part through endocytic mechanisms.
[0044] We next investigated Adβgluc, Adβgluc-Tat 47-57 and Adβgluc-Tat 57-47 in vivo. Viruses were injected into mice tail veins, which results in transduction of hepatocytes (Stein, et al., (1999) J. Virol. 73(4):3424-3429). The vectors used in this study also expressed GFP in the E3 region to permit detection of infected cells (GFP positive) relative to β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 activity. Sections of liver analyzed 10 days after i.v. vector injection show roughly equivalent levels of GFP expression for all viruses (FIGS. 2 a - c ), but varied distribution of β-glucuronidase activity (FIGS. 2 d - f ). β-Glucuronidase-Tat 47-57 and β-glucuronidase-Tats 57-47 activity were detected throughout the parenchyma of the liver as evidenced by in situ enzyme activity assay (FIGS. 2 e,f ). In contrast, transduction with Adβgluc resulted in focal staining (FIG. 2 d ).
[0045] Similar to native β-glucuronidase (Stein, et al., (1999) J. Virol. 73(4):3424-3429), we also noted spread of β-glucuronidase-Tat 47-57 and β-glucuronidase-Tat 57-47 to other tissues (FIG. 3). In some instances the penetration of the enzyme within specific organs or tissues was remarkably distinct from native β-glucuronidase. For example, in the spleen (FIGS. 3 a,b ), extensive β-glucuronidase activity was found in the marginal zone and to a limited extent in the red pulp after transduction with Adgluc. However, β-glucuronidase-Tat 47-57 fully penetrated the red pulp (FIG. 3 b ). β-glucuronidase-Tat 57-47 was comparable. Interestingly, β-glucuronidase-Tat 47-57 distribution was similar to sections from mice receiving i.p. injections of partially denatured, purified E. coli β-galactosidase-Tat fusion proteins (Schwarze, et al., (1999) Science 285:1569-1572).
[0046] We also noted increased levels of enzyme in kidney (FIGS. 3 c,d ), lung (FIGS. 3 e,f ) heart (FIGS. 3 g,h ), and skeletal muscle for β-glucuronidase-Tat 47-57 and β-glucuronidase-Tat 57-47 . Although the distribution of β-glucuronidase activity was widespread in kidney and lung in AdβglucTat 47-57 vs. Adβgluc treated mice, β-glucuronidase activity remained undetectable in both lung lavage fluid and urine.
[0047] In contrast to earlier studies with recombinant protein (Schwarze, et al., (1999) Science 285:1569-1572), we noted only a modest increase in enzyme staining in brain, all limited to the choroid plexus (FIGS. 3 i,j ). Quantitative enzyme assay of brain lysates indicated that there were no significant differences between the treatment groups (FIG. 3 k ). Together the data suggest that the 11 amino acid PTD from Tat may alter the biodistribution of native proteins expressed and secreted in vivo from transduced cells. However the addition of the Tat motif to β-glucuronidase, expressed from systemically transduced tissues of adult mice, does not significantly improve enzyme levels within brain. Possibilities for the discrepancies include differences in the type of protein delivered. Dowdy and colleagues achieved penetration of the blood brain barrier with denatured/partially renatured β-galactosidase. Fawell and colleagues used native β-galactosidase-Tat conjugates in their studies, and did not see penetration of the brain. Both studies delivered approximately 4×10 −9 mole of β-galactosidase by intraperitoneal injection, for an estimated serum concentration of 1 μM. In our studies, the Tat-modified β-glucuronidase reached an approximate serum concentration of 16 nM, and likely remained in native conformation.
[0048] It is not known if the partially-denatured, Tat-modified reporters described by Dowdy and colleagues can pass an intact blood brain barrier in larger animal models. It would also be important to know if the Tat-motifs could impart improved distribution of proteins when administered directly to, or expressed from, cells within the brain. To determine this, vectors expressing β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 (2×10 7 i.u.) were injected into the right hemisphere, and animals sacrificed 10 days later. All vectors yielded nearly equivalent levels of GFP expression (FIGS. 4 a,b ). However, the addition of the Tat motif to β-glucuronidase resulted in significantly greater distribution of enzyme compared to the non-modified protein (FIGS. 4. c vs. d ). As a consequence, there was a 1.5-fold increase in the volume of brain positive for β-glucuronidase activity (FIG. 4 e ), and a notable increase in the levels of β-glucuronidase activity in the contralateral hemisphere (FIG. 4 f ).
[0049] Ventricular administration of secreted proteins for the MPS or other lysosomal storage diseases would be preferred over multiple parenchymal injections if adequate spread of enzyme into the parenchyma can occur. Injection of the recombinant vectors into the lateral ventricles of mice led to significant transduction of ependyma as evidenced by GFP fluorescence (FIGS. 5 a,c ) (Ghodsi, et al., (1999) Exp.Neurol. 160:109-116). As shown previously, β-glucuronidase expression from Adβgluc was obvious in areas immediately adjacent to the ependyma (FIG. 5 d ). However, the penetration of β-glucuronidase-Tat was remarkably enhanced, resulting in significant increases in the volume of brain positive for active enzyme (FIG. 5 g ). In animals receiving intraventricular injection of Adβgluc, 5% of the brain was β-glucuronidase positive. In contrast, expression of β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 was distributed in 22 and 30% of the brain, respectively. Increased distribution of expressed enzyme after intraventricular injection has important implications for enzyme-based therapy or for gene therapy using vectors with high affinity to the ependymal lining, such as recombinant adenoviruses (Ghodsi, et al, (1999) Exp. Neurol. 160:109-116) and adeno-associated virus type 4 (Davidson, et al, (2000) Proc. Natl. Acad. Sci. U.S.A. 97(7):3428-3432).
[0050] Prior to this work, PTDs had been applied as synthetic peptides or used to improve transfer of nuclear and cytoplasmic proteins. We show that the PTD from HIV Tat allowed for significant improvements in the distribution of a lysosomal protein expressed and secreted from cells after viral-mediated gene transfer to liver and brain. When ependyma lining the ventricles were transduced, there was a 5 to 7 fold increase in the volume of brain positive for β-glucuronidase activity. Thus PTDs could also dramatically improve the biodistribution of recombinant enzyme following intraventricular injection. Together, our data represent a significant improvement in the development of gene and protein therapies for inherited genetic diseases affecting the brain.
[0051] The present invention provides methods of treating a genetic disease or cancer in a mammal by administering a polynucleotide, polypeptide, expression vector, or cell. For the gene therapy methods, a person having ordinary skill in the art of molecular biology and gene therapy would be able to determine, without undue experimentation, the appropriate dosages and routes of administration of the polynucleotide, polypeptide, or expression vector used in the novel methods of the present invention.
[0052] The instant invention provides a cell expression system for expressing exogenous genetic material in a mammalian recipient. The expression system, also referred to as a “genetically modified cell”, comprises a cell and an expression vector for expressing the exogenous genetic material. The genetically modified cells are suitable for administration to a mammalian recipient, where they replace the endogenous cells of the recipient. Thus, the genetically modified cells may be non-immortalized and are non-tumorigenic.
[0053] According to one embodiment, the cells are transformed or otherwise genetically modified ex vivo. The cells are isolated from a mammal (for example, a human), transformed (i.e., transduced or transfected in vitro) with a vector for expressing a heterologous (e.g., recombinant) gene encoding the therapeutic agent, and then administered to a mammalian recipient for delivery of the therapeutic agent in situ. The mammalian recipient may be a human and the cells to be modified are autologous cells, i.e., the cells are isolated from the mammalian recipient.
[0054] According to another embodiment, the cells are transformed or otherwise genetically modified in vivo. The cells from the mammalian recipient are transformed (i.e., transduced or transfected) in vivo with a vector containing exogenous genetic material for expressing a heterologous (e.g., recombinant) gene encoding a therapeutic agent and the therapeutic agent is delivered in situ.
[0055] As used herein, “exogenous genetic material” refers to a nucleic acid or an oligonucleotide, either natural or synthetic, that is not naturally found in the cells; or if it is naturally found in the cells, it is not transcribed or expressed at biologically significant levels by the cells. Thus, “exogenous genetic material” includes, for example, a non-naturally occurring nucleic acid that can be transcribed into anti-sense RNA, as well as a “heterologous gene” (i.e., a gene encoding a protein which is not expressed or is expressed at biologically insignificant levels in a naturally-occurring cell of the same type).
[0056] In the certain embodiments, the mammalian recipient has a condition that is amenable to gene replacement therapy. As used herein, “gene replacement therapy” refers to administration to the recipient of exogenous genetic material encoding a therapeutic agent and subsequent expression of the administered genetic material in situ. Thus, the phrase “condition amenable to gene replacement therapy” embraces conditions such as genetic diseases (i.e., a disease condition that is attributable to one or more gene defects), acquired pathologies (i.e., a pathological condition which is not attributable to an inborn defect), cancers and prophylactic processes (i.e., prevention of a disease or of an undesired medical condition). Accordingly, as used herein, the term “therapeutic agent” refers to any agent or material, which has a beneficial effect on the mammalian recipient. Thus, “therapeutic agent” embraces both therapeutic and prophylactic molecules having nucleic acid (e.g., antisense RNA) and/or protein components.
[0057] A number of lysosomal storage diseases are known (for example Neimann-Pick disease, Sly syndrome, Gaucher Disease). Other examples of lysosomal storage diseases are provided in Table 1. Therapeutic agents effective against these diseases are also known, since it is the protein/enzyme known to be deficient in these disorders.
TABLE 1 List of putative target diseases for PTD-based therapies. Disease a Post-natal b % Gaucher 71 13.0 Juvenile Batten 39 7.2 Fabry 36 6.6 % LSDs with CNS involvement MLD 35 6.4 58.317757 Sanfihippo A 33 6.1 Late Infantile Batten 27 5.0 Hunter 26 4.8 Krabbe 21 3.9 Morquio 21 3.9 Pompe 21 3.9 Niemann-Pick C 20 3.7 Tay-Sachs 19 3.5 Hurler (MPS-I H) 18 3.3 Sanfihippo B 18 3.3 Maroteaux-Lamy 17 3.1 Niemann-Pick A 16 2.9 Cystinosis 15 2.8 Hurler-Scheie (MPS-I H/S) 10 1.8 Sly Syndrome (MPS VII) 0 0 Scheie (MPS-I S) 10 1.8 Infantile Batten 10 1.8 GM1 Gangliosidosis 10 1.8 Mucolipidosis type lI/III 10 1.8 Sandhoff 10 1.8 other 32 5.9
[0058] As used herein, “acquired pathology” refers to a disease or syndrome manifested by an abnormal physiological, biochemical, cellular, structural, or molecular biological state. Exemplary acquired pathologies, are provided in Table 2. Therapeutic agents effective against these diseases are also given.
TABLE II Potential Gene Therapies for Motor Neuron Diseases and other neurodegenerative diseases. Candidates for Neuronal or Candidates for Gene Downstream Progenitor Cell Disease Replacement 2 Effectors 3 Replacement 4 ALS No Yes Yes Hereditary Spastin, paraplegin Yes Yes spastic hemiplegia Primary lateral No Yes Yes sclerosis 5 Spinal Survival motor neuron Yes Yes muscular gene, neuronal atrophy apoptosis inhibiting factor Kennedy's Androgen-receptor Yes Yes disease element Alzheimer's Yes Yes disease Polyglutamine Yes Yes Repeat Diseases
[0059] Delivery of a therapeutic agent by a genetically modified cell is not limited to delivery to a particular location in the body in which the genetically modified cells would normally reside. Accordingly, the genetically modified cells of the invention are useful for delivering a therapeutic agent, such as a replacement protein, an anti-neoplastic agent, or a neuroprotective agent, to various parts or the appropriate part of the body.
[0060] Alternatively, the condition amenable to gene replacement therapy is a prophylactic process, i.e., a process for preventing disease or an undesired medical condition. Thus, the instant invention embraces a cell expression system for delivering a therapeutic agent that has a prophylactic function (i.e., a prophylactic agent) to the mammalian recipient.
[0061] In summary, the term “therapeutic agent” includes, but is not limited to, the agents listed in the Tables above, as well as their functional equivalents. As used herein, the term “functional equivalent” refers to a molecule (e.g., a peptide or protein) that has the same or an improved beneficial effect on the mammalian recipient as the therapeutic agent of which is it deemed a functional equivalent. As will be appreciated by one of ordinary skill in the art, a functionally equivalent proteins can be produced by recombinant techniques, e.g., by expressing a “functionally equivalent DNA”. As used herein, the term “functionally equivalent DNA” refers to a non-naturally occurring DNA, which encodes a therapeutic agent. For example, many, if not all, of the agents disclosed in Tables 1-3 have known amino acid sequences, which are encoded by naturally occurring nucleic acids. However, due to the degeneracy of the genetic code, more than one nucleic acid can encode the same therapeutic agent. Accordingly, the instant invention embraces therapeutic agents encoded by naturally-occurring DNAs, as well as by non-naturally-occurring DNAs, which encode the same protein as, encoded by the naturally-occurring DNA.
[0062] The above-disclosed therapeutic agents and conditions amenable to gene replacement therapy are merely illustrative and are not intended to limit the scope of the instant invention. The selection of a suitable therapeutic agent for treating a known condition is deemed to be within the scope of one of ordinary skill of the art without undue experimentation.
[0063] Methods for Introducing Genetic Material into Cells
[0064] The exogenous genetic material (e.g., a CDNA encoding one or more therapeutic proteins) is introduced into the cell ex vivo or in vivo by genetic transfer methods, such as transfection or transduction, to provide a genetically modified cell. Various expression vectors (i.e., vehicles for facilitating delivery of exogenous genetic material into a target cell) are known to one of ordinary skill in the art.
[0065] As used herein, “transfection of cells” refers to the acquisition by a cell of new genetic material by incorporation of added DNA. Thus, transfection refers to the insertion of nucleic acid into a cell using physical or chemical methods. Several transfection techniques are known to those of ordinary skill in the art including: calcium phosphate DNA co-precipitation (Methods in Molecular Biology, Vol. 7, Gene Transfer and Expression Protocols, Ed. E. J. Murray, Humana Press (1991)); DEAE-dextran (supra); electroporation (supra); cationic liposome-mediated transfection (supra); and tungsten particle-faciliated microparticle bombardment (Johnston, S. A., Nature 346:776-777 (1990)). Strontium phosphate DNA co-precipitation (Brash D. E. et al. Molec. Cell. Biol. 7:2031-2034 (1987) is another possible transfection method.
[0066] In contrast, “transduction of cells” refers to the process of transferring nucleic acid into a cell using a DNA or RNA virus. A RNA virus (i.e., a retrovirus) for transferring a nucleic acid into a cell is referred to herein as a transducing chimeric retrovirus. Exogenous genetic material contained within the retrovirus is incorporated into the genome of the transduced cell. A cell that has been transduced with a chimeric DNA virus (e.g., an adenovirus carrying a cDNA encoding a therapeutic agent), will not have the exogenous genetic material incorporated into its genome but will be capable of expressing the exogenous genetic material that is retained extrachromosomally within the cell.
[0067] Typically, the exogenous genetic material includes the heterologous gene (usually in the form of a cDNA comprising the exons coding for the therapeutic protein) together with a promoter to control transcription of the new gene. The promoter characteristically has a specific nucleotide sequence necessary to initiate transcription. Optionally, the exogenous genetic material further includes additional sequences (i.e., enhancers) required to obtain the desired gene transcription activity. For the purpose of this discussion an “enhancer” is simply any non-translated DNA sequence which works contiguous with the coding sequence (in cis) to change the basal transcription level dictated by the promoter. The exogenous genetic material may introduced into the cell genome immediately downstream from the promoter so that the promoter and coding sequence are operatively linked so as to permit transcription of the coding sequence. A retroviral expression vector may include an exogenous promoter element to control transcription of the inserted exogenous gene. Such exogenous promoters include both constitutive and inducible promoters.
[0068] Naturally-occurring constitutive promoters control the expression of essential cell functions. As a result, a gene under the control of a constitutive promoter is expressed under all conditions of cell growth. Exemplary constitutive promoters include the promoters for the following genes which encode certain constitutive or “housekeeping” functions: hypoxanthine phosphoribosyl transferase (HPRT), dihydrofolate reductase (DHFR) (Scharfmann et al., Proc. Natl. Acad. Sci. USA 88:4626-4630 (1991)), adenosine deaminase, phosphoglycerol kinase (PGK), pyruvate kinase, phosphoglycerol mutase, the -actin promoter (Lai et al., Proc. Natl. Acad. Sci. USA 86:10006-10010 (1989)), and other constitutive promoters known to those of skill in the art. In addition, many viral promoters function constitutively in eucaryotic cells. These include: the early and late promoters of SV40; the long terminal repeats (LTRs) of Moloney Leukemia Virus and other retroviruses; and the thymidine kinase promoter of Herpes Simplex Virus, among many others. Accordingly, any of the above-referenced constitutive promoters can be used to control transcription of a heterologous gene insert.
[0069] Genes that are under the control of inducible promoters are expressed only or to a greater degree, in the presence of an inducing agent, (e.g., transcription under control of the metallothionein promoter is greatly increased in presence of certain metal ions). Inducible promoters include responsive elements (REs) which stimulate transcription when their inducing factors are bound. For example, there are REs for serum factors, steroid hormones, retinoic acid and cyclic AMP. Promoters containing a particular RE can be chosen in order to obtain an inducible response and in some cases, the RE itself may be attached to a different promoter, thereby conferring inducibility to the recombinant gene. Thus, by selecting the appropriate promoter (constitutive versus inducible; strong versus weak), it is possible to control both the existence and level of expression of a therapeutic agent in the genetically modified cell. If the gene encoding the therapeutic agent is under the control of an inducible promoter, delivery of the therapeutic agent in situ is triggered by exposing the genetically modified cell in situ to conditions for permitting transcription of the therapeutic agent, e.g., by intraperitoneal injection of specific inducers of the inducible promoters which control transcription of the agent. For example, in situ expression by genetically modified cells of a therapeutic agent encoded by a gene under the control of the metallothionein promoter, is enhanced by contacting the genetically modified cells with a solution containing the appropriate (i.e., inducing) metal ions in situ.
[0070] Accordingly, the amount of therapeutic agent that is delivered in situ is regulated by controlling such factors as: (1) the nature of the promoter used to direct transcription of the inserted gene, (i.e., whether the promoter is constitutive or inducible, strong or weak); (2) the number of copies of the exogenous gene that are inserted into the cell; (3) the number of transduced/transfected cells that are administered (e.g., implanted) to the patient; (4) the size of the implant (e.g., graft or encapsulated expression system); (5) the number of implants; (6) the length of time the transduced/transfected cells or implants are left in place; and (7) the production rate of the therapeutic agent by the genetically modified cell. Selection and optimization of these factors for delivery of a therapeutically effective dose of a particular therapeutic agent is deemed to be within the scope of one of ordinary skill in the art without undue experimentation, taking into account the above-disclosed factors and the clinical profile of the patient.
[0071] In addition to at least one promoter and at least one heterologous nucleic acid encoding the therapeutic agent, the expression vector may include a selection gene, for example, a neomycin resistance gene, for facilitating selection of cells that have been transfected or transduced with the expression vector. Alternatively, the cells are transfected with two or more expression vectors, at least one vector containing the gene(s) encoding the therapeutic agent(s), the other vector containing a selection gene. The selection of a suitable promoter, enhancer, selection gene and/or signal sequence (described below) is deemed to be within the scope of one of ordinary skill in the art without undue experimentation.
[0072] The therapeutic agent can be targeted for delivery to an extracellular, intracellular or membrane location. If it is desirable for the gene product to be secreted from the cells, the expression vector is designed to include an appropriate secretion “signal” sequence for secreting the therapeutic gene product from the cell to the extracellular milieu. If it is desirable for the gene product to be retained within the cell, this secretion signal sequence is omitted. In a similar manner, the expression vector can be constructed to include “retention” signal sequences for anchoring the therapeutic agent within the cell plasma membrane. For example, all membrane proteins have hydrophobic transmembrane regions, which stop translocation of the protein in the membrane and do not allow the protein to be secreted. The construction of an expression vector including signal sequences for targeting a gene product to a particular location is deemed to be within the scope of one of ordinary skill in the art without the need for undue experimentation.
[0073] The following discussion is directed to various utilities of the instant invention. For example, the instant invention has utility as an expression system suitable for detoxifying intra- and/or extracellular toxins in situ. By attaching or omitting the appropriate signal sequence to a gene encoding a therapeutic agent capable of detoxifying a toxin, the therapeutic agent can be targeted for delivery to the extracellular milieu, to the cell plasma membrane or to an intracellular location. In one embodiment, the exogenous genetic material containing a gene encoding an intracellular detoxifying therapeutic agent, further includes sequences encoding surface receptors for facilitating transport of extracellular toxins into the cell where they can be detoxified intracellularly by the therapeutic agent. Alternatively, the cells can be genetically modified to express the detoxifying therapeutic agent anchored within the cell plasma membrane such that the active portion extends into the extracellular milieu. The active portion of the membrane-bound therapeutic agent detoxifies toxins, which are present in the extracellular milieu.
[0074] In addition to the above-described therapeutic agents, some of which are targeted for intracellular retention, the instant invention also embraces agents intended for delivery to the extracellular milieu and/or agents intended to be anchored in the cell plasma membrane.
[0075] The selection and optimization of a particular expression vector for expressing a specific gene product in an isolated cell is accomplished by obtaining the gene, potentially with one or more appropriate control regions (e.g., promoter, insertion sequence); preparing a vector construct comprising the vector into which is inserted the gene; transfecting or transducing cultured cells in vitro with the vector construct; and determining whether the gene product is present in the cultured cells.
[0076] In one embodiment, vectors for cell gene therapy are viruses, such as replication-deficient viruses (described in detail below). Exemplary viral vectors are derived from: Harvey Sarcoma virus; ROUS Sarcoma virus, (MPSV); Moloney murine leukemia virus and DNA viruses (e.g., adenovirus) (Ternin, H., “Retrovirus vectors for gene transfer”, in Gene Transfer, Kucherlapati R, Ed., pp 149-187, Plenum, (1986)).
[0077] Replication-deficient retroviruses, including the recombinant lentivirus vectors, are neither capable of directing synthesis of virion proteins or making infectious particles. Accordingly, these genetically altered retroviral expression vectors have general utility for high-efficiency transduction of genes in cultured cells, and specific utility for use in the method of the present invention. The lentiviruses, with their ability to transduce nondividing cells, have general utility for transduction of hepatocytes, cells in cerebrum, cerebellum and spinal cord, and also muscle and other slowly or non-dividing cells. Such retroviruses further have utility for the efficient transduction of genes into cells in vivo. Retroviruses have been used extensively for transferring genetic material into cells. Standard protocols for producing replication-deficient retroviruses (including the steps of incorporation of exogenous genetic material into a plasmid, transfection of a packaging cell line with plasmid, production of recombinant retroviruses by the packaging cell line, collection of viral particles from tissue culture media, and infection of the target cells with the viral particles) are provided in Kriegler, M. Gene Transfer and Expression, A Laboratory Manual, W.H. Freeman Co, New York, (1990) and Murray, E. J., ed. Methods in Molecular Biology, Vol. 7, Humana Press Inc., Clifton, N.J., (1991).
[0078] The major advantage of using retroviruses, including lentiviruses, for gene therapy is that the viruses insert the gene encoding the therapeutic agent into the host cell genome, thereby permitting the exogenous genetic material to be passed on to the progeny of the cell when it divides. In addition, gene promoter sequences in the LTR region have been reported to enhance expression of an inserted coding sequence in a variety of cell types (see e.g., Hilberg et al., Proc. Natl. Acad. Sci. USA 84:5232-5236 (1987); Holland et al., Proc. Natl. Acad. Sci. USA 84:8662-8666 (1987); Valerio et al., Gene 84:419-427 (1989). The major disadvantages of using a retrovirus expression vector are (1) insertional mutagenesis, i.e., the insertion of the therapeutic gene into an undesirable position in the target cell genome which, for example, leads to unregulated cell growth and (2) the need for target cell proliferation in order for the therapeutic gene carried by the vector to be integrated into the target genome (Miller, D. G., et al., Mol. Cell. Biol. 10:4239-4242 (1990)). While proliferation of the target cell is readily achieved in vitro, proliferation of many potential target cells in vivo is very low.
[0079] Yet another viral candidate useful as an expression vector for transformation of cells is the adenovirus, a double-stranded DNA virus. The adenovirus is frequently responsible for respiratory tract infections in humans and thus appears to have an avidity for the epithelium of the respiratory tract (Straus, S., The Adenovirus, H. S. Ginsberg, Editor, Plenum Press, New York, P. 451-496 (1984)). Moreover, the adenovirus is infective in a wide range of cell types, including, for example, muscle and endothelial cells (Larrick, J. W. and Burck, K. L., Gene Therapy. Application of Molecular Biology, Elsevier Science Publishing Co., Inc., New York, p. 71-104 (1991)). The adenovirus also has been used as an expression vector in muscle cells in vivo (Quantin, B., et al., Proc. Natl. Acad. Sci. USA 89:2581-2584 (1992)).
[0080] Like the retrovirus, the adenovirus genome is adaptable for use as an expression vector for gene therapy, i.e., by removing the genetic information that controls production of the virus itself (Rosenfeld, M. A., et al., Science 252:431434 (1991)). Because the adenovirus functions in an extrachromosomal fashion, the recombinant adenovirus does not have the theoretical problem of insertional mutagenesis.
[0081] Finally, a third virus family adaptable for an expression vector for gene therapy are the recombinant adeno-associated viruses, specifically those based on AAV2, AAV4 and AAV5 (Davidson et al, PNAS, 2000).
[0082] Thus, as will be apparent to one of ordinary skill in the art, a variety of suitable viral expression vectors are available for transferring exogenous genetic material into cells. The selection of an appropriate expression vector to express a therapeutic agent for a particular condition amenable to gene replacement therapy and the optimization of the conditions for insertion of the selected expression vector into the cell, are within the scope of one of ordinary skill in the art without the need for undue experimentation.
[0083] In an alternative embodiment, the expression vector is in the form of a plasmid, which is transferred into the target cells by one of a variety of methods: physical (e.g., microinjection (Capecchi, M. R., Cell 22:479-488 (1980)), electroporation (Andreason, G. L. and Evans, G. A. Biotechniques 6:650-660 (1988), scrape loading, microparticle bombardment (Johnston, S. A., Nature 346:776-777 (1990)) or by cellular uptake as a chemical complex (e.g., calcium or strontium co-precipitation, complexation with lipid, complexation with ligand) (Methods in Molecular Biology, Vol. 7, Gene Transfer and Expression Protocols, Ed. E. J. Murray, Humana Press (1991)). Several commercial products are available for cationic liposome complexation including Lipofectin™ (Gibco-BRL, Gaithersburg, Md.) (Felgner, P. L., et al., Proc. Natl. Acad. Sci. 84:7413-7417 (1987)) and Transfectam™ (ProMega, Madison, Wis.) (Behr, J. P., et al., Proc. Natl. Acad. Sci. USA 86:6982-6986 (1989); Loeffler, J. P., et al., J. Neurochem. 54:1812-1815 (1990)). However, the efficiency of transfection by these methods is highly dependent on the nature of the target cell and accordingly, the conditions for optimal transfection of nucleic acids into cells using the above-mentioned procedures must be optimized. Such optimization is within the scope of one of ordinary skill in the art without the need for undue experimentation.
[0084] The instant invention also provides various methods for making and using the above-described genetically-modified cells. In particular, the invention provides a method for genetically modifying cell(s) of a mammalian recipient ex vivo and administering the genetically modified cells to the mammalian recipient. In one embodiment for ex vivo gene therapy, the cells are autologous cells, i.e., cells isolated from the mammalian recipient. As used herein, the term “isolated” means a cell or a plurality of cells that have been removed from their naturally-occurring in vivo location. Methods for removing cells from a patient, as well as methods for maintaining the isolated cells in culture are known to those of ordinary skill in the art.
[0085] The instant invention also provides methods for genetically modifying cells of a mammalian recipient in vivo. According to one embodiment, the method comprises introducing an expression vector for expressing a heterologous gene product into cells of the mammalian recipient in situ by, for example, injecting the vector into the recipient.
[0086] In one embodiment, the preparation of genetically modified cells contains an amount of cells sufficient to deliver a therapeutically effective dose of the therapeutic agent to the recipient in situ. The determination of a therapeutically effective dose of a specific therapeutic agent for a known condition is within the scope of one of ordinary skill in the art without the need for undue experimentation. Thus, in determining the effective dose, one of ordinary skill would consider the condition of the patient, the severity of the condition, as well as the results of clinical studies of the specific therapeutic agent being administered.
[0087] If the genetically modified cells are not already present in a pharmaceutically acceptable carrier they are placed in such a carrier prior to administration to the recipient. Such pharmaceutically acceptable carriers include, for example, isotonic saline and other buffers as appropriate to the patient and therapy.
[0088] The genetically modified cells are administered by, for example, intraperitoneal injecting or implanting the cells or a graft or capsule containing the cells in a target cell-compatible site of the recipient. As used herein, “target cell-compatible site” refers to a structure, cavity or fluid of the recipient into which the genetically modified cell(s), cell graft, or encapsulated cell expression system can be implanted, without triggering adverse physiological consequences More than one recombinant gene can be introduced into each genetically modified cell on the same or different vectors, thereby allowing the expression of multiple therapeutic agents by a single cell.
[0089] The instant invention further embraces a cell graft. The graft comprises a plurality of the above-described genetically modified cells attached to a support that is suitable for implantation into a mammalian recipient. The support can be formed of a natural or synthetic material.
[0090] According to another aspect of the invention, an encapsulated cell expression system is provided. The encapsulated system includes a capsule suitable for implantation into a mammalian recipient and a plurality of the above-described genetically modified cells contained therein. The capsule can be formed of a synthetic or naturally-occurring material. The formulation of such capsules is known to one of ordinary skill in the art. In contrast to the cells which are directly implanted into the mammalian recipient (i.e., implanted in a manner such that the genetically modified cells are in direct physical contact with the cell-compatible site), the encapsulated cells remain isolated (i.e., not in direct physical contact with the site) following implantation. Thus, the encapsulated system is not limited to a capsule including genetically-modified non-immortalized cells, but may contain genetically modified immortalized cells.
[0091] The following provides examples of how the Tat-PTD alters the properties of a representative lysosomal protein, β-glucuronidase. Similar results would be expected for all soluble lysosomal proteins. Moreover, the data would also hold for other non-lysosomal proteins that or normally secreted, or to proteins modified to contain a signal sequence to allow for their secretion. The underlying theme is that the inclusion of a PTD onto those sequences will allow for altered and improved biodistribution for therapeutic purposes.
[0092] Therefore, the following examples are intended to illustrate but not limit the invention.
EXAMPLES
Example 1
Production of Recombinant Vectors
[0093] [0093] Primer 1 (5′-AAACTCGAGATGGCCCGGGGGTCGGCGGTTGCC-3′) (SEQ ID NO:1) and primer 2 (5′-TGCTCTAGATCATCTTCGTCGCTGTCTCCGCTTCTTCCTGCCATAACCGCC (SEQ ID NO:2) ACCG-CCAGTAAACGGGCTGTT T TCCAAACA-3′)
[0094] were used to create the β-glucuronidase-Tat 47-57 fusion protein. Primer 1 and primer 3
(5′TGCTCTAGATCAATAGCCCCTCTTC TTCCGTCT (SEQ ID NO:3) CTGTCGTCGTCTACCGCCACCGCCAGTAAACGGGCTGTTTTCCA AACA-3′)
[0095] were used to make the β-glucuronidase-Tat 57-47 fusion protein. PCR fragments were digested with XhoI and XbaI and the fragments cloned into similarly cut E1 shuttle plasmids (pPacRSVKpnA; described in (Anderson, et al., (2000) Gene Ther. 7(12):1034-1038)). The resultant plasmids were named pPacRSVβGluc-Tat PTD 47-57 or pPacRSV βGluc-Tat PTD 57-47 . Adenoviruses with β-glucuronidase, β-glucuronidase-Tat PTD 47-57 or β-glucuroniase-Tat PTD 57-47 in E1 and eGFP in E3 were produced by co-transfecting PacI linearized pPacRSVβGluc-Tat PTD 47-57 , pPacRSVβGluc-Tat PTD 57-47 or pPacRSVβgluc with PacI digested E3 modified Ad5 backbones containing a RSVGFP expression cassette in E3. For ease of discussion the recombinant viruses, Ad5βgluc-Tat 47-57 /E3GFP, Ad5βgluc-Tat 57-47 /E3GFP or Ad5βgluc/E3GFP are listed as Adβgluc-Tat 47-57 , Adβgluc-Tat 57-47 or Adβgluc. Viruses were purified by CsCl gradient ultracentrifugation. Infectious units were determined by plaque assay and particle titers by OD 260 .
Example 2
In vitro Studies
[0096] HeLa cells were infected with Adβgluc-Tat 47-57 , Adβgluc-Tat 57-47 or control Adβgluc at 20 infectious units (i.u.)/cell and supernatants harvested 72 h later. β-Glucuronidase activity was quantified using the previously described fluorometric assay. Briefly, aliquots were reacted in 10 mM 4-methylumbellifryl-β-D-glucuronidase (Sigma, St. Louis, Mo.) in 0.1 M sodium acetate (pH 4.8) for 1 h at 37° C. Reactions were stopped by addition of 2 ml of 320 mM glycine in 200 mM carbonate buffer, pH 10.0 (Glaser, et al, (1973) J. Lab. Clin. Med. 82:969-977). Fluorescence was measured at 415 nm after excitation at 360 nm (TD-700 Fluorometer; Turner Design, Sunnyvale, Calif.). β-Glucuronidase activity is expressed as nanomoles of 4-methylumbellferone released per hour (FLU) per mg protein. Purified β-glucuronidase (kindly provided by William Sly, Washington University, St. Louis Mo.) was used as standard. Protein concentrations were determined using the Bio-Rad DC protein assay (Bio-Rad Laboratories, Hercules, Calif.).
[0097] NIH 3T3 or A549 cells (500,000 cells plated the day before) were incubated with 5500 units of β-glucuronidase-Tat 47-57 , β-glucuronidase-Tat 57-47 or β-glucuronidase in the presence or absence of D-mannose-6-phosphate (10 mM) for 2 h at 37 or 4° C. After incubation cells were harvested and lysates prepared for fluorometric enzyme assay, or stained for β-glucuronidase activity in situ. For β-glucuronidase staining, cells were washed in PBS, fixed in 2% paraformaldehyde for 15 min, washed twice in PBS, twice with 0.05M sodium acetate, pH 4.5, for 5 min, and then incubated in 0.25 mM Napth-As-Bi-β-glucuronide (Sigma) in the same buffer for 40 min. Cells or tissues (below) were then stained for 30 min at 37° C. with 0.25 mM Napth-As-Bi-β-glucuronide in 0.05 M sodium acetate, pH 5.2, with 1/500 2% hexazotized pararosaniline (Sigma).
Example 3
In vivo Studies
[0098] β-Glucuronidase-deficient mice were obtained from the Jackson Laboratory (Bar Harbor, Me.) and from our own breeding colony. The genotype for the latter was confirmed by morphological and genetic analyses. The animals were between 8 and 10 weeks old and weighed 16-24 g. C57BL/6 wild-type mice were purchased from Harlan Sprague (Indianapolis, Ind.).
[0099] Adβgluc-Tat 47-57 , Adβgluc-Tat 57-47 or Adβgluc were injected into the tail vein (2×10 9 i.u.) of β-glucuronidase deficient mice. Adβgluc-Tat 47-57 , Adβgluc-Tat 57-47 or Adβgluc (2×10 7 i.u. total) were injected into the right striatum or right lateral ventricle of C57BL/6 mice or β-glucuronidase deficient mice as described earlier (Stein, et al., (1999) J. Virol. 73(4):3424-3429). Animals were sacrificed 10 days after intravenous (n=3/group), striatal (n=5/group) or ventricular injection (n=5/group). Tissues were sonicated, placed in lysis solution (Sands, et al., (1994) J. Clin. Invest. 93:2324-2331) and centrifuged at 12000× g for 20 min. Aliquots were assayed using the fluorometric assay described above. For in situ enzyme assays, tissues were harvested, sectioned, and stained in situ for β-glucurondase activity as described above.
[0100] Coronal brain sections were photographed with Adobe Photoshop (Adobe system, Mountain View, Calif.), and the photos imported into NIH Image. Color thresh-holding was used, and the percentage of brain positive for activity calculated by dividing the area of staining by the total area (adjusted for ventricular size). In all cases a minimum of 2 mm (rostral to caudal) of cerebrum surrounding the injection site was scanned.
[0101] All publications, patents and patent applications are incorporated herein by reference. While in the foregoing specification this invention has been described in relation to certain embodiments, 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 may be varied considerably without departing from the basic principles of the invention.
REFERENCES
[0102] 1. Meikle, P. J., Hopwood, J. J., Clague, A. E. and Carey, W. F. 1999. Prevalence of lysosomal storage disorders. JAMA 281(3):249-254.
[0103] 2. O'Connor, L. H., Erway, L. C., Vogler, C. A., Sly, W. S., Nicholes, A., Grubb, J., Holmberg, S. W., Levy, B. and Sands, M. S. 1998. Enzyme replacement therapy for murine mucopolysaccharidosis Type VII leads to improvements in behavior and auditory function. J. Clin. Invest. 101:1394-1400.
[0104] 3. Frisella, W. A., O'Connor, L. H., Vogler, C. A., Roberts, M., Walkley, S., Levy, B., Daly, T. M. and Sands, M. S. 2001. Intracranial injection of recombinant adeno-associated virus improves cognitive function in a murine model of mucopolysaccharidosis type VII. Mol. Ther . (In Press)
[0105] 4. Fawell, S., Seery, J., Daikh, Y., Moore, C., Chen, L. L., Pepinsky, B. and Barsoum, J. 1994. Tat-mediated delivery of heterologous proteins into cells. Proc. Natl. Acad. Sci. U.S.A. 91:664-668.
[0106] 5. Schwarze, S. R., Ho, A., Vocero-Akbani, A. and Dowdy, S. F. 1999. In vivo protein transduction: delivery of a biologically active protein into the mouse. Science 285:1569-1572.
[0107] 6. Derossi, D., Calvet, S., Trembleau, A., Brunissen, A., Chassaing, G. and Prochiantz, A. 1996. Cell internalization of the third helix of the antennapedia homeodomain is receptor-independent. J. Biol. Chem. 271(30):18188-18193.
[0108] 7. Ghodsi, A., Stein, C., Derksen, T., Yang, G., Anderson, R. D. and Davidson, B. L. 1998. Extensive β-glucuronidase activity in murine CNS after adenovirus mediated gene transfer to brain. Hum. Gene Ther. 9:2331-2340.
[0109] 8. Mann, D. A. and Frankel, A. D. 1991. Endocytosis and targeting of exogenous HIV-1 tat protein. EMBO J. 10(7):1733-1739.
[0110] 9. Stein, C. S., Ghodsi, A., Derksen, T. and Davidson, B. L. 1999. Systemic and central nervous system correction of lysosomal storage in mucopolysaccharidosis type VII mice. J. Virol. 73(4):3424-3429.
[0111] 10. Ghodsi, A., Stein, C., Derksen, T., Martins, I., Anderson, R. D. and Davidson, B. L. 1999. Systemic hyperosmolality improves β-glucuronidase distribution and pathology in murine MPS VII brain following intraventricular gene transfer. Exp.Neurol. 160:109-116.
[0112] 11. Davidson, B. L., Stein, C. S., Heth, J. A., Martins, I., Kotin, R. M., Derksen, T. A., Zabner, J., Ghodsi, A. and Chiorini, J. A. 2000. Recombinant AAV type 2, 4 and 5 vectors: transduction of varient cell types and regions in the mammalian CNS. Proc.Natl.Acad.Sci.U.S.A. 97(7):3428-3432.
[0113] 12. Anderson, R. D., Haskell, R. E., Xia, H., Roessler, B. J. and Davidson, B. L. 2000. A simple method for the rapid generation of recombinant adenovirus vectors. Gene Ther. 7(12):1034-1038.
[0114] 13. Glaser, J. H. and Sly, W. S. 1973. Beta-glucuronidase deficiency mucopolysaccharidosis: Methods for enzymatic diagnosis. J. Lab. Clin. Med. 82:969-977.
[0115] 14. Sands, M. S., Vogler, C., Kyle, J. W., Gribb, J. H., Levy, B., Galvin, N., Sly, W. S. and Birkenmeier, E. H. 1994. Enzyme replacement therapy for murine mucopolysaccharidosis type VII. J.Clin.Invest. 93:2324-2331.
1
3
1
33
DNA
Adenovirus
1
aaactcgaga tggcccgggg gtcggcggtt gcc 33
2
81
DNA
Adenovirus
2
tgctctagat catcttcgtc gctgtctccg cttcttcctg ccataaccgc caccgccagt 60
aaacgggctg ttttccaaac a 81
3
81
DNA
Adenovirus
3
tgctctagat caatagcccc tcttcttccg tctctgtcgt cgtctaccgc caccgccagt 60
aaacgggctg ttttccaaac a 81 | The present invention provides polynucleotides and expression vectors containing a sequence encoding a soluble lysosomal enzyme and a sequence encoding Tat protein transduction domain (PTD), and the corresponding polypeptides. The present demonstrates the utility of these protein fusions in altering the bioavailability of proteins for use in treating genetic diseases or acquired diseases. The invention further provides cell expression systems, and methods of treating a genetic disease or cancer in a mammal using the polynucleotides, polypeptides, or expression system of the present invention. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a liquid fuel storage device including a fuel tank and a canister for use with a vehicle.
2. Description of Related Art
In order to fill-up a fuel tank with fuel smoothly, it is necessary that fuel vapor in the fuel tank be instantly emitted to the outside of the fuel tank to enable the fuel vapor to be replaced with the fuel without resistance. Further, since the fuel is vigorously ejected from a fuel gun inserted into a fuel port of the fuel tank in refueling, a lot of fuel mist is produced. Since the emission of fuel vapor and mist (hereinafter, referred to as "fuel gas") to the atmosphere causes an environmental problem, the fuel gas is generally introduced to a canister and adsorbed and captured thereby as in U.S. Pat. No. 5,090,459.
When refueling is necessary, since a fuel tank is usually almost entirely filled with a fuel gas, a large canister must be designed, taking the capacity of the fuel tank into consideration.
However, a large canister is not preferable to satisfy a trade-off request to increase the capacity of a fuel tank as well as the space in a vehicle.
To cope with this problem, a liquid fuel storage device for a vehicle has been proposed having a mechanism for inflating and deflating an air bag disposed in a tank according to a surplus space produced by an amount of storage fuel. This type of storage device has been disclosed, for example, in Japanese Patent Unexamined Publication No. 64-16426 (1989) wherein the space in a fuel tank filled with fuel gas (i.e., the space obtained by subtracting the amount of remaining fuel from the total capacity of the tank) can be reduced in refueling.
The fuel storage device arranged as described above usually requires pressurizing means (a pressurizing pump or the like) for pressurizing the air bag (by which the space occupied by the fuel storage unit as a whole is increased). Further, since the air bag communicates directly with the atmosphere to emit air in refueling, a fuel gas in the air bag which passes through an air bag film is simultaneously emitted.
SUMMARY OF THE INVENTION
In view of the above problem, an object of the present invention is to provide a liquid fuel storage device including a mechanism for inflating and deflating an air bag disposed in a fuel tank according to an amount of stored fuel, the liquid fuel storage device being arranged such that it does not need pressurizing means and does not raise the possibility of a fuel gas passing though the air bag being emitted to the atmosphere simultaneously with the emission of air to the atmosphere.
To solve the above problem, in accordance with the present invention, a liquid fuel storage device is provided which comprising:
a fuel tank;
a canister for absorbing fuel vapor as the fuel tank is refilled with fuel;
an air bag disposed in the fuel tank and constructed and arranged to inflate to occupy a space in the fuel tank according an amount of remaining fuel;
piping structure communicating the fuel tank with the engine for inflating the bag by reducing the pressure in the fuel tank;
an air introduction pipe communicating with the atmosphere and provided with a first valve mechanism for introducing air into the air bag and preventing air from flowing out of the air bag after the air bag is inflated; and
an air emission pipe provided with a second valve mechanism which is opened only in refueling to emit the air in the air bag in refueling and which is connected to the canister.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system schematic diagram showing a liquid fuel storage device according to the present invention after an air bag is inflated; and
FIG. 2 is the system schematic diagram of FIG. 1 shown during refueling.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described below in detail with reference to an embodiment shown in FIGS. 1 and 2.
The liquid fuel storage device of the invention includes a fuel tank 12 and a canister 14.
Although the present invention is described with reference to a liquid fuel storage device provided with a mechanism for keeping an interior of a fuel tank at a predetermined, reduced pressure state for a predetermined time when an engine starts, so as to check for abnormal leakage of the fuel tank, the present invention is not limited thereto. Note, the fuel tank leakage check mechanism is one of the mechanisms developed for an on-board-diagnosis system established by the United States Government for controlling air pollution generated by vehicles. The system will be described below in detail.
A fuel tank 12 having a fuel filler pipe 16 stores liquid fuel 18 and feeds the fuel 18 to the engine of a vehicle (not shown). The fuel filler pipe 16 includes a filler neck 22 provided with a fuel cap 20. A seal member 26 provided with a trap door 24 and a protective cylindrical member 28 for protecting the seal member 26 are attached to the filler neck 22. Further, a bleeder pipe 30 serving as a bleeder port in refueling is disposed in the vicinity of the extreme end of the fuel filler pipe 16 above the upper wall of the fuel tank 12 and a fuel shut-off valve 34 to which a float 32 is assembled is disposed at position apart from the extreme end of the fuel filler pipe 16, respectively. A baffle 38 for preventing an abrupt back flow of the liquid fuel in the fuel tank 12 is attached to the downstream end of the fuel filler pipe 16. Note, numeral 39 denotes a fuel return pipe.
A canister 14 temporarily adsorbs and captures fuel gas produced in the fuel tank 12. An air inlet port 14a is formed at a bottom the canister 14 and is connected to an air cleaner 44 through an air inlet pipe 42, provided with a two-position switching valve (solenoid operation type) 40. The two-position switching valve 40 is opened and closed in response to a signal (electric signal) sent by an engine controller unit (hereinafter, abbreviated as "ECU").
A fuel gas emission port 14b and a fuel gas introduction port 14c are formed at an upper wall of the canister 14. The fuel gas emission port 14b is connected to an air inlet pipe 48 through a fuel gas emission pipe 46 provided with a flow rate/pressure reduction control valve (electromagnetic valve) 45. The air inlet pipe 48 defines a reduced pressure generation chamber communicating with the engine. The flow rate/pressure reduction control valve 45 has two roles: (a) it controls a flow rate of fuel gas separated from the canister 14; and (b) it controls pressure in the fuel tank in such a manner that the control valve 45 is opened and closed in response to a sensing signal from a pressure sensor 50 attached to an inside of the seal member 26 of the filler neck 22 by a signal sent from the ECU 62, in order to check for leakage of the fuel tank 12.
The fuel tank 12 and the fuel gas introduction port 14c of the canister 14 are connected to the fuel shut-off valve 34 of the fuel tank 12 through a fuel vapor pipe 66 provided with a positive/negative pressure control valve (spring-biased two-way valve) 64. A gas introduction valve (electromagnetic valve) 68 is connected to the fuel vapor pipe 66 in parallel with the positive/negative pressure control valve 64. The gas introduction pipe 68 is also opened and closed in response to a signal sent from the ECU 62 (opened when the engine is in operation).
The bleeder pipe 30 of the fuel tank 12 is connected to the fuel introduction port 14c of the canister 14 through a bleeder pipe 72 provided with a gas shut-off valve 70 which is normally closed and only opened during refueling. Since only one fuel gas introduction port 14c is provided with the canister 14 in the illustrated example, the port 14c joins the fuel vapor pipe 66 on the canister 14 side. However, two sets of fuel gas introduction ports may be provided and connected to completely different pipes.
The gas shut-off valve 70 may be of any construction, in the illustrated embodiment, the valve 70 is opened and closed in such a manner that a valve plug driving lever 76, which is biased in a valve plug closing direction by a circular cam 74 fixed to the rotary shaft 24a of the trap door 24, moves a seal valve plug 78 upwardly and downwardly. In the illustrated embodiment, numeral 77 denotes a coil spring for easing the bias and impact on the seal valve plug 76.
In the illustrated embodiment, the gas shut-off valve 70 is provided with a fuel check valve 82 accommodating a float 80 so that fuel does not flow out to the canister 14 when the vehicle turns sideways, or the like.
In the liquid fuel storage device arranged as described above, the embodiment is characterized in the following arrangement.
The storage device includes an air bag 36 disposed in the fuel tank 12, the pressure reduction pipe (fuel vapor pipe) 66 for reducing pressure in the fuel tank 12 to inflate the air bag 36, an air introduction pipe 84 communicating with the atmosphere to introduce air into the air bag 36, and an air emission pipe 86 for emitting the air in the air bag only during refueling.
The air bag 36 is preferably made of a resin film of polyvinyl fluoride, polyamide, polyethylene, polyvinyl chloride etc. A synthetic fiber cloth of polyamide, polyester etc. having a resistance to fuel, with the inside thereof coated with fuel resistant rubber may also be used.
In this embodiment, the pressure reduction pipe need not be provided, since the aforesaid fuel vapor pipe 66 can serve as the pressure reduction pipe.
The air introduction pipe 84 is connected to the air inlet pipe 42 between the air cleaner 44 and the two-position switching valve 40. The air inlet pipe 84 is provided with a valve mechanism for preventing the air bag 36 to be deflated after the air bag has been inflated. The valve mechanism is in the form of a spring-biased one way valve (check valve) 88.
The air emission pipe 86 is connected to the bleeder pipe 72 through an air emission valve 78b, wherein a seal valve plug 78, a bleeder valve plug 78a and an air emission valve plug 78b of the shut-off valve 70 connected to the bleeder pipe 72 are formed in parallel with each other on a single valve sheet 79.
As described above, although the gas shut-off valve 70 is mechanically opened and closed by the circular cam 74 associated with the rotary shaft 24a of the trap door 24, the gas shut-off valve 70 is not particularly limited to this arrangement and may be opened and closed by an electromagnetic mechanism or the like.
Next, operation of the embodiment will be described.
When the engine is started, the two-position switching valve 40 in the air inlet pipe 42 of the canister 14 is closed in response to a signal sent from the ECU 62, the flow rate/pressure reduction control valve 45 communicating with the fuel gas pipe 46 is opened, and the gas introduction pipe 68 disposed in the fuel vapor pipe 66 connecting the fuel gas introduction port 14c of the canister 14 to the fuel shut-off valve 34 of the fuel tank 12, is opened. As a result, the air inlet pipe 48 exposed to a reduced pressure is caused to communicate with the fuel tank 12 so that the pressure in the fuel tank 12 is reduced (lower than the atmospheric pressure) defining a reduced pressure state. When the ECU 62 receives a sensing signal from the pressure sensor 50 to check the presence of abnormal leakage of the fuel tank 62, the ECU 62 controls the reduced pressure state by inputting a command signal to the flow rate/pressure reduction control valve 45 as well as determines a change of the reduced pressure state for a predetermined time, and when leakage arises, the ECU 62 issues warning through a warning lamp or the like.
Since the reduced pressure state in the fuel tank 12 is maintained for a predetermined time as described above, the air bag 36 will inflate so that pressure in the air bag 36 is also reduced. Thus, the one-way valve 88 is automatically opened against a spring force so that the atmosphere flows into the air bag 36 through the air cleaner 44 to inflate the air bag 36 according to an amount of remaining fuel in the fuel tank.
Then, after the reduced pressure state is maintained for a predetermined time, that is, in response to a signal sent from the ECU 62 which indicates that the predetermined time has elapsed after starting the engine, the two-position switching valve 40 in the air inlet pipe 42 is opened. Thus, the air inlet pipe 42 communicates with the air inlet pipe 48 so that the pressure in the air introduction pipe 84 for the air bag 36 connected to the air inlet pipe 42 is also reduced. As a result, in the air introduction pipe 84, the one-way valve 88 is also automatically closed by a spring force due to the above reduced pressure state, and even if fuel gas is produced while the vehicle travels, parks or stops (except a time of refueling) and the pressure in the fuel tank 12 is made positive, air in the air bag 36 does not escape. Naturally, the gas shut-off valve 70 of the air emission pipe 86 communicating with the air bag 36 is closed (refer to FIG. 1).
When fuel is consumed as the vehicle travels and a space is created in the fuel tank 12 to permit the air bag 36 to inflate, the air bag is inflated by a pressure difference between the inside and the outside of the air bag 36 each time the engine is started and the space in the fuel tank 12 in which fuel can evaporate, is greatly reduced. When fuel violently evaporates and the pressure in the tank is increased excessively, a positive/negative pressure control valve 64 in the fuel vapor pipe 66 is operated and fuel vapor is emitted into the canister 14 through the fuel gas introduction port 14c and adsorbed and captured by the canister 14.
Next, when the fuel cap 20 is removed for refueling and a fuel gun 90 is inserted into the fuel filler 16, the protective cylindrical member 28 advances to push and open the trap door 24. At this time, since the circular cam 74 is rotated in association with the rotation of the rotary shaft 24a of the trap door 24, the valve plug driving lever 76 lifts the seal valve plug 78 upwardly through locking means by the long diameter portion of the circular cam 74. Therefore, the bleeder valve plug 78a and the air emission valve plug 78b are in open positions and the fuel tank 12 and the air bag 36 are caused to communicate with the canister 14 through the bleeder pipe 72 (refer to FIG. 2).
When refueling is started, fuel vapor in the fuel tank 12 and mist produced in refueling are introduced into the canister 14 through the bleeder pipe 30, the shut-off valve, in an open state, and the bleeder pipe 72. On the other hand, the air bag 36 is deflated by a refueling pressure and air in the air bag 36 is introduced into the canister 14 through the air emission pipe 86, the gas shut-off valve 70 and the bleeder pipe 72.
Consequently, even if air in the air bag 36 is mixed with fuel gas, since the fuel gas is introduced into the canister 14 and adsorbed and captured by the canister 14, the emission of fuel gas into the atmosphere can be minimized.
Since the liquid fuel storage device according to the present invention is arranged as described above, the device achieves the following meritorious effects.
Since the air bag is inflated in such a manner that pressure in the fuel tank is reduced by making use of the pressure reduction pipe through which the fuel tank is connected to the pressure reduction chamber and the engine, a special pressurizing unit is not required.
The fuel vapor pipe for connecting the fuel tank to the canister can be used as the pressure reduction pipe and the bleeder pipe connected to the canister can be used as the air emission pipe for emitting air in the air bag during refueling. Consequently, when the fuel storage unit is mounted on a vehicle, any additional space is not fully occupied.
Since the valve mechanism, opened only during refueling is provided and air in the air bag is emitted during refueling through the air emission pipe connected to the canister, fuel gas passing through the air bag is captured by the canister. Thus, there is not a possibility that fuel gas is emitted to the atmosphere when air is emitted from the air bag.
The size of the canister can be reduced by the reduction of an amount of fuel gas in the fuel tank.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiment, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A liquid fuel storage device is provided for use with an automobile system including an engine, a fuel tank, and a canister for absorbing fuel vapor during refueling. The device includes an air bag disposed in the fuel tank and constructed and arranged to inflate to occupy a space in the fuel tank in accordance with an amount fuel remaining in the fuel tank. Piping structure communicates the fuel tank with the engine for inflating the air bag by reducing pressure in the fuel tank when the engine is started. An air introduction pipe communicates with the atmosphere and includes a first valve mechanism for introducing air into the air bag and prevents air from escaping from the air bag after inflation thereof. An air emission pipe includes a second valve mechanism, which is opened only in refueling to emit air in the air bag during refueling. The air emission pipe is connected to the canister. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119(e) to provisional patent application Ser. No. 60/218,486 filed Jul. 14, 2000, the disclosure of which is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
N/A
BACKGROUND OF THE INVENTION
Structured finance is a financing technique whereby specific assets are placed in a trust, thereby isolating them from the bankruptcy risk of the entity that originated them. Structured finance is known to be a market in which all parties rely to a great extent on the ratings and rating announcements to understand the credit risks and sources of protection in structured securities (of which there are many types, asset-backed commercial paper (ABCP), asset-backed securities (ABS), mortgage-backed securities (MBS), collateralized bond obligation (CBO), collateralized loan obligation (CLO), collateralized debt obligation (CDO), structured investment vehicles (SIV), and derivatives products company (DPC), synthetic CLOS, CBOs of ABS, collectively “structured finance.”) Currently, the credit quality of securities issued in connection with structured financings are determined at closing by comparing the amount of enhancement in a given transaction relative to the estimated portfolio variability of losses over the effective life of the transaction. However, these ratings are rarely, if ever, updated to reflect actual experience. Accordingly, a method is desired for dynamically updating the credit rating of structured securities based on actual credit loss and other performance.
Structured financings are typically the result of the sale of receivables to a special purpose vehicle created solely for this purpose. Securities backed by the receivables in the pool (“asset pool”) are then issued. These are normally separated into one or more “tranches” or “classes”, each with its own characteristics and payment priorities. Having different payment priorities, the tranches accordingly have different risk profiles and payment expectations as a function of the potential delinquencies and defaults of the various receivables and other assets in the pool. The senior tranche usually has the lowest risk.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a method for calculating and dynamically updating the credit quality of securities issued in connection with structured financings. Said credit quality is measured as a deviation from the relevant payment promise with respect to said securities. Such a deviation can occur when, for a variety or reasons, the assets do not generate sufficient cash flows to reimburse the investors in full, interest and principal.
In this method, data representing the structure of the transaction and data representing the current state of the asset pool are used. A Markov chain formalism is used with respect to the received data to predict the cash flows likely to be received from the asset pool. Cash flows generated by the Markov chain model are applied to the liabilities according to the exact payment priority set out in the transaction documents. This priority may include features such as triggers, insurance policies and external forms of credit enhancement. Accordingly, this method models performance of the structured security based on the cash-generating capacity of individual exposures.
Other aspects, features and advantages of the present invention are disclosed in the detailed description that follows.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention will be more fully understood by reference to the following detailed description of the invention in conjunction with the drawings, of which:
FIG. 1 is a flow chart for the structured finance performance index calculation method according to an embodiment of the present invention;
FIG. 2 illustrates a Markov state transition matrix for a structured financing transaction according to an embodiment of the present invention;
FIG. 3(A) illustrates an example of a credit loss base curve for an asset of unknown character and seasoning pattern with multiple curves showing the local variability of credit losses;
FIG. 3(B) illustrates a credit loss base curve for an automobile loan securitization, or the expected case in a rated transaction with multiple curves showing the local variability of credit losses;
FIG. 3(C) illustrates a dynamic credit loss base curve for a performing auto loan securitization according to an embodiment of the present invention with multiple curves showing the local variability of credit losses;
FIG. 3(D) illustrates the deviation from the payment promise for transactions with improving performance according to an embodiment of the present invention; and
FIG. 4 illustrates a computer system for performing the method according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A flow chart is illustrated in FIG. 1 for a method of calculating the deviation from a payment promise associated with a structured financing that may be characterized by an asset pool and one or more liability tranches according to an embodiment of the present invention.
In the present calculation method, two distinct processes are performed. The first process is performed either at closing or during the closing time period of a transaction. The second process is performed every subsequent time period until the lower of the average maturity of the asset pool or the point at which the securities have matured or been retired. The time period is measured in accordance with market customs and is typically one month. A more detailed description of the processes for the method in the present embodiment follows with reference to FIG. 1 .
The present method begins by reading various data and variables associated with the transaction at step 100 . These data will be used to compute the performance-monitoring index. The data and variables read at step 100 include data such as basic transaction parameters (interest rates, etc.), liability structure information, initial asset pool information such as the number of accounts and average quantities, initial tranche ratings as assigned by rating agencies, and specific Markov-process based parameters and deal information on which the performance monitoring index is based. The data are read in from various sources and data providers.
FIG. 2 illustrates an example of a Markov matrix having the new status corresponding to columns 0 , 1 , 2 , 3 , 4 and 5 of the matrix, and the old status corresponding to rows 0 , 1 , 2 , 3 , 4 and 5 of the matrix. The value of cell c 00 of this matrix corresponds to the probability of an account remaining in state 0 at the end of a time period given that it was in state 0 at the beginning of the period. Beyond cell c 00 , and moving to the right, each cell value represents the probability of a periodic transition from state 0 to a further delinquency condition, worsening as we move right across columns. In other words, the value in each cell corresponds to the probability that an account will move to a delinquency status indicated by the column heading given a starting position measured by the row number. In any row of the Markov matrix, the sum of the probabilities must equal one by definition. Typically, the last two cells in a row correspond to default and prepayment transition probabilities, respectively. Also, a non-zero probability cannot practically exist in more than one cell to the right of the diagonal from cell c 00 , c 11 , . . . due to timing conventions (i.e. it is physically impossible for an account in any delinquency status to become delinquent by more than one additional time period in the span of a single time period).
To determine the status-wise probability distribution of the accounts in the asset pool for the first period after closing of the transaction, a row matrix V it is used. This matrix represents the initial probability distribution of the accounts in the transaction. The Markov matrix (P) is pre-multiplied by the row matrix (i.e. V it *P) to compute the new status-wise probability distribution of accounts after the first time period. Generally, the probability distribution of the accounts for any period, n, in the future is given by the equation V it *P n . Further, the cash flows associated with a given time period are derived from the change in the probability distribution of accounts between two consecutive time periods using the credit policies in force for the assets underlying the transaction. These policies are available from one or more parties to the transaction.
The entries of the Markov matrix at each time step are computed with reference to a credit loss base curve characteristic of the relevant asset class derived from issuer data. The parameters of the known base curve, in conjunction with random deviates issuing from specified probability distributions with parameters defined by the base curve, are used to modulate one or more entries of the Markov matrix at each time period to reflect expected cash flow dynamics.
Referring again to FIG. 1 , a determination is made at step 110 as to whether we are at either the closing or during the closing month for the transaction. If the current period is the closing period, a “sigma” calibration is performed at step 120 for the transaction. The purpose of this calibration is the determination of the volatility of asset performance necessary to cause the senior tranche of the transaction to display the deviation from its payment promise corresponding to the credit rating assigned to it by the rating agencies that have rated the transaction. This calibration is accomplished via a Monte Carlo simulation that utilizes the Markov chain formalism and is performed using the exact liability structure of the transaction. After each Monte Carlo run, the above volatility is modified in such a manner as to take the senior tranche payment promise deviation closer to that implied by its credit rating. This process is continued until convergence. The result of the calibration is the standard deviation of asset performance implied by the senior tranche credit rating assigned to the transaction by the rating agencies. A by-product of these calculations is the peformance monitoring index for the other tranches of the transaction computed in the same manner, i.e. as a deviation from their payment promise.
Once the calibration has converged at step 125 , initial performance monitoring index values for each tranche are output at step 130 . By construction, the senior tranche rating is identical to the agency's rating. In general, the lower rated tranche classes will have different ratings from the rating agencies as the present method uses an objective and unique numerical scale for each letter-grade rating category (Aaa, Aa, Baa, etc.). As a result, the performance monitoring index values generated by the present method for all lower tranches will not necessarily agree with the corresponding letter-grade credit rating assigned to them by the rating agencies. The calibrated sigma is then stored at step 135 for later use in updating the performance monitoring index value for each tranche at each time period.
Data for any later period are input at step 140 from commercially available databases that aggregate transaction information based on trustee and servicer reports. This occurs during the second and each subsequent period.
Current deal performance is compared to expected performance at closing and differences are used to adjust Markov chain parameters at step 150 . These updated Markov matrices are then handled via the same process of multiplying them in succession with a row matrix V it from period two to maturity. Specifically, the defining parameters of the credit loss base curve are modified with reference to the difference between expected and actual performance. This updated base curve is then used within the Markov chain formalism described earlier to re-compute the performance-monitoring index in the same manner. Variables such as delinquencies, defaults and pre-payments may be used in the adjustments. A number of ad-hoc adjustment processes may be substituted for the ones normally employed based on the needs of particular investors or issuers. For instance, more emphasis may be placed on defaults (e.g. with automobile loan assets) or on pre-payments (e.g. with mortgage assets).
The performance-monitoring index is then computed at step 170 for the relevant time period. Prepayment assumptions based on commercially available codes and approximations may be input at step 160 for integration into the computation performed at step 170 . The Markov chain formalism is capable of interfacing with most conventional pre-payment models.
The prepayment probability is normally the second to last entry in the first row of the Markov matrix. It is referred to as the single month mortality (“SMM”) by prepayment modelers. Under the present invention, the SMM definition excludes pre-payments that originate from obligors in delinquent states. Commercially available SMM values are typically given on a dollar rather than an account basis, but the difference between the dollar and account values is generally small compared to the accuracy of most commercially available prepayment models. These models may be integrated with the Markov chain formalism described herein by inserting SMM values in the appropriate cell of the matrix.
In computing the performance monitoring index value at step 170 , the data from the pre-payment models input at step 160 and the standard deviation computed at step 135 are utilized.
The performance-monitoring index is output at step 180 so that users may receive and display the generated information.
A general idea of the concepts underlying the performance-monitoring index described herein may be obtained by reference to FIGS. 3(A)-3(D) . In FIG. 3(A) , a credit loss base curve is shown for an asset of unknown character and seasoning pattern, and with multiple curves meant to convey the local variability of credit losses. In FIG. 3(B) , another credit loss base curve is shown for an automobile loan securitization, or the expected case in a rated transaction, and with multiple curves meant to convey the local variability of credit losses. The implied rating agency credit loss base curve analysis presented in FIG. 3(B) is contrasted with results obtained in each corresponding period at step 170 of the method for the present embodiment of the invention as shown in FIG. 3(C) . The conventional analysis connected with FIG. 3(B) is not adjusted for incremental information available on the transaction, whereas the expectation as illustrated in FIG. 3(C) is adjusted by the method described according to the present embodiment.
Contrast, further, the analysis shown in FIGS. 3(B) and 3(C) with the analysis shown in FIG. 3(A) , where seasoning effects are not considered. In the case of performing pools, the method according to the present embodiment reflects the fact that the credit loss volatility of these pools will decrease as time passes, causing a corresponding improvement in the average credit quality of the securities backed by it. In other words, as loss volatility decreases with the passage of time, the expected deviation from the payment promise narrows, as shown in FIG. 3(D) . In particular, the top curve in FIG. 3(D) illustrates exemplary loss volatility at the time of closing and the bottom curve of FIG. 3(D) illustrates exemplary loss at some time after closing. In the top curve, the area under it and to the right of line 2 (the enhancement to cushion pool level losses) represents pool credit loss values that will cause losses on the securities backed by it. These latter losses can be measured in yield reduction from the payment promises. The updated analysis shown by the bottom curve, and taken some time after closing, shows a negligible reduction of yield, having negligible area to the right of line 2 .
According to the embodiments of the present invention, a performance-monitoring index is provided for periodically assessing the deviation from a payment promise associated with a structured financing, using updated asset pool performance data as it becomes available so that the performance monitoring index may be dynamically updated during the life of the transaction. The performance-monitoring index uses a Markov chain formalism to predict and adjust the prediction of future cash flows generated by the asset pool to service the securities and adjusts the loss estimate based on current information from the subject asset pool as it becomes available. The performance-monitoring index models the precise liability structure of the transaction in a cash flow framework. Thereby, the performance-monitoring index is able to determine the deviation from a payment promise, normally measured as a loss in basis point yield, on each of a plurality of tranches based on their contractual payment characteristics.
The invention is typically performed in a powerful computer environment given the number of times the basic matrix calculations are performed. As such, one or more CPUs or terminals 410 are provided as an I/o device for a network 412 including distributed CPUs, sources and internet connections appropriate to receive the data from sources 414 used in these calculations as illustrated in FIG. 4 in an embodiment of the present invention.
It will be apparent to those skilled in the art that other modifications to and variations of the above-described techniques are possible without departing from the inventive concepts disclosed herein. Accordingly, the invention should be viewed as limited solely by the scope and spirit of the appended claims. | A method for assessing and dynamically rating transactions ( 180 ) for structured finance transactions. The method assesses the deviation ( 170 ) from a payment promise to be expected from securities backed by pools of assets of various forms ( 100 ), the securities being issued in a plurality of tranches ( 125 ). The liabilities of the transaction, including triggers and external form of credit enhancement, are taken into account precisely to compute the deviation from the payment promise to be expected by liability holders. Data representing the structure of the transaction and the current state of the asset pool are received ( 100 ). A Markov chain formalism ( 150 ) is applied on the received data, and a cash flow model is constructed to predict the cash flow performance ( 180 ) of the asset pool. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rear-entry type ski boot, and more particularly a manipulation lever for closing and latching the upper of such a rear-entry type ski boot on the skier's lower leg.
2. Description of Background Information
Rear-entry type ski boots comprise an upper journalled at least partially around a horizontal transverse axis passing through a rigid shell base. The upper comprises a rear spoiler which surrounds the rear of the leg and a cuff which surrounds the front of the leg. The rear spoiler is pivoted around a horizontal transverse axis which may coincide with the journal axis of the upper on the shell base. The rear spoiler is linked to the upper and/or to the rigid shell base in such a manner so as to be adapted to pivot backwards away from the cuff to allow entry of the foot into the boot in a rear to front movement.
In order to facilitate placing the foot in the boot in a manner which is effective for skiing and comfortable for the skier, it is necessary to close and latch the upper on the skier's lower leg by latching the rear spoiler to the cuff. To accomplish this, it is conventional in the art to provide a cable for linking the cuff and the rear spoiler so as to close and latch the rear spoiler on the cuff. The ends of the cable are anchored on each lateral side of the cuff by adjustable hooks and clamps which can adjust the position of the anchoring point of the cable on the cuff. The cable then extends on both lateral sides of the rear spoiler through guides. The cable is then attached to a manipulation lever which is journalled on the rear spoiler and which is adapted to be locked in a closed position. In this closed position, the cable is stretched by the manipulation lever so as to close and latch the upper on the skier's lower leg. The manipulation lever comprises a solid plate which can be round or another shape and which occupies at least a substantial portion of the width of the dorsal portion of the rear spoiler. Alternatively, it is known to shape the lever in the shape of a "U" or horseshoe. An adjustment device can be positioned between the arms of this horseshoe shaped lever to provide functions other than the closing of the upper on the lower leg.
In prior art rear-entry type ski boots having such a closure cable, the cable extends along the lateral edges or the exterior edges of the arms of the horseshoe to the lower end of the manipulation lever. As a result, the cable is exposed to certain hazards, such as shocks or snags due to contact with obstacles or diverse objects that occurs during skiing. Moreover, the manipulation lever which closes and latches a first boot on the lower leg of the skier, and which can also function to hold the foot down in the interior of the first boot by a single downward pivoting of the manipulation lever, need not be closed manually by the skier. Rather, the skier can use the bottom of the second boot or the bottom of the ski itself to which the second boot is attached, to downwardly pivot the manipulation lever on the first boot. When the manipulation lever is closed in this fashion, the upward movement of the sole of the second boot or the edge of the ski can quickly damage the exposed closure cable on the first boot. Thus, there is a need for a manipulation lever in which the exposed cable is protected from such hazards.
SUMMARY OF THE INVENTION
It is an object of the present invention to eliminate the vulnerability of the cable for closing and latching the rear spoiler on the cuff by placing the cable in a critical zone which is safe from the hazards described above.
The invention which achieves this objective, in one embodiment, relates to a manipulation element for closing and latching a ski boot. In this embodiment the manipulation element is adapted to be used with a boot that comprises a cable attaching the boot to the manipulation element. This cable comprises a means for closing and latching the boot. In this embodiment, the manipulation element comprises means for actuating the cable to close and latch the boot and at least one protective enclosure means attached to the actuating means for at least partially enclosing the cable along at least a portion of the length of the cable to protect the cable from damage. The actuating means is attached to the boot and the cable is attached to the actuating means. In addition, the at least one protective enclosure means is journalled on the actuating means. Furthermore, the manipulation element can further comprise an elastic means for biasing the at least one protective enclosure means towards the actuating means.
In addition, at least a portion of the at least one protective enclosure means is generally horseshoe-shaped. As a result, this portion of the at least one protective enclosure means comprises two spaced apart arms which are spaced apart by a distance sufficient to accommodate the cable between the arms. Each of the arms comprises an end, and the at least one protective enclosure means is adapted to be positioned in a closed position in which the ends of the arms rests on the surface of the actuating means. In addition, the portion of the surface of the actuating means in contact with the ends of the arms of the at least one protective enclosure means is bevelled. The ends of the arms of the at least one protective enclosure means are also bevelled so that the portion of the surface of the actuating means and the ends of the arms of the at least one protective enclosure means comprise means for guiding and positioning ends of the arms into contact with the bevelled portion of the surface of the actuating means.
In addition, the boot which is adapted to be used with the manipulation element comprises a ramp, and the at least one protective enclosure means is adapted to be positioned in an open position in which a bevelled end of the at least one protective enclosure means comprises means for sliding on the ramp of the boot when the at least one protective enclosure means is in this open position. In one embodiment the at least one protective enclosure means comprises a first end and a second end. The first end comprises the above as mentioned bevelled end which slides on the ramp, and the at least one protective enclosure means is journalled on the actuating means at the second end of the at least one protective enclosure means.
In still another embodiment, the actuating means comprises two lateral edges. Furthermore, the cable extends along each of the two lateral edges of the actuating means. In this embodiment the manipulation element comprises two protective enclosure means, each protective enclosure means being positioned along a different lateral edge of the actuating means to individually protect different portions of the cable.
In still another embodiment, the actuating means comprises a lever having a first and a second end, the first end being journalled on the boot, and the protective enclosure means being journalled on the second end of the lever. In this embodiment, the manipulation lever further comprises a return spring for biasing the protective enclosure means toward the lever.
In addition, the boot which is adapted to be used with this manipulation element can comprise a rigid upper at the shell base. The upper can comprise a cuff and a rear spoiler. This spoiler is journalled around a transverse axis with respect to the shell base. The first end of the lever comprises an upper end journalled on the rear spoiler. In addition, the rear spoiler is adapted to be positioned in an open position for receiving the foot of the skier and is adapted to be positioned in a latched and closed position which the rear spoiler is latched on the cuff and around the lower leg of the skier.
In addition, the boot to be used with this manipulation element can further comprise two lateral anchors each positioned on different lateral sides of the cuff. Each anchor anchors one end of the cable to the cuff. Also, the spoiler can comprise a guide for guiding the cable from the anchors to the manipulation element. Also, the lever can comprise a lower end such that the cable is attached to the lower end of the lever.
In addition, the manipulation lever which is adapted to be used with such a boot further includes at least one protective enclosure means having at least a portion that is generally horseshoe-shaped which comprises two spaced apart arms spaced apart by a distance sufficient to accommodate the cable between these arms. Each of the arms comprises an end and the at least one protective enclosure means is adapted to be positioned in a closed position in which the ends of the arms contact the surface of the lever. The portion of the surface of the lever in contact with the ends of the arms of the at least one protective enclosure means is bevelled, as are the ends of the arms of the at least one protective enclosure means so that the portion of the surface of the lever and the ends of the arms of the protective enclosure means comprise means for guiding and positioning the ends of the arms into contact with the bevelled portion of the surface of the lever.
Furthermore, the boot that is to be used with such a manipulation element further comprises a ramp on the spoiler. The at least one protective enclosure comprises a bevelled end which comprises means for sliding on this ramp when the at least one protective enclosure means is in an open position. Furthermore, the at least one protective enclosure means comprises a first end and a second end. The first end comprises the bevelled end that slides on the ramp and the at least one protective enclosure means is journalled on the lever at its second end. Furthermore, the lever comprises two lateral edges and the cable extends along each of the two lateral edges of the lever. In this embodiment, the manipulation element comprises two protective enclosure means, each being positioned along a different lateral edge of the lever to individually protect different portions of the cable.
In still another embodiment, the manipulation element comprises the above-defined elements in combination with the above-defined boot.
In still another embodiment, the invention comprises a ski boot including an upper, a manipulation element, and a cable. The upper is adapted to be placed in the open position for receiving the foot of the skier and in a closed, latched position. The cable attaches the upper to the manipulation element, and the cable comprises means for closing and latching the upper. The manipulation element comprises means for actuating the cable to close and latch the upper, and at least one protective enclosure means attached to the actuating means for at least partially enclosing the cable along at least a portion of the length of the cable to protect the cable from damage. In this embodiment, the actuating means is attached to the upper and the cable is attached to the actuating means.
The actuating means may comprise a lever having a first end and a second end, with the first end journalled on the upper. In addition, the at least one protective enclosure means is journalled on the second end of the lever. Also, the boot may further comprise a spring for biasing the protective enclosure means toward the lever.
The boot can further comprise a shell base around which the upper is at least partially journalled. In this embodiment, the upper comprises a cuff and a rear spoiler. The rear spoiler is journalled around a transverse axis with respect to the shell base. In addition, the first end of the lever comprises an upper end journalled on the rear spoiler. Also, the rear spoiler is adapted to be positioned in an open position for receiving the foot of the skier, and the rear spoiler is adapted to be positioned in a latched and closed position in which the rear spoiler in latched on the cuff and around the lower leg of the skier.
The boot can further comprise two lateral anchors each positioned on different lateral sides of the cuff. Each anchor anchors one end of the cable to the cuff. In this embodiment, the spoiler comprises a guide for guiding the cable from the anchors to the manipulation element. In addition, the lever comprises a lower end to which the cable is attached.
In addition, at least a portion of the at least one protective enclosure means is generally horseshoe-shaped. This at least a portion of the at least one protective enclosure means comprises two spaced-apart arms spaced apart by a distance sufficient to accommodate the cable between the arms. Each of the arms comprises an end which contacts the surface of the lever when the at least one protective enclosure means is in its closed position.
The portion of the surface of the lever in contact with the ends of the arms of the at least one protective enclosure means is bevelled, as are the ends of the arms themselves so that the portion of the surface of the lever and the ends of the arms of the at least one protective enclosure means comprise means for guiding and positioning the ends of the arms into contact with the bevelled portion of the surface of the lever.
In addition, the spoiler comprises a ramp and the at least one protective enclosure means comprises a bevelled end which comprises means for sliding on the ramp when the at least one protective enclosure means is in an open position.
Furthermore, the at least one protective enclosure means comprises a first and a second end. The first end comprises this bevelled end which slides on the ramp and the at least one protective enclosure means is journalled on the lever at the second end of the at least one protective enclosure means.
The lever comprises two lateral edges and the cable extends along the two lateral edges of the lever. In this embodiment, the manipulation element can comprise two protective enclosure means, each protective enclosure means being positioned along a different lateral edge of the lever to individually protect different portions of the cable.
In still another embodiment, the invention comprises a protective enclosure for protecting a cable adapted to close and latch the spoiler of an upper of a ski boot on the lower leg of the skier. The cable closes and latches the spoiler on the lower leg of the skier in response to the closing of a manipulation lever on the spoiler. Furthermore, the cable is attached to the spoiler and is attached to the manipulation lever at an attachment point. The protective enclosure which is adapted to be used with such a boot comprises means for at least partially enclosing at least a portion of the cable extending between the spoiler and the attachment point to the manipulation lever, and means for journalling the enclosing means on the manipulation element. The protective enclosure can further comprise biasing means for biasing the enclosing means toward the manipulation element. Furthermore, at least a portion of the enclosing means can be generally U-shaped and can comprise two spaced-apart arms for receiving the cable therebetween.
In addition, the manipulation element which is adapted to be used with this protective enclosure can comprise a surface so that the ends of the two spaced-apart arms contact the surface of the manipulation element when the enclosing means is positioned in a closed position. Furthermore, the ends of the two spaced-apart arms can be bevelled, as can a portion of the surface of the manipulation element so that the bevelled arms comprise means for positioning and guiding ends of the two spaced-apart arms onto the bevelled portion of the surface of the manipulation element. Furthermore, the manipulation element that can be used with this protective enclosure can comprise a first end and a second end. The first end of the manipulation lever can be journalled on the rear spoiler and the journalling means of the protective enclosure can be attached to the manipulation lever at the second end of the manipulation lever. In addition, the enclosing means can comprise first and second ends. The journalling means is attached to the first end of the enclosing means. In addition, the spoiler that is used with the protective enclosure means of the present invention can comprise a ramp. The protective enclosure means that is designed to be used with such a boot includes an enclosing means comprising a second bevelled end. In this embodiment, the enclosing means is adapted to be placed in an open position in which the second bevelled end of the closing means contacts the ramp.
In still another embodiment, the present invention includes a protective enclosure defined above in combination with a substantially identical protective enclosure. In this embodiment, the manipulation lever which is to be used with a pair of protective enclosures comprises two lateral sides along which the cable extends. The two protective enclosures are each positioned along the different lateral sides of the manipulation lever for individually protecting different portions of the cable.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics of invention and the advantages thereof will become evident in view of the detailed description which follows in connection with the attached drawings in which:
FIG. 1 illustrates a perspective view of the closing of a manipulation lever of the present invention on a first boot by the use of a second boot;
FIG. 2 illustrates a side view of closure/manipulation lever according to the present invention in which the lever is in its latched, closed position;
FIG. 2a illustrates a partial cross-sectional view taken along line II--II of FIG. 2;
FIG. 3 illustrates a side view of the lever in an open and an intermediate position shown in dashed and chained lines during the manipulation of the lever.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 two rear-entry type ski boots are shown. Each such boot comprises a one piece rigid shell base 1 including a sole 2. Each boot also comprises an upper journalled on shell base 1 around a transverse axis 3 that is approximately horizontal. The upper comprises a cuff 4 and a rear spoiler 5. In a preferred embodiment the rear-entry ski boots that are illustrated in FIG. 1 also include an interior boot 6 composed of a soft material which is positioned inside shell base 1, cuff 4 and rear spoiler 5.
Rear spoiler 5 is adapted to be displaced into an open position, an intermediate position, and a closed and latched position. In the open position (not shown) rear spoiler 5 is pivoted backwardly in the rearward direction away from cuff 4 so as to permit entry of the foot and lower leg into the boot. In an intermediate position illustrated by the boot in the lower left portion of FIG. 1, rear spoiler 5 is pivoted forward from its open position so as to be adjacent to or in the immediate vicinity of the lower leg of the skier and cuff 4. In its latched position which is forward of the intermediate position, rear spoiler 5 is closed and latched on cuff 4 and on the lower leg of the skier. In this closed and latched position of the rear spoiler 5 the skier can safely ski. This closed and latched position is illustrated by the boot in the upper right portion of FIG. 1.
The closing of the upper and/or rear spoiler 5 on the skier's lower leg is accomplished by the use of a cable 7 and a manipulation lever 8. The ends of cable 7 are laterally anchored on either lateral side of cuff 4 by an adjustable anchoring device 9 that uses, for example, hooks and latches to adjust the position at which cable 7 is anchored on cuff 4 as is known in the art. Alternatively, cable 7 can be guided on or inside cuff 4 while surrounding the rear portion of the wearer's lower leg. From the adjustable anchor device 9, cable 7 extends through lateral guides 10 positioned on either lateral side of spoiler 5. After passing through lateral guides 10, cable 7 then extends downwardly on both lateral sides of the dorsal zone of rear spoiler 5 until cable 7 is anchored to or passes through the lower end of manipulation lever 8.
Manipulation lever 8 is journalled at its upper end on a transverse axis pin 11 supported on rear spoiler 5. Manipulation lever 8 is adapted to be displaced in the direction of arrow F as seen in FIGS. 1 and 3 against the bias of a spring device (not shown).
Manipulation lever 8 is adapted to be positioned in an open position, a series of intermediate positions and a closed, latched position. In the open position, seen in solid lines in FIG. 3, the cable is untensioned to permit movement of rear spoiler 5 into its open and intermediate positions. In the intermediate positions of lever 8, one of which is illustrated in dashed and chained lines in FIG. 3, manipulation lever 8 has been displaced from its open position toward its closed position. In its closed position, illustrated in FIG. 2, lever 8 tensions cable 7 to latch and close spoiler 5 on cuff 4 and on the skier's lower leg.
The operation of the opening and closing of lever 8 (either automatic or manual, depending upon the presence of the spring) and a latching of the manipulation lever to close rear spoiler 5 on cuff 4 is known in itself and in the art and thus, does not require further explanation.
The boot in the upper right portion of FIG. 1 has its rear spoiler already latched and closed upon cuff 4 by the placing of manipulation lever 8 in its closed, latched position. In contrast, the boot in the lower left portion of FIG. 1 has its rear spoiler 5 in an intermediate position in which the spoiler 5 is not yet closed or latched on cuff 4 and therefore, is not yet tightened around skier's lower leg. The closing and latching of spoiler 5 on cuff 4 is accomplished, as illustrated in FIG. 1, by placing the weight of the raised boot in the upper right portion of FIG. 1 on lever 8 of the boot in the lower left portion of FIG. 1 and pressing downwardly in the direction of arrow F. Alternatively, manipulation lever 8 of the boot in the lower left portion of FIG. 1 could be manually moved in the direction of arrow F by the skier's hands. It can be clearly seen from FIG. 1 that if cable 7 were exposed as it traverses lateral portions of lever 8 on the boot in the lower left portion of FIG. 1, cable 7 would be damaged when the boot in the upper right portion of FIG. 1 is pressed downwardly on lever 8 of the boot in the lower left portion of FIG. 1. This damage would occur even more readily if the raised boot were already attached to its ski.
The present invention prevents such damage to cable 7 because cable 7 is protected by a surrounding and protecting enclosure 12. Protecting enclosure 12 is journalled on journal axis pin 13 on lever 8. Journal 13 is positioned in the general vicinity of the lower end of lever 8 near or adjacent to or at the point at which cable 7 is connected and attached to manipulation lever 8. Furthermore, protective enclosure 12 can extend along the entire length of manipulation lever 8 or along a portion of the length of lever 8. Therefore, protective closure 12 can protect cable 7 from damage along the entire length of manipulation lever 8.
In the embodiment illustrated in the drawings, the two portions of cable 7 that extend along opposite lateral edge of manipulation lever 8 are each protected by a different individual protective enclosure 12. However, it is also within the scope of the present invention to use a single protective enclosure for protecting each of these two lateral portions of cable 7 on either lateral side of manipulation lever 8. Such a single protective enclosure would extend across the entire width of lever 8. The entire description of protective enclosure 12 which follows and which is directed to individual enclosures on either lateral side of manipulation lever 8 also applies to such a single protective enclosure without going beyond the scope of the invention.
To summarize, protective enclosure 12 is journalled around a transverse axis 13 on lever 8 adjacent to the free end of lever 8, the free end of lever 8 being defined as the end of lever 8 that is opposite from journal 11. In addition, protective enclosure 12 can extend along the entire length of lever 8 when lever 8 is in the closed position as seen in FIG. 2. Alternatively, enclosure 12 can extend almost the entire length of lever 8 so that enclosure 12 is spaced a small distance from journal 11 which is sufficient to ensure that enclosure 12 does not interfere with journal 11 and journalling of lever 8 on spoiler 5 around journal 11. As a result, protective enclosure 12 extends toward journal 11 of lever 8 on rear spoiler 5 without interfering with the journal 11 and the journalling of lever 8 on rear spoiler 5.
Journal 13 is equipped with a spring 13a (seen in dashed lines in FIG. 2) which permanently biases enclosure 12 toward lever 8 and hence, against cable 7 when rear spoiler 5 is in an unlatched position as seen on the boot in the lower left portion in FIG. 1. Moreover, the free end of protective enclosure 12, which is defined as the end opposite from journal 13, has a rounded or bevelled edge 14 which is characterized by an absence of any perpendicular surfaces. This rounded edge 14 is designed to slide on a ramp 15 positioned on rear spoiler 5 above the guides 10 and appears clearly in solid lines in FIG. 3. Rounded edge 14 of enclosure 12 is adapted to slide on ramp 15 without jamming so as to permit unobstructed pivoting of manipulation lever 8 on journal 11.
Protective enclosure 12 preferably has a horseshoe-shaped cross-section having two spaced apart arms 12' as illustrated in FIG. 2a. Enclosure 12 is adapted to be positioned in a closed, locked position which is seen in FIGS. 2 and 2a. In this locked position, the ends of each arm of enclosure 12 rest on the upper surface 8' of lever 8 in a manner so as to entirely enclose cover cable 7 so as to protect cable 7 from scraping. The end of the arms of enclosure 12 and that portion of the surface of lever 8 that contacts these arms can both be bevelled for better positioning and guiding the arms of protective enclosure 12 on lever 8.
FIG. 3 ilustrates the displacement of lever 8 from its open position toward its closed position. Between the opened and closed position of lever 8, lever 8 can occupy a plurality of intermediate positions one of which is illustrated in dashed and chained lines in FIG. 3. The position of enclosure 12 when lever 8 is in one intermediate position is also illustrated by dashed and chained lines. The open position of lever 8 is illustrated in solid lines in FIG. 3. When lever 8 is displaced in the direction of arrow F as seen in FIGS. 1 and 3 from its open position to an intermediate position, protective enclosure 12 is biased by its spring 13a so that the non-perpendicular edge 14 of enclosure 12 slides on ramp 15 and comes to rest upon the top of cable 7, which is seen in dashed lines in FIG. 3. When edge 14 slides on ramp 15, enclosure 12 is in its open position. Enclosure 12 remains in contact with and encloses at least a portion of cable 7 as lever 8 is displaced from its intermediate positions to its closed, latched position to protect cable 7 while the skier latches the boot and enclosure 12 remains in contact with and encloses cable 7 when the boot is in its closed, latched position to protect cable 7 when the skier skis. During this displacement of lever 8 from its open to its closed position the tension of cable 7 which is anchored at adjustment means 9 on cuff 4, pulls rear spoiler 5 and the journal 11 of lever 8 toward its closed position on cuff 4 which is shown by arrow F' in FIG. 3.
Based upon the above description, it will be evident that lever 8 which is equipped with protective enclosure 12 permits the full protection of cable 7 at all times both during skiing as well as during the placing of the boot on the foot, or on the ski where the edges of the ski would otherwise quickly damage cable 7.
Although the invention has been described with reference to particular methods, means, and embodiments, it is understood that the invention is not limited to the particulars disclosed but extends to all equivalents within the scope of the claims. | A manipulation element for closing and latching the rear spoiler of a ski boot onto the lower leg of a skier. The boot includes a cable which attaches the boot to a manipulation element. The manipulation element actuates the cable to close and latch the rear spoiler onto the lower portion of the leg. The manipulation element includes an element for actuating the cable to close and latch the boot. This actuating element is journalled on the rear spoiler, and includes a protective enclosure journalled on the actuating element for at least partially enclosing the cable along at least a portion of the length of the cable to protect the cable from damage. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns an improved tape spool for a two-spool tape cartridge in which a flexible, elastic drive belt contacts the tape on the tape spools and whereby movement of the belt causes movement of the tape between the spools.
2. Description of the Prior Art
The belt driven tape cartridge of U.S. Pat. No. 3,692,255, issued to Von Behren and assigned to the assignee of the present invention, has been very successfully utilized to interface with computers where rapid acceleration and deceleration of the tape are required. In the cartridge there disclosed, a magnetic recording tape is convolutely wound on two tape spools and is bidirectionally driven between the spools by an endless flexible belt in frictional contact with the tape on both spools.
When the cartridge of the Von Behren patent was first marketed in 1972, its magnetic recording tape had a width of 1/4 inch (6.35 mm), a thickness of 1 mil (0.025 mm), and was driven at 30 inches (762 mm) per second. Data were originally recorded on the tape at a density of 1600 flux reversals per inch (63 per mm). Current cartridges come in a variety of sizes and the recording tapes range in width from 0.150 inches (3.81 mm) to 0.250 inches (6.35 mm), may be as thin as 0.6 mil (0.015 mm), may be driven at 90 or more inches (2286 mm) per second, and data is recorded at densities of 10,000 flux reversals per inch (394 per mm) or more. In addition, data are recorded on a plurality of independent, parallel tracks, which may number in excess of 32, spaced across the width of the magnetic recording tape.
Although no problems were encountered when the cartridge was first introduced, the higher tape speeds, recording densities, and track densities have created a need for reduced rotational friction in the tape spools and improved spool positioning during winding and unwinding of the magnetic tape.
SUMMARY OF THE INVENTION
The present invention discloses a tape spool for use in a data cartridge which includes an anti-friction bearing and means for retaining the spool at a predetermined axial position with respect to the cartridge. Particularly, the tape spool is adapted for mounting on and rotation around a cylindrical pin extending a predetermined distance from one of the cartridge walls, and includes two flanges interconnected by a hub providing a cylindrical tape winding surface, a bore extending through the hub and one of the flanges and closely but freely fitting the pin, a bearing protrusion, which may be hemispherical, extending from the other of the flanges into the bore, wherein the extension of the pin from the cartridge wall is greater than the length of the hub bore to the bearing protrusion so that the spool is suspended above the cartridge wall for free rotation about the pin. Frictional contact between the cartridge and the spool is limited to the hemispherical protrusion of the flange and the end of the pin, and thus is very low.
The improved tape spool of the invention may also include a wear-button protrusion extending from the other of the flanges opposite and coaxial with the hub bore which may be contacted by a spring connected to an inner wall of the cartridge, which spring resiliently biases the spool into contact with the pin and resists axial movement of the spool. Thus the spool is maintained at a predetermined position relative to the tape cartridge and the magnetic tape, resulting in uniform winding of the magnetic tape upon the spool.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more thoroughly described with reference to the accompanying drawings, wherein like numbers refer to like parts in the several views, and wherein:
FIG. 1 is a top plan view of a belt driven tape cartridge, partially in section, containing the improved tape spool of the present invention;
FIG. 2 is a cross-sectional view of the spool of the present invention taken generally along the line 2--2 of FIG. 1; and
FIG. 3 is an alternate embodiment of a tape spool for use in the cartridge of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate a data cartridge 10 of the type described in U.S. Pat. No. 3,692,255 (Von Behren) which includes a thin base plate 12, usually of aluminum, and a clear or translucent polymeric cover 14, which, when assembled, define a thin, generally rectangular enclosure. Enclosed within the data cartridge 10 are a pair of tape spools 16 and 18, three tape wrap pins 20, 22 and 24, a pair of tape guides 26 and 28, a length of magnetic recording tape 30, a driving belt 32, a pair of belt guide rollers 34 and 36, and a belt driving roller 38.
The tape spools 16 and 18 are supported by the cartridge base plate 12 for free rotation about spaced parallel axes. The magnetic recording tape 30 is convolutely wound on the tape spools 16 and 18 in opposite directions about their axes. A tape 30 guide path between the tape spools 16 and 18 is defined by the three tape wrap pins 20, 22 and 24 and the two tape guides 26 and 28.
The cartridge 10 is formed with a cutaway portion 40 along the tape path which provides access to the magnetic tape 30 by a magnetic transducer 42. The cutaway portion 40 is normally closed by a spring-loaded door 44 which is opened as shown upon insertion of the data cartridge 10 into a tape recorder (not shown). A second opening 46 is provided in the cartridge cover 14 to provide access to the belt driving roller 38 by a drive roller 48 driven by a reversible motor 50. The magnetic transducer 42, the drive roller 48, and the reversible motor 50 are illustrated in phantom lines as they form a portion of the tape recorder rather than the data cartridge 10. The cartridge belt driving roller 38 is provided with a reduced diameter 51 to prevent contact between the driving belt 32 and the magnetic recording tape 30. The driving belt 32 is thin, continuous, flexible and elastic. It has a uniform cross-sectional area and it extends around the belt driving roller 38 and the belt guide rollers 34 and 36, contacting the tape 30 on the tape spools 16 and 18.
The length of the belt 32 is less than the length of the path along which it extends so that when the belt 32 is stretched into position it will have an installed tension or pretension. The angle of wrap of the driving belt 32 at the tape spools 16 and 18 is at least 60 degrees and provides the necessary contact between the belt 32 and the tape 30 wound on the tape spools 16 and 18 to assure frictional driving of the tape 30 and the tape spools 16 and 18.
Rotation of the belt driving roller 38 in a counterclockwise direction (as viewed in FIG. 1) by the drive roller 48 causes the belt 32 to traverse its path in a counterclockwise direction and the tape 30 to move from the tape spool 18 to the tape spool 16, the tape spool 18 serving as a supply spool and the tape spool 16 serving as a take-up spool. Opposite rotation of the driving roller 38 by the drive roller 48 will cause tape to be supplied by the tape spool 16 and convolutely wound upon the tape spool 18. A predetermined frictional coupling between the belt guide rollers 34 and 36 and their respective support shafts applies a predetermined drag to the belt 32 as it passes around the guide belt rollers 34 and 36, thereby increasing the tension of the belt 32 as it passes around each of the guide rollers 34 and 36. This increased tension in the belt 32 increases the length of the belt 32 according to its elasticity and thereby the speed at which the belt 32 passes around the spool 18 is increased compared to that at which it passes around the spool 16. This increased speed causes tension in the tape 30 as well as the ability to take up any slack developed in the tape 30 between the tape spools 16 and 18 as is more fully taught in U.S. Pat. No. 3,692,255.
The improved tape spool 16 or 18 of the present invention is best illustrated in FIG. 2 and includes an upper flange 52 and a lower flange 54 interconnected by a hub 56 providing a cylindrical tape winding surface 58. The spool 16 or 18 is preferably molded of plastic with the hub 56 and lower flange 54 molded as a single unit and the upper flange 52 molded separately and attached to the hub 56 either by an adhesive or welding. The spool 16 or 18 is mounted to the cartridge 10 on and for rotation around a pin 60 which is press-fitted into a hole 62 in the cartridge plate 12 to extend a predetermined distance above the plate 12. The spool 16 or 18 is journaled for free rotation around the pin 60 by means of a bore 64 provided in the hub 56, which bore is sized to closely but freely fit the diameter of the pin 60.
To reduce rotative friction of the spool 16 of 18 about the pin 60, the upper flange 52 is provided with a bearing protuberance 66 which extends into the hub bore 64 and contacts the pin 60. The bearing protuberance 66 is preferably frusto-conical or hemispherical in shape and preferably has a rounded surface 68 which reduces the area of contact between the protuberance 66 and the pin 60. It will be recognized, however, that the protuberance 66 could simply be a cylindrical projection which contacts the pin 60 at a flat surface or the pin 60 could simply contact the flange 52. It is desirable, however, to include the bulk of material provided by the protuberance 66, rather than simply allowing the pin 60 to contact the flat, lower surface of the upper flange 52, because the upper flange 52 is molded of a polymer and may be somewhat abraded or frictionally heated by contact with the pin 60. The relatively large bulk of material provided by the protuberance 66 minimizes any damaging effects caused by such heating and the rounded shape of its surface 68 further minimizes heat caused by friction and reduces abrasion caused by the pin 60.
In order to further reduce friction and abrasion generated between the pin 60 and the bearing protuberance 66, the terminal surface 70 of the pin 60 may likewise be rounded rather than flat as illustrated. The length of the pin 60, from the surface of the cartridge plate 12 to its terminal end 70, is selected to be slightly greater than the length of the hub bore 64 from the flange 54 to the protuberance 66 so that the spool 16 or 18 is suspended by contact between the pin 60 and the protuberance 66 such that the lower flange 54 rotates free of contact with the cartridge plate 12.
Thus far a tape spool 16 and 18 has been described which will be effective to greatly reduce friction between the spool 16 or 18 and the pin 60 as the spool 16 or 18 rotates in use. If it could be assured that the data cartridge 10 would only be used at low tape speeds and that the cartridge 10 would always be oriented in an upright position such that the pin 60 were vertical, the bearing protuberance 66 would be all that was required for adequate performance since gravity could be relied upon to maintain the bearing protuberance 66 in contact with the pin 60 and prevent the spool 16 or 18 from lifting with respect to the cartridge plate 12 and oscillating on the pin 60 as tape 30 was being wound or removed. However, high speed rotation of the spools 16 and 18 may cause lifting or oscillation of the spool 16 or 18 relative to the pin 60 and imperfect convolute winding of the tape 30 upon the spool 16 or 18. Such movement of the spool 16 or 18 may cause damage to the edges of the tape 30 by contact with the flanges 52 or 54 and may be detrimental to tape guidance throughout the cartridge 10. In addition, the data cartridge 10 may be oriented in use in a position other than that shown in FIG. 2, in which case gravity would not assist in maintaining the protuberance 66 in contact with the pin 60.
To minimize lifting and oscillation of the spool 16 or 18 relative to the pin 60, the upper flange 52 is further provided with a wear-button protuberance 72 extending from the flange 52 opposite and coaxial with the hub bore 64. The cartridge cover 14 is provided with a spring 74 which contacts the wear-button protuberance 74 and urges the bearing protuberance 66 into contact with the pin 60. Although it might be possible to eliminate the spring 74 and allow the wear-button protuberance 74 to bear directly against the cover 14, such an arrangement would be difficult to achieve because tolerances would have to be controlled tightly and either a lack of contact between the cover 14 and the spool 16 or 18 or excessive pressure between the cover 14 and the spool 16 or 18 would likely exist. The spring 74 is, therefore, provided to provide resiliency and a limited amount of travel to compensate for tolerance variations in the length of the pin 60 and the manufacture of the upper flange 52.
The wear-button protuberance 72 is provided to prevent contact between the upper flange 52 and the cartridge cover 14 or the spring 74. The preferred shape of the wear-button protuberance 72 is frusto-conical or hemispherical and either shape preferably includes a rounded outer surface 76 to minimize the area of contact between the protuberance 72 and the spring 74.
The preferred type of spring 74 is illustrated in FIGS. 1 and 2 and consists of double-cantilever spring arms 78 and 80 extending between a central, circular spool-contacting area 82 and diametrically opposed areas 84 and 86 of a spring mounted ring 88, which ring 88 is suitably attached to the cartridge cover 14.
The spring arms 78 and 80 are preferably wound in a flat helix to increase the length of the arms 78 and 80 and thus the resilient travel of the spring 74.
FIG. 3 illustrates an alternate embodiment of a tape spool 90 according to the present invention in which a bearing protuberance 92 and wear-button protuberance 94 are provided as opposite sides of a spherical ball 96 which is press-fitted, adhesively attached, or welded to a collar 98 which is in turn attached to the upper flange 100 of the spool 90 by an adhesive, welding or press-fitting. The sphere 96 and collar 98 may also be machined or molded as an integral unit of metal or plastic or the collar 98 may be eliminated and the sphere 96 pressed or otherwise attached to the upper flange 100 by means of a hole in the flange 100 closely fitting the sphere.
Although the arrangement of FIG. 3 requires a greater number of separate pieces and greater assembly than does the arrangement of FIG. 2, the arrangement illustrated by FIG. 3 may be advantageous in that the sphere 96 which provides the bearing and wear-button protuberances 92 and 94 need not be of the same material used to produce the upper flange 100. Thus the sphere 96 may be manufactured of a highly abrasion-resistant material, such as metal, acetal resin or polycarbonate, while the upper flange 100 is manufactured of a softer but more economical material such as acrylonitrilebutadiene-styrene copolymer or high-impact polystyrene. FIG. 3 also illustrates an alternative to the spring 74 of FIG. 2 by providing a straight leaf spring 102 which includes a mounting portion 104 and spring arms 106 (only one is shown) which extend from opposite ends of the mounting portion 104 to contact each of the spools 16 and 18. The mounting portion 104 of the spring 102 may be attached to the cartridge cover 108 by any suitable method, but preferably is riveted thereto. It will be recognized that the leaf spring 102 of FIG. 3 could be used in conjunction with the spool 18 of FIGS. 1 and 2.
Either of the alternate embodiments described herein is effective to greatly reduce friction between the rotating spool and its mounting pin and also to prevent oscillation of the spool relative to the pin. Although only two embodiments have been illustrated, it will be apparent to those skilled in the art that many modifications are possible. All of such modifications which fall within the spirit and scope of the appended claims are intended to be included in the present invention. | A tape spool including two flanges interconnected by a hub providing a cylindrical tape winding surface is adapted for mounting on and rotation around a cylindrical pin extending from one of two spaced, parallel walls of a data cartridge by providing a bore extending through the hub and one of the flanges which closely but freely fits said pin, and a bearing protrusion extending from the other of the flanges into the bore wherein the extension of the pin from its cartridge wall is greater than the length of the bore to the bearing protrusion so that the spool is suspended above the wall for free rotation about the pin. Oscillation of the spool on the pin may be prevented by also providing a wear-button protrusion extending from the other of the flanges opposite and coaxial with the bore and a spring which extends from the remaining cartridge wall to contact the wear-button protrusion and force the spool into contact with the pin. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the automated packaging of transportable spools of wire, most typically heavier gauges of wire such as bale binding wire.
2. Related Art
Wire is typically packaged and transported in spools. More precisely, lengths of wire are wound in spirals which form a cylinder as the wire accumulates. A central, axial empty space is also cylindrical so that the finished volume of wound wire is toroidal in shape. This packaging shape is generally maintained by radial binding straps or wires which pass through the central axial space and wrap around a cross section of the volume of wire to be bound in a radial loop which will prevent the wire from unwinding.
When commercial volumes of heavy gauge wire are spooled, the weight of such volumes of wire become an issue in handling, packaging and transporting the spools. For example, typical volumes of bulk material baling wire are too heavy to be moved, stored or transported without the use of machinery such as fork trucks. These bound toroids of wire, conventionally referred to as “cores,” are difficult to handle by fork truck and may be damaged by fork truck handling, unless they are placed on a handling aide such as a pallet. Handling wire cores by pallet still necessitates placing the core on the pallet to begin with, and later removing it from the pallet for placement in a position for its ultimate use.
In other regards, there is a constant need in the industry for increasing the speed, automation, efficiency weight capacity of wire core binding, as for example, by incorporating electro servo motors into the binding process.
Apparatuses and methods for winding and binding wire into cores are known. See, for example, U.S. Pat. No. 3,129,658 to Valente; U.S. Pat. No. 3,908,712 to Paletzki; U.S. Pat. No. 3,583,311 to Hill et al.; U.S. Pat. No. 3,974,761 to Hill. Various wire binders are known, See U.S. Pat. No. 3,548,739 to Glasson; U.S. Pat. No. 3,675,568 to Martelee; U.S. Pat. No. 3,921,510 to Glasson; U.S. Pat. No. 4,024,805 to Glasson; U.S. Pat. No. 3,678,845 to Francois; U.S. Pat. No. 3,842,728 to Elineau; and U.S. Pat. No. 4,301,720 to Elineau. Various core handling devices have also been developed. See, U.S. Pat. No. 3,633,492 to Gilvar; U.S. Pat. No. 3,788,210 to Lingemann; and U.S. Pat. No. 4,020,755 to Bohlmark. None of these systems, however, solve the problem of handling and transporting the heavy wire cores output by these and other prior art machines. Moreover, prior art devices are limited in their speed and efficiency.
SUMMARY OF THE INVENTION
The present invention is an apparatus and method of wire core binding that produces a wire core integrated with a collapsible carrying spool specifically designed to facilitate the handling and transportation of the wire cores output on the spools.
The apparatus of the present invention receives an unbound, loose, uncompressed spiral of wire wound onto one of the novel, collapsible carrying spools of the present invention. A conveyor belt extends into a binding station where it deposits the loose wire “core” on its spool. Once in the binding station, the wire spiral is compressed by a compressor. While compression is still being applied, binding wire guide tracks close around the wire core to guide binding wire radially around the wire core. The guide tracks are aligned with gaps between compression plates. The binding wire is tightened, tied and released according to known techniques.
In a preferred embodiment of the present invention there are four binding wire guide tracks. Two binding wire tying heads use electro servo motors to simultaneously guide, tighten and bind two radial binding wires through two of the guide tracks. Thereafter, the tying heads rotate 90° where the other two guide tracks are used to guide, tighten and tie a third and a fourth binding wire around the wire core. The wire guide tracks are then removed from engagement with the wire core. Compression is released on the wire core, leaving it to remain compressed by the restraining binding wires. Finally, the bound, compressed wire core, still resting on its integrated collapsible carrying spool, is received by an extending exit conveyor by which it is removed from the binding station.
The present invention incorporates a novel spool for handling and transporting the wire core. The spool has horizontal base members and stand members whose vertical separation allows insertion of fork truck forks. Another novel aspect of the spool is that it has expandable and retractable contact members which work in cooperation with a central shaft having a handle. The cooperation of the contact members and shaft is such that the contact members expand to hold the wire core securely in place when the handle is lifted by an outside device such as a fork truck or an overhead hook. When lifting traction is released from the shaft, the contact members release their radial expansion contact with the wire core so that the core may be easily removed from the spool.
Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the wire core binding apparatus with the compressor and guide tracks elevated, before the wire core spool is inserted.
FIG. 2 is a perspective view of the wire core disposed within the binding station, with the compressor and guide tracks elevated.
FIG. 3 is a perspective view of the wire core binding apparatus with the compressor and guide tracks engaged with the wire core.
FIG. 4 is a perspective view of the wire core within the binding station with the compressor and guide tracks engaged with the wire core, and with the tying heads engaged with the wire core in a second position.
FIG. 5 is a closer perspective view of the wire core in the binding apparatus with the guide tracks and compressor engaged.
FIG. 6 is a perspective view of the binding table.
FIG. 7 is a depiction of the integrated spool of the present invention.
FIG. 8 is a depiction of the integrated carrying spool of the present invention in an expanded mode.
FIG. 9 is a depiction of the integrated core spool of the present invention in a collapsed position.
FIG. 10 is a depiction of a contact member of the spool of the present invention.
FIG. 11 is a depiction of the lower base member and axial lifting member of the wire core spool of the present invention.
FIG. 12 is a perspective view of the collapsible spool with flat sides for alignment.
FIG. 13 is a close up view of the entry conveyor with side walls for alignment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the accompanying drawings in which like reference numbers indicate like elements, FIG. 1 is a perspective view of the automatic wire core binder with integrated spool of the present invention. Unbound wire core, 2 , having been previously wound onto wire core spool, 4 , is carried along entry conveyor, 6 , towards the apparatus. Entry conveyor, 6 , incorporates extending arms, 8 , which, upon arrival thereon of the wire core, 2 , and spool, 4 , extend beyond conveyor assembly, 6 , to carry the wire core, 2 , and spool, 4 , into the binding station, 10 .
In the binding station, 10 , the wire core, 2 , and carrier spool, 4 , are placed on table, 12 , by the extending arms, 8 , of the conveyor belt, 6 . The extending arms thereafter retract, leaving the core, 2 , and the carrier spool, 4 , on table, 12 , as in FIGS. 2, 3 and 4 .
Table, 12 , is comprised of separate components, preferably four in number as shown in FIG. 6 . Each component is comprised of a table top section 11 and at least one leg 14 . These four table top sections are disposed on a level plane, adjacent to one another but with a space between them. Accordingly, four gaps, 15 , are left between the table top quadrants 11 . These gaps are a path for the passage of a binding wire through the table top and between the table top quadrants.
Spool, 4 , also has gaps, preferably four, that allow binding wire to pass through them. The spool is described more fully below. The spool gaps align with the table gaps. The table 12 and spool 4 will cooperatively receive the components that will descend through the center of the core, 2 , during the binding and compression operation described more fully below.
To align the table 12 and spool 4 , the table top has a locator pin, 13 . The depicted embodiment has a central conical pin, 13 , for properly centering the core spool on the table. Upon receipt of wire core, 2 , and carrier spool, 4 , the locator pin helps to assure the proper position of carrier spool, 4 , so that its gaps align with the table gaps 15 .
The table legs, 14 , have lower guide track sections, 16 A and 16 B, as seen in FIGS. 1 and 6.
At least two techniques may be used to rotationally align the spool gaps with the table gaps, 15 . One method uses at least one locator pin offset from the center of the table (not shown). Preferably a plurality of pins on the table top are received by holes in the spool bottom which are located in a position corresponding to proper gap alignment. The pins may be in the spool and holes in the table. Alternatively, the pins may retract and extend by known means, may be spring biased to extend, or may be fixed.
A second gap alignment technique is to configure the spool with straight edges on the sides and base, 150 in FIG. 12 . The spool base is then dimensioned to slide down the entry conveyor with its straight edges in close sliding cooperation with sidewalls, 152 in FIG. 13, mounted on the conveyor. This configuration aligns the gaps parallel to the spool's line of travel down the conveyor. Gaps perpendicular to the long axis of the conveyor belt are then aligned by the conveyor extension arms. The arms are indexed to accurately place the spool on the table. Preferably the indexing is executed by a “cyclo” index box, in a known manner.
Disposed around the baling station is support frame, 20 , as seen in FIGS. 1-4. Support frame, 20 , is in a known, pre-determined spacing and alignment around table, 12 . Preferably both table, 12 , and frame, 20 , are fixedly attached to a base plate or floor. Generally, support frame, 20 , secures operational component assemblies, which are compressor, 22 , and rotating tying head bracket, 24 .
Compressor, 22 , is slidably attached to two diagonally opposed vertical beams of frame, 20 . Compressor boom, 26 , is fixedly attached at either end to slide guides, 28 on frame 20 . Compressor elevators, 30 , lower the compressor, 22 , to compress a wire core, as in FIGS. 1, 2 , 3 and 4 , and raise the compressor, 22 , after the wire core has been bound. The compressor is in its raised position in FIG. 1 . The top of compressor elevators, 30 , are attached to compressor boom, 26 , or slide guides, 28 . The bottom end of compressor elevators, 30 , are attached to frame, 20 , although they may alternatively be attached to the floor. Compressor elevators, 30 , may provide lift by any number of equivalent means including pneumatic power, hydraulic power or mechanical means.
Compressor, 22 , includes compression arms, 32 , and compression face plates, 34 . Compression plates, 34 , contact the wire core on its top surface and transfer the compressing force to the wire core, 2 . Compression arms, 32 , extend down vertically from where they are attached to compression boom, 26 . Solid compression arms, 32 , are of a pre-configured length in order to bring compression faces, 34 , into contact with wire core, 2 . Alternatively, they may be made variable in length by any conventional mechanical means, in order to accommodate wire cores of varying heights.
Also attached to compressor, 22 , are four wire guide track upper sections, 40 A and 40 B, best seen in FIG. 5 . Guide track upper sections, 40 A and 40 B, are for guiding the binding wire around the wire core. Each binding wire guide track section, 40 A and 40 B, is comprised of a straight, vertical interior section disposed to descend into the central, axial, open hole through the middle of the wire core. Binding wire guide track sections, 40 A and 40 B, are aligned to descend between vertical components of carrying spool, 4 , described in detail below. Alternatively, binding wire guide track sections, 40 A and 40 B, may be further dimensioned to extend below the bottom surface of the wire core, 2 , and below the bottom stand and base of the wire core carrier, 4 , upon full decent of compressor, 22 . Preferably, the interior vertical section of binding wire guide track sections, 40 , are straight and the top portion is curvilinear, most preferably semi-circular. However, any shape is equivalent provided the binding wire guide track sections redirect a progressing binding wire from a vertical direction on the outside of the wire core, 2 , to or from a vertical direction through the axial interior hole of the wire core, 2 .
Also supported by frame, 20 , is rotating tying head bracket, 24 , best seen in FIGS. 1-4. The rotating tying head bracket's axis of rotation is coaxial with the wire core, 2 , and carrying spool, 4 . Support frame, 20 , has a top central beam, 50 . Substantially at the middle of beam, 50 , is a pivot axis, 52 , attached to beam, 50 , and extending upwards therefrom into and through rotational fixation with the rotating tying head bracket top bar, 54 . In the depicted embodiment rotating tying head bracket, 24 , is designed to rotate 90°. The top tying head bar, 24 , is guided and supported through its rotation by arcuate guide rails, 56 , which are fixedly attached to support frame, 20 , at brackets, 58 . Top tying head bar, 24 , is capped at its ends with wheels or bosses, 60 , in rotating or sliding communication with guide rails, 56 .
Rotation actuator, 62 , is pivotally fixed to top tying head bar, 24 , at bracket, 64 , and pivotally fixed to support frame, 20 , at bracket, 66 . Rotation actuator, 62 , may extend and contract pneumatically, hydraulically or mechanically. Extension and retraction of rotation actuator, 62 , swings the tying heads, 72 , around the circumference of the wire core, 2 , allowing the tying heads, 72 , to move from a first position to a second position. The first position is engaged with first and second binding wire guide tracks, 40 A and 16 A. The second position is engaged with third and fourth binding wire guide tracks, 40 B and 16 B. Preferably, the four binding wire guide tracks are 900 from one another, although other numbers of guide tracks and angles between them may be used.
Attached to top tying head bar, 24 , and hanging downward from it are two tying head anchor bars, 70 . Attached to the vertical anchor bars, 70 , are tying head assemblies, 72 , shown in detail in FIG. 5 . The tying head assembly, 72 , is comprised of a binding wire propulsion electro-servo motor, 74 , a knotter, 76 , a knotter actuator electro-servo motor, 78 and drive wheels, (not shown) and a gripper and a cutter (within knotter 76 ). Tying heads incorporating electro-servo motors are preferred, and most preferred are tying heads actuated through electro-servo motors and controlled by programmable logic circuits. However, a variety of binding wire and binding strap propulsion, guiding and fastening mechanisms are known in the art. Any of these mechanisms incorporated into the apparatus herein described is considered to be within the scope of the present invention. In FIG. 5 the tying heads, 72 , are in their first position.
Binding wire looping, tightening and knotting operates as follows. Upon being brought into operative communication with one another, the tying head assembly, 72 , and guide tracks, 16 A and 40 A, describe a substantially complete loop in a single vertical plane. The loop circumscribes the object to be bound, in this case the wire core, 2 .
Binding wire guide track sections, 16 A, 16 B, 40 A and 40 B, are all comprised of two longitudinal guide track halves extending for the length of the guide tracks. The guide track halves are biased together by any of a variety of equivalent biasing means, conventionally by springs 80 exerting inward tension, as seen in FIG. 6 . On the internal faces of at least one wire guide track half, facing the other half are concave grooves (not shown) which form a channel for receiving and guiding advancing binding wire while the guide track halves are biased together by the springs 80 .
Once in place, binding wire propulsion electro-servo motor, 74 , by means of drive wheels frictionally engaged with the binding wire (not shown) drives a length of the binding wire into and around the guide tracks, 16 A, 16 B, 40 A and 40 B. The pre-determined length of binding wire completes a loop around the wire core, 2 . By means of a limit switch (not shown) or a programmable logic circuit control measuring the distance of wire travel through the guide track, the propulsion motor stops when the binding wire has completed the loop around the wire core, 2 . Upon completing this loop, a cutter (not shown) cuts the proximal end of the binding wire.
Upon completing its loop around the wire core, 2 , a gripper (not shown) grips the distal end of the binding wire and holds it fast. Thereafter, propulsion electro-servo motor, 74 , reverses the direction of the drive wheels (not shown) in order put tension on the binding wire. Since the wire, through the guide track, is disposed in a loop around the wire core, 2 , the tension exerts an inward force on the wire in the wire guide track channel. The propulsion motor, 74 exerts a pre-configured degree of tension sufficient to overcome the strength of the biasing springs 80 holding the two binding wire guide track halves together. When this pre-determined amount of tension overcomes the inward biasing strength of the springs, 80 , the binding wire is pulled from the guide track and free of it. Once the wire is free of the guide track, the propulsion servo motor, 74 , continues to apply reversing tension until the binding wire comes into tight, binding contact with the wire core, 2 . Upon reaching a pre-configured tension, length, or other equivalent control means, the propulsion motor drive wheels continue to exert a pre-determined torque on the binding wire, holding it in binding contact with the wire core. At this point the binding wire is ready to be knotted.
Thereafter a knotter, 76 , is propelled by a knotter propulsion electro-servo motor, 78 , through a pre-configured number of gear rotations to twist the ends of the binding wire together to form a knot.
It will be noted that in the depicted embodiment the four wire core binding wires are applied to the wire core in pairs. The first pair is perpendicular to the line of travel of the conveyor belts. The second pair is parallel to the direction of the wire core's travel along the entry conveyor belt, 6 , and the exit conveyor belt, 90 . In order to maintain an open passageway into the baling station, 10 , for entry and exit of the wire core and carrying spool, the rest position of the tying head assemblies, 72 , is in the first position, perpendicular to the conveyor belt line of travel as in FIGS. 1, 2 and 3 . This position is also in operative alignment with the first pair of binding wire guide tracks 16 A and 40 A.
After depositing the wire core in the baling station, 10 , the extendible conveyor belt arms, 8 , are retracted. This allows space for rotation of the binding wire tying head bracket in an arc that will bring the tying head assemblies, 72 , into their second position, which is in operative engagement with the second pair of binding wire guide tracks, 16 B and 40 B, parallel to the conveyor belt line of travel.
Accordingly, after finishing the looping, tightening, cutting and tying of the first pair of binding wires around the wire core, the tying head bracket, 24 , rotates (in this embodiment in a counterclockwise direction from a perspective above the apparatus) in order to swing the tying head assemblies, 72 , into operative engagement with the second pair of binding wire guide tracks, 40 B and 16 B, in the second position as seen in FIG. 4 . After reaching operating engagement with the second pair of binding wire guide tracks 16 B and 40 B, the binding procedure for the second pair of binding wires is the same as that described for the first pair of binding wires, above. After the second pair of binding wires are looped, tightened, cut and knotted, the tying head bracket, 24 , counter rotates (clockwise in this embodiment) back to its original position. Rotation of the tying head bracket, 24 , is achieved by the action of rotation actuator arm, 62 , which extends to push top tying head bar, 24 , counterclockwise into its second position in alignment with the second pair of tying binding wire guide tracks, 40 B and 16 B. Thereafter rotation actuation arm, 62 , retracts to pull top bar, 54 , clockwise back into the first position, which is also the rest position, aligned with tracks 40 A and 16 A.
After all four binding wires have been tightened and tied around the wire core, the compression apparatus, 22 , is raised which allows wire core, 2 , to naturally expand, which expansion is immediately arrested by the binding wires, which now hold the wire core in its preferred compressed volume and shape.
It will be noted that in order for the binding wire to come into binding contact with the wire core after its tensioning and release from the binding wire guide tracks, the binding wire must have a free path to the core, uninterrupted by any pieces of the apparatus. Otherwise, any intervening apparatus piece would be bound to the core and the core could not be withdrawn from the apparatus. The four compression arms, 32 , and four compression plates, 34 , are separate from one another to provide a clear path to the wire core for the binding wire. As the binding wire is tensioned and drawn tight against the wire core it proceeds between each of the four compression plates, 34 . Likewise, the binding wire is raised up through the table, 12 , through the gaps 15 between the four quadrants 11 of the table's upper surface.
A novel aspect of the present invention is the design of the wire core collapsible carrying spool. It is integrated with the binding procedure and allows the wire core to be bound while on the carrying spool, having been previously deposited on the carrying spool. The collapsible carrying spool incorporates gaps in its base and stand layers, which gaps cooperatively align with the gaps in the top of the table, 12 , and likewise allow passage therethrough of the binding wire in order that the binding wire directly contacts the wire core, 2 , without binding in any unwanted parts of the apparatus, see FIGS. 7-11. The structure and the apparatus of the collapsible carrying spool are more fully described below.
After the binding wires have been tightened, knotted and cut, and after the tying head assemblies, 72 , have rotated back to their rest positions perpendicular to the conveyor belts and after the compression apparatus, 22 , has been lifted by extension of compressor apparatus lifting arms, 30 , an exit path from the binding station, 10 , is clear for removal of the wire core, 2 , and collapsible carrying spool, 4 . Accordingly, exit conveyor, 90 , extends conveyor arms, 92 , (See FIG. 3) into the binding station, 10 , where they operatively engage the collapsible carrier spool, 4 , in order to lift it from the binding table, 12 , and withdraw it from the binding station, 10 . Thereafter the combination of the bound wire core, 2 , and collapsible carrying spool, 4 , travel down exit conveyor, 90 , to a position where they may be handled and transferred. This cycle repeats.
It will be evident to those of skill in the relevant arts that objects other than wire cores may be bound in the manner described herein without departing from the scope of the present invention.
Collapsible Carrier Spool
FIGS. 7-11 depict the collapsible carrying spool of the present invention. It is expandable and contractible in a radial direction as seen in FIGS. 8 and 9. In its expanded position, the spool tightens against the inside of the wire core for secure handling. In its contracted position the spool loosens from the inside of the core and is easily removed from the wire core. The spool is also designed to cooperate with the compressing and binding apparatus during binding of the wire core, as previously described.
The collapsible carrying spool of the present invention is comprised of a plurality of expandable contact members, 100 , seen individually in FIG. 10 . In the herein described preferred embodiment, there are four contact members. Different numbers of contact members may be used. A vertical, expandable contact member is in the preferred embodiment a tube, although rods, bars, plates and the like may be used. Each expandable contact member, 100 , is fixedly attached at its lower end to a base plate, 102 . The base plate, 102 , is wedge-shaped in the presently described preferred embodiment, the wedge corresponding to 90°. The base plate shape may be square or other shapes, provided that the assembled base plates have gaps between them for the binding wires to be drawn through while a wire core is on the spool and in the binding apparatus. The expandable contact member also has an upper boss, 104 , and a lower boss, 106 , on its inner aspect, each boss having at least one through hole. In the depicted preferred embodiment, an upper portion of the expandable contact member is angled inwards in order to prevent it catching on wire being placed on it or removed.
FIG. 11 depicts the collapsible carrier spool central lifting member, 110 , which is coaxial with the wire core. Fixedly attached to the bottom of the axial, central lifting member, 110 , are four wedge-shaped stands, 112 . Radial supports, 114 , attach and strengthen the union between the stands, 112 and central lifting member, 110 . Along with separators, 116 , supports, 114 , comprise a platform on which base plates, 102 , may rest in one position while maintaining a vertical space between the base plates, 102 , and stands, 112 . Stands, 112 , like the base plates, 102 , are disposed such that a gap is maintained between adjacent stand members. The vertical contact members, 100 , and their base plates, 102 , will be disposed over the base stand members and in coordination with them such that the gaps between adjacent base plates, 102 , and stands, 112 , are parallel and aligned. The aligned gaps are a path through the spool for passage of a binding wire. In this manner, the gaps in the spool and table and the space between the compressor arms 32 form a path through the entire assembly through which a binding wire may be drawn tight against the wire core held by the spool. Gaps are apparent at 118 . In a preferred embodiment these gaps are also wide enough to accommodate passage therethrough of binding wire guide tracks, 16 A, 16 B, 40 A and 40 B. In the depicted embodiment, the gaps widen near the axial central member 110 to accept insertion of the inboard portion of the guide tracks.
The central lifting member, 110 , also has upper and lower bosses, 120 and 122 , also each having through holes. The central axial member also has a handle, 124 , for picking up the carrier spool and wire core with handling equipment such as fork trucks or lifting hooks.
Assembly of these components into the collapsible carrying spool is by means of eight expansion arms, seen in FIG. 7 . Each of the eight expansion arms, 130 A and 130 B, are pivotally attached to the through holes in bosses, 104 , 106 , 120 and 122 . Hence, the four upper expansion arms, 130 A, have an inner end with a through hole pivotally attached to central lift member upper boss, 120 , by means of a pin, bolt, rivet or other conventional pivoting fixation device. Each of the upper expansion arms, 130 A, are also pivotally attached through similar pivoting fixation devices to the vertical contact members' upper bosses, 104 . Similarly, lower expansion arms, 130 B are pivotally connected at their inner end to the central, axial lift member lower bosses, 122 , and pivotally connected at their outer end to vertical expansion member lower bosses, 106 .
The pivoting, actuate motion of the expansion arms, 130 A and 130 B, allow vertical contact members, 100 , to move upwards and inwards in relation to central lifting member, 110 , to reach a collapsed or contracted position. They also allow vertical members, 100 , to move downward and outward in relation to central lifting member, 110 , until their downward and outward motion is arrested by contact with supports, 114 , and stops, 116 , which is the expanded position.
It can be seen in FIGS. 8 and 9 that the upward motion of the vertical contact members, 100 , moves the contact members, 100 , closer together, narrowing their overall diameter as a group and taking them out of contact with a wire core inner surface. In this position the spool is “collapsed,” facilitating removal of the core from the spool. When the vertical contact members, 100 , are moved in a downward motion, the outward arcuate motion of the expansion arms, 130 , expand the overall radius of the group of the vertical contact members, bringing each of them in contact with the inner surface of a wire core disposed on the spool. In this expanded position, the core is tightly secured to the spool during handling.
Outward expansion of the vertical contact members is actuated by the normal force of the weight of the wire core in a downward motion against the base plates, 102 . The weight of the core may exert a force in combination with an opposite upward force on the central lifting member, 110 , which force is applied by any of a variety of handling machines such as fork trucks or lifting hooks, which are engaged by an operator with handle, 124 . Hence a secure, tight engagement with the wire core carried by the spool is directly established by the act of lifting the spool.
Correspondingly, the spool may be “collapsed” by a downward force on the central lifting member, 110 , or an upward lifting force on the base plates, 102 , or a combination of the two. The base plates, 102 , are separated vertically from the base stands, 112 , a sufficient distance for the forks of a fork truck to be inserted between them. This presents another option for transporting the wire core/spool assembly, or mounting the spool at a station where the wire core will be used. Station forks or lifting forks exerting upward pressure on base plates, 102 , will narrow the contract members, 100 , and loosen the wire core from the spool.
In view of the foregoing, it will be seen that the several advantages of the invention are achieved and attained.
The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention and various embodiments and with various modifications as are suited to the particular use contemplated.
As various modifications could be made in the constructions and method herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. For example, the apparatus and method of the present invention may be used to bind objects other than wire cores. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents. | An apparatus for binding a transportable wire core including a binding table comprised of sections in spaced relation sufficient to allow passage between them of a binding wire, and a collapsible carrying spool having base members being in spaced relation sufficient to allow passage between them of a binding wires. The spool is positionable on the table such that the base members of the spool and the sections of the table are aligned in operative cooperation. Guide tracks have first sections attached to the table and in operative alignment between the spool base members and the table sections. Guide track second sections are translatable between a removed position that allows a wire core on a spool to be positioned on the binding tables and an engaged position that operatively engages the binding wire guide track first sections. The second guide track sections operatively align between the sections of the table and the base members of the spool. A binding wire tying head loops binding wire around the wire core through the guide track sections, tensions the binding wire between the sections of the table and the spool and into direct contact with the wire core, and finally cuts the binding wire and knots it. | 1 |
This application is a continuation of application having Ser. No. 454,537 filed 12/30/82 now U.S. Pat. No. 4,476,788 which in turn is a continuation-in-part of application having Ser. No. 385,869 filed 6/7/82 now U.S. Pat. No. 4,480,370.
This invention relates to a heated railway tank car and more particularly to a heated tank car having the heat exchanger assembly provided therein.
BACKGROUND OF THE INVENTION
Railway tank cars are commonly used to transport liquid commodities that must be heated to enable the material to flow and unload through the bottom or top mounted discharge valve. At the present time, the material is heated by steam which passes through coils positioned on the exterior surface of the car or by coils which are positioned in the interior of the car. Typical of the prior art devices may be found in U.S. Pat. Nos. 2,145,614; 2,558,648; 2,772,784; 3,143,108; 3,176,764; 3,228,466; 3,595,307; and 3,685,458.
U.S. Pat. No. 2,145,614 discloses internal and external heating coils. U.S. Pat. No. 2,558,648 shows a heating coil secured exteriorly to a lower portion of a tank car. U.S. Pat. No. 2,772,784 describes the use of a cylindrical jacket encompassing the tank car for the purpose of applying heating from hot water flowing through the jacket. U.S. Pat. No. 3,142,108 shows a plurality of pans attached to the bottom portion of a truck trailer tank for supplying heat to the tank. U.S. Pat. No. 3,176,764 describes an integral-coil tank wall section associated with the lower portion of a tank car to transfer heat to the tank car. U.S. Pat. No. 3,228,466 shows an external heating arrangement for a storage tank. U.S. Pat. No. 3,595,307 shows another arrangement of a heating system disposed exteriorly of a tank car. Finally, U.S. Pat. No. 3,685,458 describes a heating assembly secured exteriorly to a bottom portion of a tank car.
It is apparent from the above-identified patents that there are large areas of the cars that are not subject to the heated steam and that the tank saddles and underframes attached to the bottom end of the tank act as large heat sinks which radiate heat out to the air rather than inwardly to the product. A problem also associated with the external and internal coils is that they are substantially horizontally disposed which makes them difficult to drain after the steam has been disconnected thereby causing freezing and corrosion and subsequent failure to the coils.
Still another problem associated with the prior art is that the material at the upper end of the tank is heated faster than the material at the bottom of the tank. The material at the upper portion of the tank is heated for longer than is desirable since the material will not begin to flow from the tank until the material around the discharge valve has been sufficiently heated to enable it to flow from the tank. Still another problem associated with the prior art devices is that a "boot" of material is formed in the bottom end of the car. The "boot" forms due to some commodity precipitants going to the bottom of the car due to heating and to lack of agitation. The "boot" also forms due to the heat sink effect of the steel attached to the tank at this particular location. The "boot" is the product remaining in the car after the car has been unloaded and the "boot" keeps building or accumulating thereby reducing the effective capacity of the car. At some time, the "boot" must be removed by chipping or other manual removal process.
Also, the prior art rail tank car using heated coils is not too suitable for the unloading of congealable, heat sensitive materials. Because of this, many problems have been incurred.
First, the quality of the many commodities has been affected due to over heating. On certain materials, overheating has caused the complete rejection of the commodity by the customer.
Second, heating by present methods has proven ineffective due to the problem of film buildup on the surfaces. This is caused by the settlin9 of solids to the bottom of the car during the heating process. If not removed, the baking of the product to the surface will greatly reduce heating efficiency. The boot upon heating can also cause corrosion of the bottom of the tank.
The third, and often overlooked problem, is contamination of new high quality material by burnt commodity or heel.
Fourth is the hazard which is presented to a person who must enter this enclosed environment to remove settled or burnt material.
The concept being proposed is the use of a heat system to be installed in the bottom of a tank car with sufficient slope to permit total drainage of the commodity. Such a system would concentrate the heat in the bottom of the car to obtain maximum transfer of heat at the bottom of the commodity (lading). The heated portion of the lading, as it rises through the lading causes the unheated portions of the lading to descend to the bottom to effectively cause mixing or rolling of the lading. Such thorough and uniform heating of the lading prepares the lading for faster unloading and prevents the lading being subjected to excessive heat which burns or caramelizes the lading. Also, the application of the heat at the bottom of the lading causes faster melting of the lading in and around the outlet valve
Heating efficiency is greater with the new system during unloading because the entire heating surface remains in contact with the lading during the unloading until the tank is almost empty. Coil cars lose heating efficiency through exposure of coils as the lading level drops in the car.
Initial tests indicate that the use of a heated exchanger in contact with the bottom of the lading improves heating efficiency. Data taken, using a series of probes located in tank cars, with readings taken every five minutes, proved that the improved heat system gave uniform heating of the contents. It was noted during the tests that a rolling action occurred during the heating process, and the lading turned, allowing mixing of the hot and cold portions.
In the tests, an external coil tank car and a plate (novel heat exchanger) tank car of equal capacity were used. Temperature probes were installed 6", 24", and 42" above the bottom of each tank car at the center. The boiler pressure was maintained at 76 to 80 PSI and the condensate was monitored for volume and termperature. In the coil tank car, the condensate flow was 3 gallons per minute with temperatures of the condensate reading 70° F. or less for the first 1 and 1/2 hours, and then rising to a final temperature of 90° F. In the plate tank car, the same procedure was followed as for the coil tank car, but the condensate temperature rose rapidly to 135° F. and held at a steady pace, requiring less than half of the previous time.
The temperatures in the coil tank car rose rapidly in the top portions of the lading when compared with the temperatures at the bottom portion of the lading. This heat layering was noted and monitored after 2 hours of heating, at which time, rolling or mixing action was noted. To determine this rolling action, dye was periodically added to both cars. The plate tank car showed rapid movement of the lading due to the concentration of the heat at the bottom of the car, while the coil tank car showed very slow mixing. The lading in both of the tank cars consisted of water.
Another test was run on the plate tank car only. The test was conducted using an animal fat (congealed). The heat exchanger heated the fat rapidly, then, as the rolling action started, the temperature dropped off and paralleled the temperature rise of the lading. It was noted that the valve outlet area temperature rose rapidly. This is important, for the faster the valve temperature rises, liquifying the lading in this area, the quicker the unloading can begin.
In another test, a plate tank car was filled with blackstrap molasses, which weighs 11.5 pounds per gallon. In 5 minutes, the heat system was raised to a temperature of 80° F., and the temperature around the valve outlet was at 59° F. The temperature of the molasses rose evenly throughout and there were no layers of heat in the molasses, as usually happens in present coil tank cars, wherein there is a hot layer of lading at the top and a cold layer of the lading at the bottom. The plate car was then ready to be unloaded in 15 minutes after application of the heat. After the pumping was completed, there was no molasses left in the tank car, and the lading that was removed was tested. None of this lading was burned (caramelized), which is common in high sugar products in present coil tank cars.
Thus, it can be seen that the invention accomplishes at least all of the stated objectives, which are more specifically reiterated hereinbelow:
Since units of the heat exchanger are sloped, substantially all of the condensate is drained out and the heat exchanger is not subject to any freezing.
Since the lading is substantially resting on top of the heat exchanger which applies heat over a large area of the lading, no air pockets or hot spots occur as they do in an external coil prior art tank car.
A tank car using the inventive heat exchanger, as opposed to the prior art external coil tank car, unloads much faster than the coil tank car in winter.
No cooking of the lading occurs because the heat exchanger applies uniform heat over a large area of the lading.
Approximately 4/5ths to 5/6ths of the subject tank car is empty before any portion of the heat system (heat exchange units) is exposed to the atmosphere in the tank, as opposed to the prior art internal pipe coils and external coils which are completely exposed when the tank car is 7/8ths empty. Therefore, the inventive heat system continues to be in contact with the lading and heat the lading, keeping it fluid until the tank car is empty.
The pitch of each heat exchanger unit of almost 1:12 (8% grade) assures a complete unloading and prevents material buildup.
All of the heat is at the bottom of the tank car, and as the heat rises, the tank car will unload much faster, saving BTU (British Thermal Units) costs. The side coils on an external coil car do not do much good because the heat goes about 8 inches into the lading and goes through commodity to the top of the tank car. Also coils at sides of car are closer to top of car and overheat the top of the car.
By positioning the heating system off the floor of the tank car, heat sinks caused by the tank cradles, body bolsters, and trucks are non-existent or eliminated.
External coils on a coil car are positioned or spaced from one another a minimum of 6 inches between the welded positions which cause a lot of dead spots between the coils and such coils are spaced even farther apart on the bottom of the car in order to miss the stub sills and body webbing, as opposed to the inventive heat system which provides a solid (i.e. substantially continuous) heating surface at the bottom of the tank car.
In view of the flow arrangement in the heat exchanger, there is no need to steam jacket the outlet valve.
Because of the slope possessed by each unit of the heat exchanger and the rolling action of lading caused by the heating action and the slope of the heat exchanger, there is no corrosion or product buildup, as opposed to the formation of a boot in an external coil tank car, which boot cuts down on the efficiency of heat transfer on the bottom coils of the tank car and which acts as an undesirable heat insulator.
The application of heat at the bottom of the lading creates internal circulation commencing at the bottom, then upwardly through the lading, causing the cool portions of the lading to move downwardly towards the bottom, thereby creating a rolling or mixing action, resulting in a faster and uniform heating of the lading.
Since the present heating system uniformly heats the lading, the temperatures of the heating medium need not be excessive, thereby avoiding damage to plastic linings used within the tank cars, as would occur in a coil tank car.
Further, in a modified form of the invention, heat exchanger is provided with appropriate ports for the immediate purging of any condensate forming in the heat exchanger. The foregoing avoids a buildup of the condensate which opposes the introduction of the pressurized heating medium. Also such condensate buildup saps the incoming heat so that it is revaporized. In cold weather, the buildup of condensate forms a liquid plug which has to be bodily moved forward by the incoming heating medium, thereby requiring an increase in the pressure of the incoming heating medium.
Therefore, it is a principal object of the invention to provide an improved heated tank car.
A further object of the invention is to provide a heated tank car having a heat exchanger provided in the interior thereof with the heat exchanger being insulatingly spaced above the bottom of the tank to achieve a more efficient and uniform heating of the material.
A still further object of the invention is to provide a heated tank car which eliminates the heat sink problems normally associated with conventional heated tank cars.
Still another object of the invention is to provide a heat exchanger for a tank car which is sloped towards the middle of the car so that condensate will drain from the heat exchanger thereby reducing corrosion of the heat exchanger.
Still another object of the invention is to provide a heated tank car which prevents the formation of a "boot" at the bottom of the car.
A further object of the invention is to provide drainage means in the heat exchanger for purging any heating medium condensate that may form within the heat exchanger.
Still another object of the invention is to provide a heated tank car employing an inclined heat exchanger therein to assist the flow of material to the discharge valve of the car.
These and other objects will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan longitudinal sectional view of the tank car and heat exchanger therein:
FIG. 2 is a partial side longitudinal sectional view of the car and heat exchanger:
FIG. 3 is an enlarged sectional view taken on lines 3--3 of FIG. 1:
FIG. 4 is an enlarged sectional view taken on lines 4--4 of FIG. 1:
FIG. 5 is an enlarged sectional view taken on lines 5--5 of FIG. 4:
FIG. 6 is an enlarged sectional view taken on lines 6--6 of FIG. 1;
FIG. 7 is a plan longitudinal partial sectional view of a tank car equipped with a modified heat exchanger therein:
FIG. 8 is an enlarged sectional view taken on lines 8--8 of FIG. 7;
FIG. 9 is an enlarged sectional view of a further embodiment of the heat exchanger: and
FIG. 10 is an enlarged partial sectional view of a still further embodiment of the heat exchanger;
FIG. 11 is another embodiment of the heat exchanger utilizing two heating units, one above and one below;
FIG. 12 is an embodiment similar to that shown in FIG. 11 except that the upper heating unit is disposed exteriorly of the tank;
FIG. 13 is an embodiment using a pair of heating units for heating a tank car provided with additional dead air spaces; and
FIG. 14 is a further embodiment of a heat exchanger wherein a heating unit is secured directly to the inside of the tank car, without using brackets.
SUMMARY OF THE INVENTION
A heated tank car is disclosed which has a heat exchanger means positioned therein above the bottom of the tank. The heat exchanger comprises a pair of heat exchanger units which are secured to and supported by the ends and side walls of the tank and which extend downwardly from the ends of the tank towards the center of the tank. Each of the heat exchanger units comprises spaced-apart top and bottom walls or plates which have a plurality of spaced-apart baffle plates secured thereto and extending therebetween to define a plurality of baffles or passageways within the heat exchanger. An inlet valve or pipe is in communication with the inner end of each of the heat exchanger units with the baffle plates being arranged so that heated water or steam is directed back and forth through the heat exchanger for subsequent discharge through the heat exchanger for subsequent discharge through a discharge pipe or valve extending downwardly from the heat exchanger unit through the tank car. The peripheries of the heat exchanger units are supported by and secured to the side walls and end of the tank so that a sealed compartment or dead air space is created below the heat exchanger thereby reducing the heat sink effect of the tank saddles and under frames attached to the tank. To further accelerate the heating of the lading, additional heating units may be disposed adjacent the top of the tank so that the lading is sandwiched between opposed heating units. The heat exchanger means may be provided with drainage parts communicating between the passageways and the discharge pipe for purging heating medium condensate that may form during the heating of the tank car.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The numeral 10 refers to a conventional railway tank car comprising a wheeled support 12 of conventional design. Storage container or tank 14 is mounted on the frame 12 by conventional means such as by tank saddles 16. Tank 14 generally has a cylindrical configuration although the bottom 18 of the tank 14 slopes inwardly from the ends of tank heads 20 and 22 towards a discharge valve assembly 26. It is to this conventional tank car structure that the heat exchanger of this invention is mounted and which will be referred to generally by the reference numeral 28.
Heat exchanger 28 comprises heat exchanger units 30 and 30' which are identical except for being mirror images of each other. Inasmuch as units 30 and 30' are identical, only unit 30 will be described in detail with "'" being indicated on unit 30' to indicate identical structure.
Heat exchanger unit 30 comprises arcuate top and bottom plates 32 and 34 having a plurality of baffle plates 36 secured thereto and extending therebetween as best illustrated in FIG. 1 to create a plurality of passageways 38 therebetween. The peripheries of plates 32 and 34 (FIG. 3) are secured together and sealed by a wall member 40 extending therearound and define therewith a heat exchanger medium containing chamber 43. As seen in FIG. 1, the inner end of wall 40 is curved at 41 so as to conform to the configuration of the upper end of the discharge valve 26. The numeral 42 refers to an inlet extending upwardly through the bottom of the tank 14 and in communication with the interior of the heat exchanger as best seen in FIGS. 2 and 3. Outlet 44 also extends upwardly through the bottom of the tank 14 and is in communication with the interior of the heat exchanger as illustrated in FIG. 2.
More specifically, the heat exchanger unit 30 is defined as follows.
The heat exchanger outer wall 40 has a curved outer end portion 40a, 40a', a flat inner end portion 40b, 40b' with a curved tank outlet surrounding portion 40c, 40c' (FIG.1), and longitudinally extending flat side portions 40e and 40f that diverge inwardly toward one another.
The baffle plates 36 include U-shaped outer baffle plate member 33 surrounded by wall 40 and having outer longitudinally extending legs 33a, 33db that diverge outwardly from one another, the outer ends 33c of legs 33a, 33b being spaced away from curved end portion 40a; and laterally extending inner end portion 33d that has a central curved portion 33e going around part of the tank drain 26 and having U-shaped outwardly directed bight portion 33f surrounding the inlet 42.
The baffle means further includes longitudinally elongated fins or plates 35, 35 adjacent wall portion 40b and connecting with the curved portion 40a and extending short off the inner end portion 33d; a hairpin shaped longitudinally entending central baffle plate 37 having outwardly diverging leg portions 37a, 37a ending short of the outer curved portion 40a and inner curved end portion 37b curved around part of heat exchanger outlet 44; and a shortened central plate 39 that extends in slightly between leg portions 37a, 37a.
The heat exchanger 32 has the same baffle construction and need not be described further.
The numerals 46 and 48 (FIG. 1) refer to tubing provided at the upper surface of the bottom plate 34 to assist in draining the condensate in the heat exchanger unit toward the outlet or discharge 44. The baffles 36 are provided with openings 49 at the tubes 46 and 48 to enable the condensate in the passageways to flow through the baffle plates so that the condensate is discharged closely adjacent the outlet 44.
Bars 50 and 52 are welded to the interior surface of the sides of the tank as seen in FIG. 3. Bars or brackets 54 and 56 are secured to the sides of the heat exchanger unit 30 and are welded to the bars 50 and 52 respectively. Bar or bracket 54 or 56 is also secured to the outer ends of the heat exchanger unit 30 and is welded to the bar 50 or 52 on the interior surface of the tank head end 20 or 22.
The conventional tank car 10 may be converted to the heated tank car of this invention by first removing a portion of all of the ends or heads 20 and 22. Preferably, the bars 50 and 52 would then be welded to the interior surfaces of the side walls of the tank. The heat exchanger units 30 and 30' are then inserted into the interior of the tank so that the brackets 54 and 56 rest upon the bars 50 and 52 respectively and so that the inner end of the units are positioned adjacent the discharge valve 26. The tank bottom 18 would have been previously cut away to provide the inlets and outlets of the heat exchanger to extend downwardly through the bottom 18 of the car. The heads 20 and 22 are then replaced in conventional fashion with brackets 54 and 56 then being welded in a continuous fashion to the interior surfaces of tank heads. The new brackets 54 and 56 are also welded to the bars 50 and 52. Preferably, the inner ends of the heat exchanger units would also be welded together so that a sealed compartment or dead air space 60 is created below the heat exchanger and the bottom 18.
In use, assuming that the car contained a liquid commodity, steam or hot water would be connected to the inlets 42 and 42'. The incoming steam passes around the discharge valve 26 and then travels in the paths defined by the arrows in FIG. 1 for subsequent discharge through the outlets 44 and 44'. Heating of the material (lading) by the heat exchanger would initially cause the material in contact with the heat exchanger to flow towards the discharge valve 26 assisted by the weight of the material on top. This method of heating the lading eliminates part of the material being overheated awaiting for the material to start flowing downwardly through the discharge valve. The provision of the space 60 between the heat exchanger and the bottom of the tank prevents the undercarriage and saddles of the car from acting as heat sinks so that a much more efficient heating of the lading is obtained. The fact that the heat exchanger slopes towards the discharge valve assists the flow of material to the discharge valve 26.
Thus it can be seen that a novel heated tank car has been provided which provides a more efficient heating of the lading and which eliminates the formation of a "boot" of material at the bottom of the car. It can also be seen that the sloping of the heat exchanger unit and the elements 46 and 48 aid in the prevention of condensate accumulating in the heat exchanger thereby eliminating the serious problem of corrosion normally associated with prior art devices.
A further feature of the invention lies in the elimination of the heating medium condensate which forms inside the heat exchanger during the process of heating the lading in the tank car. The foregoing feature is illustrated with the following embodiment of the heat exchanger illustrated in FIGS. 7 and 8.
Within a tank 114, there is mounted a heat exchanger 128 comprising a pair of heat exchange units 130, 130. Since both units are identical in construction, only the left portion of the tank 114 is shown supporting one of the heat exchange units 130, 130. Since the heat exchanger 128 is supported in the same manner as the heat exchanger unit 28 described in reference to FIGS. 1-6, there is no necessity for describing the support structure.
The heat exchanger unit 130 comprises arcuate top and bottom plates 132 and 134 supporting therebetween a plurality of channels 135 and 137 as defined by baffle means in the form of a corrugated member 139 interposed between the top and bottom arcuate plates 132 and 134. It will be noted, as viewed in FIG. 8, that the channels do not possess equal cross-sectional areas. For example, the channel 135 is smaller than the channel 137, the smaller channels 135 functioning to direct a heating medium (steam) upwardly from an inlet 142 toward a tank head 120 and the larger channel 137 directing the heating medium (steam) downwardly toward outlet 144.
Referring particularly to FIG. 7, the heating medium such as steam entering the heat exchanger means 128 through the inlet 142 progresses upwardly through the narrow channel 135 until it reaches heater exchanger curved end portion 140a, at which time, the steam subdivides into two portions which flow along a pair of wide channels 137, 137 until the steam portions reach a minor manifold 141 which directs the steam into narrow channels 135a, 135a. The steam upon reaching the curved end portion 140a, is redirected thereby into wide channels 137a, 137a, the steam continuing on its way until it meets an inner wall 143 which redirects the steam into narrow channels 135b. Thereafter, the steam, after it leaves the channels 135b, impinges on the curved end portion 140a which redirects the steam along the wide channels 137b, the steam finally completing its passage in a main manifold 145 communicating with the atmosphere through an outlet 144. In the alternative, the exiting steam may reenter a reheating chamber in the steam apparatus (not shown) generating the steam.
As was previously described in reference to the first embodiment shown in FIGS. 1-6, application of heat at the bottom of the lading will develop a rolling or a circulating flow in the lading as heat continues to be imparted to the lading. That is, the heated portion of the lading, as it rises through the lading causes the unheated portions of the lading to descend to the bottom to effectively cause mixing or rolling of the lading. Such thorough and uniform heating of the lading prepares the lading for faster unloading and prevents the lading being subjected to excessive heat which burns or carmellizes the lading. Similar circulation of lading occurs in the embodiment shown in FIGS. 7 and 8.
To increase the heating and the flow movements of the lading, the heat exchanger 128 is provided with feeder lines 147, 149, and 151. The flaring out of the passages lines as they proceed out to ends of the tank, also enhances flow movements of the steam and condensate and increases faster heating of the lading. These feeder lines communicate between the narrow channel 135 and the wide channels 137b, thereby permitting a portion of the steam entering the channel 135 to be directed outwardly into the outermost channels 137b to provide steam quickly for quick heating of the extremities of the heat exchanger with steam to assist in purging the heat exchanger with steam and more quickly warm up the lading. To further increase the heating and the flow movements of the lading, the heat exchanger 128 may be provided with additional feeder lines 147a and 147b, as shown particularly in FIG. 7. The additional feeder lines 14a and 147b interconnect between the channel 135 and the channels 135a to thereaby direct a portion of the steam flowing in the channel 135 to the channels 135a.
Referring still to FIG. 7, any condensate that forms in channels 137a and 135b will flow downwardly toward the inner wall 143 and pass through an internal drainage port 153 into the minor manifold 141 to join with additional condensate which is formed in channels 137 and 135a, which additional condensate also flows towards the inner wall 143, and then finally exits through an external drainage port 155 which communicates with the outlet 144. As is apparent, the drainage provides removal of the condensate during application of the steam and adequate gravity drainage of the exchanger after the tank car has been emptied. Any condensate formed in central channel 135 flows downward below the steam moving upstream and out drainage port 142 and through port 155 to outlet 144.
The corrugated member 139, as shown in FIG. 8, is secured to the top arcuate plate 132 and the bottom arcuate plate 134 by appropriate manner, such as welding. This ensures that there is no transverse heating medium flow between adjoining channels 135 and 137.
The feeder lines 147, 149, 151, 147a and 147b, may be arranged to pass through the walls forming the various channels. However, in the preferred arrangement, the various feeder lines do not pass through the walls of the channels, but are disposed exteriorly of the channels. Referring to FIG. 8, the feeder lines, for example, feeder lines 147a, are secured exteriorly of the heat exchanger 128 by being secured underneath the bottom arcuate plate 134. The particular feeder lines 147a extend between and communicate with the channels 135 and 135b.
From the arrangement shown in FIGS. 7 & 8 it is seen that the steam coming into the inlet and going up the central passage and then along the side passages the heat exchanger permits any condensate water that is formed to roll down well below the steam and by this technique the steam can quickly get to the steam exiting at the bottom of the tank without having to push any water or condensate out through the passageways and therefore permit a fast purging of the heat exchanging system.
Although the embodiment disclosed in FIG. 8 uses a corrugated member 139 to define a plurality of different size channels, it is apparent that other arrangements may be employed for creating the channels. For example, as shown in FIG. 9, a heat exchanger 228 comprises baffle means having a plurality of spaced narrow channels 235 which are defined by a series of longitudinal half-oval members 235a secured to a top arcuate plate 232 and a bottom arcuate plate 234 and a plurality of wide channels 237 defined by the spaces between adjoining half-oval members 235a. Since the half-oval members 235a do not provide sufficient rigidity to the heat exchanger 228, a pair of longitudinal bars 259 are secured between the top and bottom arcuate plates 232 and 234, respectively. The longitudinal bars 259, in conjunction with adjacent half-oval members 235a, define a pair of channels 235b adjacent each of said longitudinal bars 159. The arrangement of the spacing of the narrow channels 235 conducting the steam in an upward directions, and the wide channels 237 directing the steam on its return path in a downwardly direction is the same as was described in reference to the embodiment shown in FIGS. 7 and 8. For example, as shown in FIG. 9, the narrow channels 235 formed by the half-oval members 235a, are separated by the wide channels 237 established between the top arcuate plate 232 and the bottom arcuate plate 234 and the adjoining half-oval members 235a, or by the wide channels 235b established between the top arcuate plate 232 and the bottom arcuate plate 234 and the longitudinal bars 259. From the foregoing example, it is obvious that other arrangements may be employed for defining the channels between the top and bottom arcuate plates 232 and 234, respectively.
A number of feeder lines, such as feeder line 251, interconnect the innermost channel with outermost channels to direct a portion of the steam to the outer boundaries of the heat exchanger 228. The remaining structural details of the embodiment shown in FIG. 9 are the same as those in connection with the embodiment described in FIGS. 7 and 8. In other words, the arrangement of the inlet, outlet and drainage ports would be the same.
FIG. 10 shows a modified structure of a heat exchanger means 328 having a plurality of channels or passageways 338 defined by longitudinal arcuate members 335 adjoining each other and secured to an arcuate plate 332.
A number of feeder lines, such as feeder line 351, interconnect the innermost channel with the outermost channels to direct a portion of the steam to the outer boundaries of the heat exchanger 328.
FIG. 11 shows another modified structure of a heat exchanger means wherein heat exchanger 428 comprises a pair of heat exchanger units 430a and 430b, oppositely disposed with respect to each other to apply heat to the lading between said heat exchanger units. As described in reference to the preceding embodiments, the heat exchanger units are insulated from the wall of the tank 414 by dead air spaces 460a and 460b. Some of the channels are interconnected by feeder lines 447, as previously described in reference to the embodiment shown in FIG. 7.
FIG. 12 shows a still further modification of a heat exchanger means 528 having a pair of heat exchanger units 530a and 530b adapted to impart heat to a lading inside the tank 514. The heat exchanger unit 530a is similar to the heat exchanger units previously described. The heat exchanger unit 530b comprises a series of tubes arranged in serpentine fashion on top of the tank 514. The arrangement of the two heat exchanger units 530a and 530b imparts heat to the lading disposed between these heat exchanger units. Some of the channels in the heat exchanger units 530a, 530b are interconnected by feeder lines 557. The heat exchanger unit 530b can be permanently mounted on top of the tank 514 for heating lading, such as sulfur, requiring a large input of heat for liquefacation purposes. Alternatively, the heat exchanger unit 530b may be a portable unit which can be placed atop the tank 514, as the occasion demands.
The embodiment illustrated in FIG. 13 is secured within a tank 628 which has been provided with additional dead air spaces 660c as defined by upstanding walls 661. These additional dead air spaces 660c cooperate with dead air spaces 660a, 660b to increase heat transfer from heating units 630a, 630b to the lading in the tank 614. As in the preceding embodiments, feeder lines such as feeder lines 647 interconnect some of the channels in the heating units.
FIG. 14 shows another way of securing a heat exchanger unit 730a to a tank 714. Instead of using intermediate members for securing the heat exchanger unit to the tank, the intermediate members comprising brackets 54, 56 and bars 50, 52, as shown in FIG. 3, these intermediate members can be eliminated by securing the heat exchanger units 730a directly to the tank 714 by appropriate manner such as a continuous welding bead 730c which secures the outer periphery of the heating unit to the tank 714.
This invention, as described, should not be restricted to the precise details of construction shown, since various changes and modifications may be made therein without departing from the scope of the invention or sacrificing the advantages to be derived from its use. | A heated tank such as in a railroad tank car has a heat exchanger spaced from the bottom of the car to define a dead air space to insulate the heat exchanger from the bottom. The heat exchanger extends substantially longitudinally and transversely across the entire bottom of the car to provide a large heating transfer surface to the lading supported by the exchanger. A portion of the exchanger substantially encompasses a discharge valve of the tank car to provide heat transfer to the valve during unloading. The heat exchanger slopes toward the discharge valve to facilitate total removal of the lading. An inlet and an outlet associated with the heat exchanger are disposed adjacent the discharge valve for additional transfer of heat to the discharge valve. Baffles in the heat exchanger define a plurality of serpentine passages for conducting a heating medium. Feeder lines interconnect a central passage with outermost passages for introducing a portion of the heating medium in the outlying passages to obtain more uniform heating across the surface of the heat exchanger. The feeder lines serve to return a portion of the condensate to the central passage to avoid build-up of the condensate. A modified heat exchanger also includes a series of ports at a downwardly sloped end for purging condensate forming in the passages. The purged condensate is discharged through an outlet which is situated away from the inlet so as not to sap incoming heat. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a kitchen ventilator for removing air laden with grease, smoke, fumes and moisture rising from various types of cooking units.
In a restaurant kitchen, for example, there are usually a number of cooking units lined up side by side in a row. Some of these cooking units such as broilers and fryers produce considerable quantities of smoke, fumes, grease particles and moisture while other units such as ranges and griddles generate such pollutants in considerably less amounts. Kitchen ventilators have heretofore been designed with sufficient air flow capacity to remove the smoke, fumes, grease and moisture from the most active of the pollution generating cooking units such as the broilers and fryers. This results in excess and unnecessary ventilation for those cooking units generating less pollution such as the ranges and the griddles.
Such excess ventilation is wasteful of energy in two ways. First, an excessive flow of air must be handled by the exhaust fan, thus requiring a larger fan motor which consumes more electrical energy than necessary. Second, the excess air withdrawn from the kitchen is replaced, at least in part, by air from the dining room and other parts of the restaurant. In cold weather this produces a heat loss in the dining room and other parts of the restaurant which must be compensated by the central heating system. In hot weather an excess of cool air is withdrawn from the dining room, increasing the load on the air conditioning system and again requiring additional electric power to maintain a comfortable temperature in the dining room.
Objects of the present invention are therefore to provide a kitchen ventilator which does not remove an excessive volume of air from the atmosphere over cooking units which do not generate large quantities of smoke, fumes, grease particles and moisture, to provide a kitchen ventilator having supplemental inlet throat choke means to reduce the airflow over such cooking units and to provide such choke means as attachments to be applied to appropriate parts of the ventilator without reducing the airflow to other parts of the ventilator which must be capable of exhausting large quantities of such pollutants.
SUMMARY OF THE INVENTION
In the present construction supplemental inlet throat choke attachments are provided to reduce or throttle the flow of air through portions of the ventilator where the maximum available rate of air removal is not required to remove the pollutants generated by the associated cooking units. One such attachments is mounted on the outer face of a damper baffle which is hinged to the upper boundary of the inlet throat opening of the ventilator. This attachment protrudes toward the front edge of a grease trough which forms the lower boundary of the inlet throat opening whereby the width of the inlet opening is reduced by the protrusion of the attachment.
In open position the damper baffle is inclined downward and rearward toward a back wall of the ventilator. A second attachment on the back wall protrudes forward toward the lower edge of the damper baffle in open position to form a second throat choke or throttle where the incoming air enters the grease extractor portion of the ventilator. A third attachment is applied to extend an upper baffle in the grease extractor.
In the usual installation one or more such damper baffles are associated with a common grease trough in the manner described to form an inlet throat opening extending above a row of the various cooking units. The inlet throat choke attachments are applied only in the region of those cooking units which produce a relatively small volume of smoke, fumes, grease, and moisture to restrict the airflow in this portion of the ventilator. By the use of such attachments the main parts of the ventilator may be of uniform standarized construction and the cost of manufacture and installation is not increased by reason of the different airflow characteristics of different parts of the ventilator. A single ventilator is made to function as two separate ventilators having different characteristics.
The invention will be better understood and the foregoing and other objects and advantages will become apparent from the following description of the preferred embodiment illustrated in the accompanying drawings. Various modifications may be made in the construction and arrangement of parts and certain features may be used without others. All such modifications within the scope of the appended claims are included in the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a kitchen ventilator embodying the invention.
FIG. 2 is a perspective view with parts broken away.
FIG. 3 is a view on the line 3--3 in FIG. 1.
FIG. 4 is a view on the line 4--4 in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, the present kitchen ventilator 10 is mounted over a row of typical cooking units some of which generate large quantities of smoke, fumes, grease particles and moisture and others of which generate much less of such pollutants and may be referred to as less contaminating. The more polluting units such as broiler 11 and fryer 12 are positioned at one end of the row and the less polluting units such a range 13 and griddle 14 are positioned at the other end of the row. This row of cooking units may be backed up against a wall of the kitchen or they may be placed in an island arrangement at a distance from any wall.
The purpose of ventilator 10 is to capture the smoke, fumes, grease and moisture generated by the cooking units and remove these pollutants from the kitchen to maintain a comfortable working atmosphere in the kitchen and also to prevent the dispersal of such pollutants into the dining room and other parts of the restaurant. In order to remove the pollutants a considerable quantity of air must be removed from the kitchen.
Heretofore the air removal capability of such ventilators has been uniform along of the length of the row of cooking units. In order to provide sufficient air removal capability or capacity with a single ventilator over the high pollution units such as the broiler and fryer a considerable excess of air was removed over the low polluting units such as the range and griddle. As previously pointed out this was wasteful of energy both from the standpoint of excess capacity in the ventilator itself and from the standpoint of the extra heating or cooling required in the dining room and other parts of the restaurant to compensate for the air removed by the kitchen ventilator.
In the present ventilator greater economy is achieved by reducing or eliminating excess air removal from the kitchen over the low polluting range and griddle units. The particular advantage of the present form of construction is that this desirable result is accomplished by the mere addition of simple attachments to one section of the ventilator without sacrificing economy of construction obtained by a single ventilator unit which is uniform in design and dimensions over the whole length of the row of cooking units. The attachments convert a single ventilator into the equivalent of two separate and different ventilators.
A damper baffle 30 is mounted on a horizontal pivot 31 at the upper boundary of inlet throat opening 22. Extending upward from damper baffle 30 the front wall of the ventilator comprises removable panels 32 having handle latching means 33. Air entering inlet opening 22 is drawn upward through a grease extractor between panels 32 and backwall 24 into a suction chamber 35 from whence it is removed by an exhaust duct 36 containing an exhaust fan and fire damper (not shown).
The grease extractor comprises upper and lower horizontal baffles 40 and 41 projecting forward from backwall 24 and a baffle 42 projecting rearward from each of the two front panels 32 at a level between backwall baffles 40 and 41. Baffles 40 and 41 are equipped with cleaning and fire extinguishing nozzles 43 supplied by water or steam pipes 44 incorporated in the baffles.
Damper baffle 30 is also a grease extracting baffle in its open position shown in solid lines in FIG. 3. In open position the damper baffle 30 projects downward and rearward beneath baffle 41 to form a second throat opening at 45 of approximately the same width as inlet throat opening 22. This baffle arrangement produces sharp reversals in the direction of flow of the grease laden airstream to extract grease particles by centrifugal force at each reversal of direction of flow. A flange 46 on the lower edge of damper baffle 30 provides a grease gutter to convey extracted grease to one end of the damper baffle so that it will not drip through the rising airstream at random points and be recaptured by the air stream. Flange 46 terminates just short of the ends of the damper baffle to provide drain openings out of the main flow of the air stream.
Damper baffle 30 pivots to a closed position shown in broken lines at 30A engaging the underside of baffle 41 to close the throat opening 45. Damper baffle 30 is closed automatically in case of fire by the control mechanism 50 in FIGS. 1 and 2 which has a manual reset knob 51 for opening the damper baffle. The automatic closing in response to fire is actuated by thermostats 52 in FIGS. 3 and 4 as explained in the Gaylord U.S. Pat. No. 3,055,285. Control mechanism 50 also causes fire quenching steam or water to be discharged from nozzles 43. Such control mechanism may also include means for using nozzles 43 in washing cycles to wash grease from the grease extracting baffles.
Grease trough 20, inlet opening 22 and damper baffle 30 extend the entire length of the ventilator over all of the cooking units 11-14. FIG. 4 illustrates two attachments 60 and 61 which are applied to reduce the rate of air flow into the ventilator over the less polluting range and griddle units 13 and 14. Attachment 60 is an elongated angle plate of L-shape in cross section mounted on the upper portion of the front face of damper baffle 30 to protrude toward front edge 21 of grease trough 20 and reduce the width of the inlet opening as indicated at 22A. Attachment 60 thus acts as a throttle or choke in the inlet throat opening.
The lower edge of angle plate 60 is attached to the damper baffle by screws 62 and the upper edge is attached by spot welds or other suitable means. Attachment 60 is readily removable by removing screws 62 and burning off the spot welds.
Attachment 61 is an L-shaped angle plate which projects forward from back wall 24 toward the lower edge of damper baffle 30 in open position to reduce the width of the opening at this point as indicated at 45A in FIG. 4. Thus the attachment 61 acts as a second throttle or choke restricting the inlet flow into the ventilator. The lower edge of angle plate 61 is supported by upstanding lips 65 on back wall 24 and the upper edge is attached by screws 66. This attachment is removable by merely removing the screws 66.
A third flat plate attachment 63 is secured to baffle 42 by screws 64 to extend this baffle closer to backwall 24 and maintain adequate air velocity in the sharp turn of the upward flowing air stream around this baffle for effective centrifugal grease extraction.
It is found in practice that the angle plates or chokes 60 and 61 do not change the velocity of the air in the inlet opening 22A whereby this velocity remains adequate to withdraw the contaminated air over the range 13 and griddle 14 without allowing such air to escape into the kitchen. In other words the velocity of flow through openings 22A and 45A in FIG. 4 is the same as the velocity through openings 22 and 45 in FIG. 3.
As shown in FIG. 4 the angle plate chokes 60 and 61 and flat plate choke 63 reduce the width of the respective openings at these points by approximately one half whereby the volume of air withdrawn from the kitchen per minute over the range and griddle units 13 and 14 is only one half that withdrawn from the kitchen over the broiler and fryer units 11 and 12, per linear foot of inlet opening. This materially reduces the load on the exhaust fan of the ventilator and correspondingly reduces the load on the dining room heating or cooling sysem which must replace the heated or cooled air removed by the kitchen ventilator.
At the same time the attachments 61 and 63 maintain undimished velocity at these two points of sharp reversal in the direction of air flow so that the reduction in volume of air does not reduce the effectiveness of the grease extractor.
The invention is not limited to the particular volume ratio expressed above; this is determined by the polluting effects of the low pollution cooking units in relation to the polluting effects of the high pollution cooking units in a particular installation.
The attachments 60, 61 and 63 are fabricated in strips of indefinie length and then cut to a length corresponding to the combined width of the low polluting cooking units 13 and 14. As shown, these attachments are associated with the same damper baffle 30, and corresponding baffle 42, that extend over the higher pollution cooking units 11 and 12. In kitchens having a longer row of cooking units there may be more than one damper baffle 30 and more than two baffles 42 and in such case the length of attachments 60, 61 and 63 is made to correspond to the combined width of the low polluting cooking units regardless of the number of damper baffles 30 and baffles 42 involved.
If the kitchen is rearranged to put the high polluting cooking units on the right and low polluting cooking units on the left in FIG. 1, the present attachments are readily adaptable to such change by merely removing them from the right end of the ventilator and attaching them to the left end. | Choke attachments are applied to that portion of the inlet of the ventilator serving low pollution cooking units in a row of various types of cooking units in a restaurant kitchen. This reduces the rate of air removal from the kitchen, and in most cases also the rate of air removal from an adjoining dining room, to conserve energy without impairing the efficiency of the ventilator. | 5 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates in general to optical systems for projecting an image of a mask on a substrate in laser material processing applications. The invention relates in particular to methods and apparatus for uniformly illuminating the mask.
DISCUSSION OF BACKGROUND ART
In laser material processing applications, such as crystallization, annealing, or nozzle drilling systems, a certain spatial distribution of laser radiation on a substrate or material being processed is often required. One well-known method of providing the spatial distribution includes illuminating an area of a mask which has a pattern of apertures therein with the laser radiation, and projecting an image of the aperture patterns on the substrate. Certain applications, particularly laser crystallization, demand a very high degree of uniformity of illumination of the mask.
Several arrangements have been used or proposed for providing such uniform illumination on a mask. The complexity of the arrangements is usually inversely dependent on the quality of the laser radiation delivered from the laser providing that radiation. More complex designs are required for lasers that provide beams that are multimode in at least one axis, are not symmetrical in cross-section, or have an intensity distribution that is not Gaussian in at least one axis. The effectiveness of any such arrangement, of course, can be compromised if the distribution of radiation in the beam varies with time. This can occur in gas-discharge lasers, particularly in high-pressure, pulsed gas-discharge lasers such as excimer lasers. Such variations can be random variations on a spatial scale that is a fraction of the overall dimensions of the laser-beam, and can appear as spatial modulations in a more general distribution of the radiation on the substrate. The variations can also be longer term, temporal variations that effect primarily the general distribution of the radiation on the substrate. Optical arrangements for re-distribution of radiation in a laser-beam have relied on using devices such as anamorphic optical systems, diffractive optical elements, and “beam homogenizing” devices such as microlens arrays, diffusers, and light-pipes.
In prior-art excimer-laser projection systems it has been possible to provide a general or intensity variation as low as between about 1% about 2% of nominal over the illuminated area using a combination of anamorphic optical elements and anamorphic microlens arrays to shape and homogenize radiation in the laser-beam. Radiation distribution at this level of uniformity often rises from a low level at edges of the illuminated area to a maximum at the center of the illuminated area. This is sometimes referred to by practitioners of the art as a “center-up” distribution. In certain demanding applications, laser crystallization in particular, an absolute intensity variation of less than 1.5% is preferred. When random and temporal variations of energy distribution are combined with the 1% and 2% general energy distribution variation of 1.5% or less is difficult to achieve consistently. Accordingly, there is a need to reduce the variation in general distribution of energy below the level that has been achieved to date in prior-art laser projection systems.
SUMMARY OF THE INVENTION
The present invention is directed to a method and apparatus for illuminating a mask with a beam of radiation from a laser. In one aspect, the present invention comprises directing the laser beam through a plurality of optical elements located on a longitudinal axis. The optical elements are arranged to project the beam onto the mask to illuminate the mask. The configuration and arrangement of the optical elements is selected such that the intensity of radiation in the laser-radiation beam on the mask is nearly uniform in a transverse axis of the beam. Uniformity of radiation in the laser-radiation beam on the mask in the transverse axis is optimized by partially blocking at least one edge of the laser-radiation beam at a location between selected ones of the optical elements.
In another aspect of the invention, the edge blocking of the laser-radiation beam is accomplished by a least one stop extending partially into the laser-radiation beam at the selected location. In one preferred embodiment of the invention, the stop has a width less than the transverse-axis width of the laser-radiation beam and the stop has a rounded tip at an end thereof extending into the laser-radiation beam. In one example, the nearly uniform distribution provided by the optical elements is the above discussed “center-up” distribution having a single, central, peak value and a 2σ (two standard deviations) uniformity of about 2.08%. In one uniformity-optimization provided by the edge-blocking with the stop, the optimized distribution has two peak values having a centrally located trough value therebetween, and has a 2σ uniformity of about 1.36%.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, schematically illustrate a preferred embodiment of the present invention, and together with the general description given above and the detailed description of the preferred embodiment given below, serve to explain principles of the present invention.
FIG. 1 is a three-dimensional view schematically illustrating an excimer laser projection system in accordance with the present invention including an excimer laser delivering a laser-beam having a long-axis and a short-axis perpendicular to each other, an anamorphic telescope arranged to expand and shape the laser-beam, a beam homogenizer including two pairs of cylindrical-microlens arrays for spatially redistributing energy in the expanded, shaped laser-beam, a narrow stop arranged to partially block the expanded, shaped and partially homogenized beam between two of the microlens arrays, and condensing and field lenses for focusing the shaped, homogenized beam onto a mask.
FIG. 2 schematically illustrates one preferred example of the beam-stop of FIG. 1 having a rounded tip for insertion into the beam.
FIG. 3 is an elevation view of the projection system of FIG. 1 seen in the short-axis of the laser-beam, and schematically illustrating a preferred positioning of the beam-stop between arrays in one pair of the microlens arrays of FIG. 1 and illustrating further detail of the condensing optics and mask.
FIG. 4A is an elevation view seen in the short-axis of the laser-beam, and schematically illustrating details of the beam-stop and the beam between the microlens arrays of FIG. 3 .
FIG. 4B is a plan view from above seen in the long-axis of the laser-beam, and schematically illustrating further details of the beam stop and the beam between the microlens arrays of FIG. 4A .
FIG. 5 is a graph schematically illustrating intensity as a function of distance along the long-axis of the beam on the mask in one example of the projection system of FIG. 1 from which the beam stop has been removed from the beam.
FIG. 6 is a graph schematically illustrating intensity as a function of distance along the long axis of the beam on the mask in another example of the projection system of FIG. 1 in which the beam stop is of the form depicted in FIG. 2 , and aligned with the propagation axis of the beam and partially inserted into the beam by an experimentally determined distance along the short-axis direction of the beam.
FIG. 7 is a graph schematically illustrating intensity as a function of distance along the long axis of the beam on the mask in yet another example of the projection system of FIG. 1 in which the beam stop is of the form depicted in FIG. 2 , and aligned with the propagation axis of the beam and partially inserted into the beam along the short axis direction of the beam beyond the distance of the example of FIG. 6 .
FIGS. 8A-D are three-dimensional views schematically illustrating alternate arrangements of two or more beam stops between the microlens arrays of FIG. 3 .
FIG. 9 is a three-dimensional view schematically illustrating an arrangement of a beam stop in accordance with the present invention between microlens arrays of another pair of microlenses of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, wherein like components are designated by like reference numerals, FIG. 1 , FIGS. 2A and 2B , FIG. 3 , and FIGS. 4A and 4B schematically illustrate an embodiment 10 of an optical system in accordance with the present invention for projecting an image of a mask on a substrate. An excimer laser (not shown) delivers a beam 14 propagating along a system axis (the Z-axis in an X, Y, Z, Cartesian axis system). In an optical system such as system 10 it is usual to provide a variable attenuator (also not shown) to allow power in the beam to be varied according to the application. A description of such an attenuator is not necessary for understanding principles of the present invention.
Beam 14 , on leaving the excimer laser, has an elongated cross-section. In one example of an excimer laser the beam leaving the laser has a width of about 12.0 mm and a length of about 35.0 mm. The length and width of the beam define the X and Y-axes, which are often referred to by practitioners of the excimer laser art as the long-axis and short-axis respectively.
Turning mirrors 42 and 44 direct the beam (after having traversed any attenuator) into an anamorphic telescope 18 , here, including cylindrical lenses 46 and 48 and a spherical lens 50 . The purpose of telescope 18 is to adapt the beam to the aperture of a beam-homogenizer formed by microlens arrays 54 , 56 , 58 and 60 . Details of the telescope and other important system groups are depicted in FIGS. 1 and 3 . FIG. 1 is a three dimensional view. FIG. 3 is a view in the plane of the short-axis of optical system 10 showing further detail of components of system 10 . In FIG. 3 , the long-axis appearance of certain components is schematically depicted in dashed lines and designated by reference numerals having a subscript L. In FIGS. 1 and 3 , only the general direction of propagation of beam 14 is depicted, as a single line collinear with the longitudinal optical axis (the Z-axis) of system 10 . In FIGS. 4A and 4B , multiple lines 14 depict bounds of the beam.
A turning mirror 52 directs the collimated beam into the beam homogenizing arrangement 20 comprising microlens arrays 54 , 56 , 58 , and 60 . Microlens array 54 includes a plurality of elongated plano-convex cylindrical microlenses 55 and microlens array 56 includes a plurality of elongated plano-convex microlenses 57 . Microlens arrays 54 and 56 can be described as the “long-axis beam-homogenizer”. Preferably there are twelve microlenses in each array, however, in FIG. 3 only four microlenses are depicted in each array for convenience of illustration. The microlenses in each array are aligned parallel to the short-axis and have positive optical power in the long-axis and zero optical power in the short-axis. The microlenses in one array are arranged as a long-axis optical relay with corresponding microlenses in the other array. Beam 14 next traverses microlens arrays 58 and 60 , forming what can be described as the “short-axis beam-homogenizer”. Microlens array 58 includes a plurality of plano-convex cylindrical microlenses 59 and microlens array 60 includes a plurality of planoconvex microlenses 61 . Again, only four microlenses are depicted in each array for convenience of illustration. The microlenses in each array are aligned parallel to the long-axis and have positive optical power in the short-axis and zero optical power in the long-axis. The microlenses in one array are arranged as a short-axis optical relay with corresponding microlenses in the other array.
Located between microlenses 58 and 60 is an elongated partial-shutter or beam-stop 62 , details of a preferred form of which are schematically depicted in FIG. 2 . Interaction of the stop with the beam, and a preferred location of the stop with respect to the beam are schematically depicted in FIGS. 4A and 4B . The purpose of stop 62 is to prevent the above discussed “center-up” intensity distribution in an image projected on the substrate by the optical system. Stop 62 preferably has a width W (see FIG. 2 ) that is between about 5% and about 50% of the long-axis width BW of beam 14 between microlenses 58 and 60 (see FIG. 4B ). The stop preferably has a rounded tip 62 A having a radius about equal to W/2. The stop is preferably positioned over the longitudinal axis 15 of the optical system (see again FIG. 4B ). The stop is preferably positioned closer to microlens array 60 (the exit microlens array of the short-axis beam-homogenizer) than to microlens 58 (the entrance microlens array of the short-axis beam-homogenizer), and most preferably positioned immediately adjacent the exit microlens array. It is also possible that stop 62 be located adjacent microlens array 60 , between lens 22 and microlens array 60 . Stop 62 preferably extends into the beam in the short-axis direction for a distance between about 3% and about 35% of the short axis beam height (see FIG. 4A ). The stop must not, however, extend across the system optical axis. The optimum extension-distance may vary from system to system but can be quickly determined experimentally for any stop dimension in the preferred range.
After traversing the short-axis beam-homogenizer, the collimated beam 14 traverses a spherical lens 22 having positive power and is directed by turning mirrors 66 , 68 , and 70 to a plano-convex cylindrical lens 24 having positive power in the short-axis and zero-optical power in the long-axis. After traversing lens 24 the beam traverses another plano-convex cylindrical lens 26 . Lens 26 has positive power in the long-axis and zero-optical power in the short-axis. An effect of lenses 22 , 24 , and 26 is project beam 14 on a mask 28 with an elongated cross-section (indicated in FIG. 1 by dashed line 30 ) having a length between about 25 mm and 125.0 mm and a width 8 between about 3 mm and 25 mm. That portion 14 S (see FIG. 3 ) of beam 14 passing through patterns of apertures (not shown) is directed by turning mirrors 72 and 74 to an imaging lens 32 . Imaging lens 32 focuses light 14 S as an image (not shown) of the aperture patterns in mask 28 . The long-axis distribution of light intensity on mask 28 produced by the above described optical elements (normally center-up) can be modified according to the shape and positioning of stop 62 . This modification is discussed below, beginning with reference to FIG. 5 .
FIG. 5 is a graph schematically illustrating intensity as a function of distance along the long-axis of the beam on mask 28 in one example of the optical system 10 of FIG. 1 from which stop 62 has been removed from the beam. Intensity distribution is measured between points designated by dashed lines L 5 and R 5 . It can be seen that between those lines the intensity rises steadily from each line never falling below the lowest value in the measurement range (indicated by horizontal line H 5 ) and reaching a peak value about mid-way between lines L 5 and R 5 . This is the above-described center-up distribution that stop 62 is able to modify. In this measurement, the intensity variation between the lines L 5 and R 5 is 2σ=2.08% (where σ is the standard deviation from the mean).
FIG. 6 is a graph schematically illustrating intensity as a function of distance along the long-axis of the beam on mask 28 in one example of the optical system 10 of FIG. 1 including a stop 62 in accordance with the present invention. In this example, the long-axis beam width (BW) between microlens arrays 58 and 60 is about 100 mm. Stop 62 has a width W of about 15 mm with a rounded tip 62 A having a radius of about 7.5 mm. Microlens arrays 58 and 60 are axially spaced apart by about 330 mm, and stop 62 is located about 15 mm from microlens array 60 . Short-axis beam width BH at the location of stop 62 is about 25 mm. It is believed that stop 62 extends between about 3 mm and 6 mm into the beam in the short-axis direction into the beam.
It should be noted, in this regard, that the exact extension of the beam was not measured, and in fact, as the edge of the beam can not be precisely defined, an exact extension is equally difficult to define. An optimum extension of the stop was determined by testing various extension depths of the stop and measuring the long-axis intensity distribution of radiation at the mask level.
Intensity distribution is measured between points designated by dashed lines L 6 and R 6 . It can be seen that between those lines the intensity initially rises steadily from each line to a peak value close to each of the lines falling to a lower value, centrally, between the two peaks. The intensity, however, never falls below the lowest (edge) value in the range, indicated by horizontal line H 6 . In this measurement the intensity variation between the lines L 6 and R 6 is about 1.36% (2σ).
FIG. 7 is a graph schematically illustrating intensity as a function of distance along the long-axis of the beam on mask 28 in another example of the optical system 10 of FIG. 1 including a stop 62 in accordance with the present invention. In this example, the dimensions of stop 62 , the spacing of the microlens arrays, the beam widths between the microlens arrays and the axial distance position of stop 62 from microlens array 60 are the same as in the example of FIG. 6 . In this example, however, stop 62 extends deeper into the beam in the short-axis direction into the beam than in the example of FIG. 6 .
Intensity distribution is measured between points designated by dashed lines L 7 and R 7 . It can be seen that between those lines the intensity initially rises steadily from each line to a peak value close to each of the lines falling to a value below the lowest (edge) value in the range, indicated by horizontal line H 7 . Further, there is significant, relatively high frequency, modulation over about one-half of the long-axis extent of the beam. This modulation has a peak-to-valley excursion comparable to the total intensity variation in the example of FIG. 6 . In the graph of FIG. 7 , the intensity variation between the lines L 7 and R 7 is about 7.14% (2σ).
In other experiments, the effect of placing a stop at other locations was investigated, for example, closer to microlens array 58 than to microlens array 60 , and at various positions between microlens arrays 54 and 56 . In each case, the effect was to produce modulation comparable to or greater than the modulation exhibited in the example of FIG. 7 .
It is believed that a stop having a rounded tip, whether semicircular as in the examples described, or having some non-semicircular curvature such as elliptical, parabolic, or hyperbolic, will provide an intensity distribution having less modulation than would be produced by a tip having an angular form, however, the use of a stop having a tip of an angular form is not precluded. It is also possible that a variation of intensity less than 1.3% may be obtained by arranging two or more stops 62 in the edge of the beam. Some possible arrangements of the stops between microlens arrays 58 and 60 are schematically depicted in FIGS. 8A , 8 B, 8 C, and 8 D.
In the arrangement of FIG. 8A there are two stops, one thereof in an upper edge of the beam and the other in the lower edge of the beam. The stops, here, are aligned with each other, and aligned over system axis 15 . In the arrangement of FIG. 8B there are also two stops, but each thereof is in the upper edge of the beam, and the stops are aligned with one on either side of the system axis in the long axis direction. In the arrangement of FIG. 8C there are two stops in the upper edge of the beam aligned as in the arrangement of FIG. 8B and one stop in the lower edge of the beam aligned over the system axis as in FIG. 8A . In the arrangement of FIG. 8D , there is one stop in the upper edge of the beam and one stop in the lower edge of the beam. Here, the stops are aligned displaced from the system axis on opposite sides thereof.
It may also be possible to improve short-axis beam uniformity by inserting one or more stops into the beam between microlens arrays 54 and 56 of the long-axis beam homogenizer. An arrangement in which one stop is inserted is depicted in FIG. 9 . Here, the stop extends partially into the beam in the long-axis direction. Those skilled in the art will recognize without further illustration or detailed description that multiple stop arrangements are also possible for improving short-axis beam uniformity.
It is emphasized, here, that the multiple stop arrangements described above are merely a sample of possible such arrangements that may provide improved beam uniformity. Whatever the number and alignment of the stops, however, each stop should have a width less than the long-axis beam width at the location of the stops, and should not extend into the beam across the system axis. It is also emphasized that while the present invention is described above in the context of a particular excimer-laser projection system in which the efficacy of the invention has been experimentally determined, the invention is applicable in other laser projection systems having a different arrangement of beam shaping, projection optics, or beam homogenizing optics.
The present invention is described above in terms of a preferred and other embodiments. The invention is not limited, however, to the embodiments described and depicted. Rather, the invention is limited only by the claims appended hereto. | An optical system for projecting a laser-beam on a mask to illuminate the mask includes a beam homogenizing arrangement including spaced arrays of microlenses. The beam homogenizing arrangement redistributes light in the laser beam such that the intensity of light in the laser-beam on the mask is nearly uniform along a transverse axis of the laser-beam. A stop extending partially into the laser-beam between the microlens arrays provides a more uniform light-intensity on the mask along the transverse axis than can be achieved by the microlens arrays alone. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to endoprosthetic devices and, more specifically, to a scapular endoprosthetic device for full repair of glenoid defects.
Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
Patients suffering from diseases or deformities of the glenoid fossa of the scapula, prior to the instant invention, have very few options for repair. Bone grafts are sometimes utilized, relying on healthy bone (if available) from another area of the patient's body, donated bone from a cadaver, or synthetic bone in certain situations. However, such real bone grafts are limited in usefulness due to the complexities of the shoulder joint, and are problematic with regard to patient reactions to medication, bleeding, post-operative infection, and attendant pain at the harvest and graft sites. Synthetic bone, on the other hand, while reducing the incidence of rejection and post-operative infection, is limited in usefulness as well due to, again, the complexities of the shoulder joint and the physical stresses experienced therein during normal joint operation.
Current glenohumeral repair techniques include hemiarthroplasty (resurfacing or stemmed), total shoulder replacement, or reverse total shoulder replacement. Resurfacing hemiarthroplasty involves resurfacing of the humeral head joint surface with a cap-like prosthesis of highly polished metal. This is a relatively minimal repair, that relies on the existence of adequate cartilage within the glenoid fossa and a generally otherwise healthy humerus. A stemmed hemiarthroplasty involves a prosthetic humeral head joint surface with an intramedullary stem for fixation within the humeral shaft. This type of repair is often necessitated by severe fractures of the humeral head, but requires a relatively healthy glenoid with intact cartilage surface.
Total shoulder replacement, as the name implies, involves replacement of the entire glenohumeral joint and is typically necessitated by severe arthritis, physical damage, or disease action resulting in loss of joint cartilage. In a standard total shoulder replacement a stemmed hemiarthroplasty repair is mated with a glenoid socket prosthetic component to complete the artificial shoulder joint. The glenoid socket component is either cemented or “press-fit” into the bone of the original glenoid fossa. In a reverse total shoulder replacement scenario the socket and ball components of the repair are reversed, such that the socket portion is fixated on the humeral head and the metal ball portion is fixated in the glenoid fossa.
The current repair methods—hemiarthroplasty and total shoulder repair—each require adequate scapular structure for support and fixation. In instances where disease process has deteriorated the scapular structure such that the glenoid fossa and surrounding bone is not viable, existing repair devices and techniques are useless. What is needed is a scapular glenoid fossa replacement device to effect shoulder repair to restore patient function in such instances of scapular deficiency.
BRIEF SUMMARY OF THE INVENTION
The present invention is embodied in numerous forms, including an embodiment of a glenoid fossa endoprosthetic device, the device comprising: a glenosphere or glenosocket joint component including a first and second fixation plate affixed thereto, the first and second fixation plates disposed to form a space therebetween for receiving a scapula neck of a patient, the first fixation plate having a plurality of holes for placement of setscrews, the threads of which to be received by the second fixation plate. In another embodiment the device further comprises an oblique setscrew for fixation of the device to the inferior body of the scapula neck. In yet another embodiment the device, wherein the second fixation plate comprises a plurality of setscrew holes that correspond with the first fixation plate setscrew holes, the device further comprises a thread engagement plate for attachment to the first or second fixation plate, the attached thread engagement plate for receiving the threads of a setscrew placed in the hole of the other fixation plate. In yet another embodiment the device further comprises a porous mesh surface treatment on an inner surface of a fixation plate to improve osteoconductivity.
The present invention includes another embodiment of a glenoid fossa endoprosthetic device comprising: a Morse taper and a first and second fixation plate affixed thereto, the first and second fixation plates forming a space therebetween for receiving a scapula neck of a patient, the first fixation plate having a plurality of holes for placement of setscrews, the threads of which to be received by the second fixation plate, the Morse taper for receiving a glenosphere or glenosocket joint component. In yet another embodiment the device further comprises a glenosphere or glenosocket joint component. In yet another embodiment the device further comprises an oblique setscrew for fixation of the device to the inferior body of the scapula neck. In yet another embodiment the device, wherein the second fixation plate comprises a plurality of setscrew holes that correspond with the first fixation plate setscrew holes, the device further comprises a thread engagement plate for attachment to the first or second fixation plate, the attached thread engagement plate for receiving the threads of a setscrew placed in the hole of the other fixation plate. In yet another embodiment the device further comprises a porous mesh surface treatment on an inner surface of a fixation plate to improve osteoconductivity.
The present invention is also embodied in a glenoid fossa repair method, the method steps comprising: resecting all or a portion of a glenoid fossa of a scapula of a patient to remove diseased or damaged tissue; selecting a glenosphere or glenosocket joint component, the component comprising a first and second fixation plate affixed thereto, the first and second fixation plates disposed to form a space therebetween for receiving a scapula neck of a patient, the first fixation plate having a plurality of holes for placement of setscrews, the threads of which to be received by the second fixation plate; positioning the first and second fixation plates over the scapular resection to position the glenosphere or glenosocket joint component in the approximate position of the resected glenoid fossa; fixating the first and second fixation plates to the scapula by passing a setscrew through each of the first fixation plate setscrew holes and corresponding holes formed in the scapula neck of the patient to engage the corresponding hole in the second fixation plate, wherein the setscrew threads grip the second fixation plate to compress the scapula neck between the first and second fixation plates; and completing the shoulder joint repair. Steps of additional embodiments further comprise: installing an oblique setscrew through the lateral end of the glenosphere or glenosocket joint component for fixation of the joint component to the inferior body of the scapula neck. In another embodiment, wherein the second fixation plate comprises a plurality of setscrew holes that correspond with the first fixation plate setscrew holes, the method steps further comprise: installing a thread engagement plate on the second fixation plate, the attached thread engagement plate for receiving the threads of a setscrew placed in the hole of the first fixation plate. Another embodiment, wherein the joint component further comprises a Morse taper, the method steps further comprise: selecting a glenosphere head or a glenosocket head for the shoulder repair and installing the selected head on the Morse taper. In another embodiment, wherein the joint component further comprises a Morse taper, the method steps further comprise: installing an oblique setscrew through the Morse taper for fixation of the joint component to the inferior body of the scapula neck; and selecting and installing on the Morse taper a glenosphere head or a glenosocket head for the shoulder repair.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
The present invention will be more fully understood by reference to the following detailed description of the preferred embodiments of the present invention when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a depiction of an embodiment of the glenoid fossa endoprosthetic device invention featuring a glenosocket joint component;
FIG. 2 is a depiction of another embodiment of the glenoid fossa endoprosthetic device invention featuring a glenosphere joint component;
FIG. 3 is a depiction of another embodiment of the glenoid fossa endoprosthetic device invention featuring a Morse taper device allowing for interchangeable glenosphere and glenosocket members;
FIG. 4 is a depiction of the glenoid fossa endoprosthetic device invention as installed in a standard total shoulder repair arrangement; and
FIG. 5 is a depiction of the glenoid fossa endoprosthetic device invention as installed in a reverse total shoulder repair arrangement.
The above figures are provided for the purpose of illustration and description only, and are not intended to define the limits of the disclosed invention. Use of the same reference number in multiple figures is intended to designate the same or similar parts. Furthermore, when the terms “top,” “bottom,” “first,” “second,” “upper,” “lower,” “height,” “width,” “length,” “end,” “side,” “horizontal,” “vertical,” and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawing and are utilized only to facilitate describing the particular embodiment. The extension of the figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiment will be explained or will be within the skill of the art after the following teachings of the present invention have been read and understood.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a depiction of an embodiment of the glenoid fossa endoprosthetic device invention featuring a glenosocket joint component ( 100 ). As shown, the glenosocket member ( 102 ) has a lateral face ( 104 ) with which to engage the complimentary humeral head feature on a patient's humerus, and a medial face ( 106 ) having a first fixation plate ( 108 ) and a second fixation plate ( 110 ) extending therefrom. The fixation plates are substantially rigid, and are either formed as part of the medial face during the machining process, or otherwise attached using a common metal bonding process. The machined members and all other metal components of the embodiment are manufactured from biologically compatible and stable metals. In the instant embodiment the glenosocket joint components are titanium, but may be surgical stainless steel, niobium, gold, platinum, or the like, or some combination thereof. Moreover, combinations of metals and/or biocompatible polymers may also be utilized and are within the scope of the claimed invention.
The fixation plates ( 108 and 110 ) are substantially parallel and are positioned to form a space therebetween for receiving the resected scapula neck area of the scapula of a patient. The anteroposterior thickness of the scapula in this area varies among patients, with an adult patient measuring approximately 15 mm to 22 mm and a child patient approximately 10 mm to 15 mm. However, the thickness and composition of the fixation plates ( 108 and 110 ) is such that a minimal amount of flexure is accommodated to allow for superior gripping of the resected scapula area during fixation. The device is easily sized in this regard in order to accommodate any patient.
The first fixation plate ( 108 ) features a plurality of holes ( 112 ) to allow placement and passage of fixation setscrews ( 114 ). In the instant invention the setscrews ( 114 ) are hex headed countersunk screws that utilize a countersunk hole to maintain the head of the screw substantially flush with the fixation plate upon installation. Further, the thread tip is tapered and features a cutting edge feature for cutting threads in metal upon rotation. A plurality of corresponding holes ( 116 ) in the second fixation plate ( 110 ) receives the threaded portion of the setscrews and allows threads to be cut therein. Accordingly, upon device installation, the gap between the first and second fixation plates decreases as the setscrews draw the fixation plates inward with setscrew ( 114 ) rotation. Though a particular setscrew is depicted and described, one of ordinary skill will appreciate that other common setscrews may also be utilized.
In another embodiment the glenoid fossa endoprosthetic device also utilizes a thread engagement plate ( 118 ) for gripping of the threaded portion of the setscrews ( 114 ). As depicted the thread engagement plate ( 118 ) is formed to provide a channel to receive the first or second fixation plate ( 108 and 110 ). In this configuration the setscrew holes in each fixation plate are of the same diameter to allow the setscrews to be placed from either direction. For example, if the surgeon chooses to place the setscrews through the first fixation plate ( 108 ) and into the second fixation plate ( 110 ), the thread engagement plate ( 118 ) is added to the second fixation plate ( 110 ) as shown so that the setscrew ( 114 ) thread tip may cut threads into the thread engagement plate ( 118 ) holes.
It is also possible to splay the setscrews ( 114 ), or otherwise allow one or more of the setscrews to enter a hole at an oblique angle. The device also allows the use of an oblique setscrew ( 118 ) that enters from the glenosocket face ( 104 ) on an oblique angle in order to engage the remaining scapula body inferiorly to provide added fixation and stability to the repair.
FIG. 2 is a depiction of another embodiment of the glenoid fossa endoprosthetic device invention featuring a glenosphere joint component ( 200 ). As shown, the glenosphere member ( 202 ) has a lateral face ( 204 ) with which to engage the complimentary humeral head feature on a patient's humerus (in this instance, in a reverse total shoulder arrangement), and a medial face ( 206 ) having a first fixation plate ( 208 ) and a second fixation plate ( 210 ) extending therefrom. Other than the glenosphere member ( 202 ), this embodiment shares features and functionality with the previous embodiment. Each fixation plate ( 208 and 210 ) features a plurality of holes ( 212 and 216 ) for placement of setscrews ( 214 ) therethrough. Threads from the setscrews ( 214 ) may engage the fixation plate ( 210 ) material, or an optional thread engagement plate ( 218 ).
FIG. 3 is a depiction of another embodiment of the glenoid fossa endoprosthetic device invention featuring a Morse taper device allowing for interchangeable glenosphere and glenosocket members ( 300 ). As shown, the device utilizes a Morse taper member ( 302 ) for accepting either a glenosphere member ( 304 ) or a glenosocket member ( 306 ). The benefit to this configuration is that a single shoulder joint repair kit may include the option of a standard or reverse total shoulder configuration. The device configuration may be determined prior to installation, and the appropriate glenosocket/glenosphere member may be subsequently installed.
The medial face, as with the previous embodiments, has a first fixation plate ( 308 ) and a second fixation plate ( 310 ) extending therefrom. Setscrews utilize the holes therethrough for affixation of the device to the resected scapula as before. Additional oblique setscrews may be utilized ( 312 ) for added stability. A porous mesh surface treatment is also applied to the inner surfaces ( 314 ) of the fixation plates ( 308 and 310 ) to improve osteoconductivity. This porous mesh surface treatment may be utilized in the previous embodiments and has the added benefit of providing for greater stability of the overall repair.
FIG. 4 is a depiction of the glenoid fossa endoprosthetic device invention as installed in a standard total shoulder repair arrangement. As shown, an embodiment of the glenosocket joint component ( 100 ) is chosen, but the Morse taper embodiment with a glenosocket feature may also be utilized. One of ordinary skill will appreciate that the repair relies on common surgical procedures for performing a standard total shoulder joint repair.
The patient's glenoid fossa/scapula neck ( 402 ) area is exposed and the diseased or injured tissue is removed to achieve a clean margin. The remaining bone is prepared, with sufficient bone removed to prevent impingement with the repair device ( 100 ). The repair device first and second fixation plates ( 108 and 110 ) are positioned over the scapular resection to position the glenosocket joint component in the approximate location of the original glenoid fossa. The device is thin fixated by installing the setscrews ( 114 ) through the first fixation plate ( 108 ) into the second fixation plate ( 110 —not shown). The setscrews ( 114 ) may engage the second fixation plate directly, or may engage an added thread engagement plate as described above. As the setscrews ( 114 ) are tightened the fixation plates ( 108 and 110 ) compress slightly to further grip the scapula. An optional oblique setscrew ( 118 ) may also be utilized to engage the remaining scapula neck inferiorly. The shoulder joint repair may then be completed as with a standard total shoulder repair by joining the glenosocket ( 102 ) with the humeral head component ( 404 ).
FIG. 5 is a depiction of the glenoid fossa endoprosthetic device invention as installed in a reverse total shoulder repair arrangement. As shown, an embodiment of the glenosphere joint component ( 200 ) is chosen, but the Morse taper embodiment with a glenosphere feature may also be utilized. One of ordinary skill will appreciate that this repair, likewise, relies on common surgical procedures for performing a reverse total shoulder joint repair.
As above, the patient's glenoid fossa/scapula neck ( 502 ) area is exposed and the diseased or injured tissue is removed to achieve a clean margin. The remaining bone is prepared, with sufficient bone removed to prevent notching with the repair device ( 100 ). The repair device first and second fixation plates ( 208 and 210 ) are positioned over the scapular resection to position the glenosocket joint component in the approximate location of the original glenoid fossa. The device is thin fixated by installing the setscrews ( 214 ) through the first fixation plate ( 208 ) into the second fixation plate ( 210 —not shown). The setscrews ( 214 ) may engage the second fixation plate directly, or may engage an added thread engagement plate as described above. As the setscrews ( 214 ) are tightened the fixation plates ( 208 and 210 ) compress slightly to further grip the scapula. The shoulder joint repair may then be completed as with a standard total shoulder repair by joining the glenosphere ( 202 ) with the complimentary humeral head component ( 504 ).
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. Accordingly, the scope of the invention is established by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced by the claims. Further, the recitation of method steps does not denote a particular sequence for execution of the steps. Such method steps may therefore be performed in a sequence other than that recited unless the particular claim expressly states otherwise. | An endoprosthetic device for replacement of a diseased or damaged scapular glenoid fossa. The device includes a glenosphere or a glenosocket member, or provides the option of mating a glenosphere or glenosocket member via a Morse taper. The device also features opposing fixation plates that grip resected scapular area anteroposteriorly to fixate the device through use of a plurality of setscrews. An Oblique setscrew that engages the scapular body inferiorly may be added for improved fixation. A porous mesh surface treatment on the inner faces of the fixation plates may be utilized to improve osteoconductivity. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to systems for degassing liquids to remove unwanted permanent air gasses, as for example boiler feed water or removal of contaminants such as hydrogen sulfide, unwanted carbon dioxide, and radon. It further relates to systems for scrubbing contaminants from other gasses by contacting the contaminated gasses with relatively clean water, and extends this field to one wherein the liquid used for scrubbing is virtually completely cleaned of all dissolved gasses or volatile contaminants so that the scrubbing may be very complete and rapid. It further relates to the separation of dissolved gasses from industrial liquids, as for instance in removing dissolved hydrocarbon gasses from crude oil or removing dissolved gasses such as helium for storage and later use. It also relates to the instant evaporation of dissolved volatiles such as solvents contained in a liquid and removing them in the equipment to be described or suggested.
2. Description of the Prior Art
The three main types of systems which the present invention intends to improve on are (a) Deaerating devices such as open-air heated tanks for partial removal of dissolved permanent air gasses and other contaminants which may become gaseous in a boiler and reduce a boiler or other piece of industrial equipment's efficiency. (by Systems for holding a contaminated liquid under a partial vacuum, with or without heating, to volatilize and remove the contaminants by diffusion. (c) Systems generally known in the chemical industry as scrubbers, wherein a liquid contaminated with undesired permanent gasses or volatile liquids are sprayed to form drops or spread on high-surface area configurations, allowing diffusion of the undesired dissolved materials to the relatively uncontaminated gas with which it is placed in contact, usually but not necessarily air.
Under the process of the prior art, the liquid to be decontaminated is spread over a very large, thin layer that expedites degassing according to Fick's law of diffusion. A disadvantage of this prior art process is that it facilitates the evaporation of large and largely uncontrolled quantities of the liquid being cleaned. Since the vapor produced by evaporation carries with it the contaminant, a secondary stream of condensate is produced when the vapor is condensed out to facilitate the production of a vacuum. This condensate stream is more highly contaminated than the original liquid being cleaned. Thus this new liquid stream creates a second source of liquid with a concentrated contamination that must be treated. For instance, if the original contaminated liquid, say water, is initially contaminated with a noxious hydrocarbon such as benzene in the amount of 10 -8 molecules of benzine per molecule of water, and further that the quantity of evaporation of water is 0.01 that of the contaminated feed stream, then a contaminated stream of condensate results, containing concentrated benzene in the amount of 10 -6 molecules of benzene per molecule of condensate water. The net effect is that present systems using extended thin films on high-area surfaces provide a system that is very expensive to build., and which requires excessive refrigeration to condense the excess liquid evaporated. Further, as above this secondary stream produces a new source of highly contaminated liquid with a new and exaggerated disposal problem.
SUMMARY OF THE INVENTION
The present invention is a process for rapidly removing dissolved permanent gases and volatile contaminants from a liquid. This is accomplished by forcing the contaminated liquid stream through a cavitating venturi designed to not only free the dissolved air or other gasses and evaporate volatile contaminants, but then to coalescea sizeable fraction of the gas released, typically found in very small bubbles, to larger bubbles. The micro-bubbles are difficult to separate or break because their buoyancy is small compared with their resistance to rising under gravity. The larger bubbles coalesced are easily separated by low centrifugal forces and are relatively easily broke. By designing the equipment so that the liquid is not exposed in thin films, or for extended times and large areas to the low-pressure mixture of vapor and gas, the gas being released when the bubbles break, excessive evaporation is avoided. In the best case almost the only vapor that will be released is that necessary to saturate the gas bubbles. This is minimal because of the very high specific volume of wet steam at its very low partial pressures found in the system. Additional components of the system to accomplish the desired processes of separating the large bubbles, breaking them and removing their gaseous contents without additional significant evaporation are described in the patent specification. Their function is to not only separate the large, coalesced bubbles from the main stream carrying the micro-bubbles not coalesced, but to break them, at the same time isolating the main stream, which then can be further processed in second third stages or more stages while limiting contact of the liquid streams from the low pressure air-vapor released thereby limiting further evaporation. For example, the liquid may flow through one or more turns of tubing following its initial processing through title cavitating venturi. After centrifugal separation, the stream containing the large, soft bubbles is stripped from the main stream 12 in FIG. 1 and sent to one of several types of secondary bubble breakers and separators.
Because evaporation of the contaminated liquid can occur only at a free vapor-liquid surface or interface, it is the method and intention of this invention to limit insofar as practicable evaporation except to the gas bubbles. This process can best be understood by examining in some detail the total process and equipment design as they relate to Fick's law of diffusion: ##EQU1## where dn is the number of molecules moving, across an interface of thickness δ, of area A, in a time dt, driven by a concentration gradient, C 1 -C 2 at a rate determined by an experimental diffusion constant, D. One caveat. Eq.(1) is generally understood without qualification to be at constant pressure, and the concentration gradient the number of molecules, say of gas, per unit of liquid. Not so in this case where the concentration gradient is replaced by a solubility factor. With the large reduction in pressure--it may be by a factor to as high as 1/100th or greater in the throat of the cavitating venturi--the solubility is very low and the dissolved constituents--gas or volatile molecules--move from wherever they occur in the contaminated liquid against the concentration gradient until a new solubility saturation in the liquid at the lower pressure is achieved. For instance, in the practical case we approach in our design, a reduction in pressure to, say 1/30th of an atmosphere, or about 0.03 bar, the dissolved gas and volatilized contaminants will exit the liquid until a solubility saturation value at the lower pressure is reached, irrespective of the actual concentration. No matter; so far as is known, Equal.(1) holds in this case, where the moving force is as now re-defined in terms of solubility and solubility change with a change in pressure.
To reexamine the state of the art contactor, a large pressure vessel with extended surfaces supporting thin films of liquid, would be dictated by Eq.(1). The through-put of contaminated liquid is maximized by paying attention to the demands of diffusion as shown here. Just so in my new system, except that the diffusion is limited, insofar as practicable, to the bubbles (mostly air but containing the contaminant as a vapor). The large area, A, is achieved in the very large surface area of the bubbles of air, large and small. The diffusion distance, δ, is minimized by the close spacing (due to their very large numbers) of the micro-bubbles formed in the venturi's throat: So far as is known, neither the diffusion constant, D nor the concentration gradient (or in its place the solubility deficit, as I now choose to call it) is changed by the new hardware I propose. In any case, diffusion to incipient micro-nuclei inherent in most liquids is extremely rapid; the entire removal down to the new solubility level is accomplished in a distance of tens of mms and a time of a few thousandths of a second. The further coalescence of these very small (hard) micro-air bubbles to large, soft air bubbles occurs in a further short time of perhaps a few or tens of thousands of a second, depending on equipment size, i.e. the length of the straight coalescing section 6 in FIG. 1.
To recap to this point. Micro air bubbles carrying the dissolved volatile or gaseous contaminant are formed in the intake section of the CV, then coalesced in the very large steam bubbles formed in the straight throat. These large steam bubbles, now containing air from the coalesced micro air bubbles are then condensed abruptly in the cavitating diffuser of the CV 8 in FIG. 1, which causes a rapid pressure rise to above the saturation pressure of the liquid being cleaned. The portion of the flow carrying the large air bubbles is then separated in a centrifugal separator for example, 10 in FIG. 1 from the part of the flow carrying the micro-bubbles not coalesced 16 in FIG. 1. The stream carrying the large bubbles is sent to a breaking device such as 24 in FIG. 2, and the bubbles'0 contents sent to the vacuum system. The equipment is designed to avoid insofar as practicable further contact of the degassed liquid with the low pressure air stream flowing to the vacuum system and further to keep that liquid in thick sections, effectively maximizing δ while minimizing A to prohibit insofar as is practicable evaporation of the liquid being cleaned. In the best possible design, almost no steam would be released except for the very small amount needed to saturate the air bubbles. The volume of the air bubbles then controls the total vapor released, and this is the heart of this patent application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, shows a schematic of a longitudinal cross section of the Cavitating Venturi (CV) with three sections identified, the entrance nozzle 2, the straight section 6 and the diffuser 8, which empties into a centrifugal separator 10 in which the large air-vapor bubbles formed in the straight section are removed from the remainder of the liquid charge 16. The fraction of the liquid containing the large, easily broken bubbles 20 are then sent via duct 12 to a simple device for breaking the bubbles, releasing their contents which then go to the vacuum system not shown. The portion of the flow carrying very small micro-bubbles not coalesced in the first CV are then passed to a second CV, or more if necessary, allowing continuous staging to reduce the gas content of the liquid to virtually any desired level.
FIG. 2 shows a simple device 24 for breaking the large bubbles separated in the centrifugal separator shown in FIG. 1, useful in systems of limited through-put. This device also is usable as a simple centrifugal separator obviating, in some cases the need for the centrifugal separator 10 of FIG. 1.
FIG. 3, shows a more complex device 38 capable of handling very large through-puts in large capacity systems. Like that in FIG. 2, it is capable of separating the large and very small bubbles following the CV, but it is believed that a best design would use a number of stages, each as shown in FIG. 1
FIG. 4, shows an alternative separator and large bubble breaker 11 in section, with an impeller projecting through the inner layer of liquid carrying the large bubbles separated from the remainder carrying the micro-bubbles as shown in section in FIG. 1.
FIG. 5, shows a cross-section through a cavitating venturi, and above it possible pressure along its length.
FIGS. 6A, 6B, and 6C show three combinations of the novel components shown in earlier FIGS. 1 through 4, with each combination achieving the desired processes of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The functions of the various parts of the invention is as follows. First, referring to FIG. 1, the contaminated or gas-saturated liquid is introduced at a preferred velocity and pressure through the duct 2, which empties into the nozzle portion of the cavitating venturi (CV),which is made up of 4, 6 and 8. The straight section 6 is maintained It a suitable absolute pressure just below the saturation pressure of the liquid, as determined by the liquid's temperature. The stream is diffused to a final desired pressure in the conical section, the diffuser 8, designed according to Bernoulli's principle. The entry section of a CV can release dissolved gasses from solution into very small bubbles (estimated to be of 1μin diameter). One inventive aspect of the invention derives from the phenomena of small bubbles coalescing in a low-pressure throat of a CV.
Upon exit from 8, the stream now consists of a mixture of liquid, very small (uncoalesced) air-gas vapor bubbles and large bubbles coalesced in the straight section 6. The stream exiting 8 is rotated rapidly in a suitable circular duct 10, in which the large bubbles are moved by centrifugal force to the inner portion of 10 and 16, and from which the liquid stream containing the large bubbles is stripped from the flow into duct 12 in a suitable elbow 14. The remainder of the liquid flow, containing micro-bubbles of air, gas and vapor are passed to the next stage or stages, each of which consists of a CV and separation system as shown in this, FIG. 1.
FIG. 2 shows in section (all parts are circular in cross-section except for the scoop 46 in FIG. 3) a simple device for reversing the flow from a number of stages, through each stage's duct 12, combined into 20. The flow from 20 goes to bubble breaking devices such as are shown in FIGS. 2 and 3. In FIG. 2 1 show a stationary device with no moving parts that receives the stream 20 consisting of liquid carrying large bubbles or a mixture of large and small bubbles if the separator 10 is not used, which impinges on a surface of rotation 26. This breaks the bubbles by splashing and further by sending the reversed stream, now traveling downward, through a suitable metal screen 28. The liquid now separated from the gasses flow from the separator 24 through a duct 30 for final disposal, use, or further processing. The separated gasses, (vapor and contaminating gasses) are sent to the vacuum system for discharge and final disposal Note that if separator such as 10 is not used, the flow from 30 would go to a subsequent or stage or stages, each starting with a suitably sized CV to handle the flow, which now has part of its dissolved gasses and volatiles removed. Any number of stages may be utilized to achieve the desired level of decontamination or degassification.
An alternative separator suitable for very large systems (large contaminated liquid flows) is shown in FIG. 3. Here, the large bubble carried in a liquid stream as from 12 FIG. 1, is introduced through a rotating annular duct 36 discharging into a rotating cylinder 38, lined with a suitably shaped co-rotating parabolic cone 40. The bubbles 42 are rapidly separated to the outer surface of the cone 40 to its top, where the bubbles are broken as the stream is flung outward into a co-rotating annulus 44. From 44, the liquid now largely gas-free, is scooped up by a stationary scoop 46 by impact and the cleansed liquid is discharged from the system through a stationary duct 48. A note on the design on the approximately parabolic cone of rotation 40: The water would, without this solid cone assume a parabolic surface shown as a dashed line just inside 40 which would have the unfortunate trait of providing a large free surface for evaporation of the liquid exposed to the low pressure of the vacuum system. To avoid this undesired and uncontrolled evaporation, the cone is made slightly larger in diameter at every point than it would be if it coincided with the free surface of rotation. Thus the separated air-liquid (a foam) rising to the cone's top is sized to be fully wetted by the bubble-liquid mixture, so avoiding the undesired evaporation, a major function of this invention. Only in a very narrow annulus 44 at the top of the system is the liquid exposed to the vacuum system, and then in heavy layers and only very briefly. In terms of the lesson taught by Eq. (1), those factors promoting evaporation according to Fick's law are minimized, except as they relate to the formation of gas-vapor bubbles in the CV, where they are maximized. To a first approximation, the only liquid evaporated (none is desired for reasons stated earlier) is that necessary to saturate the air bubbles. The volume of vapor released to the air bubbles is the same as the volume of the volume of air in the bubbles, according to Dalton's law of partial pressures. When and if we learn to rapidly break very small micro-bubbles, that vapor will further be reduced as the permanent air gasses in the micro-bubbles is compressed, and so too the air's volume. According to Dalton's law of partial pressures, the volume of the vapor would be that of the air which since it must be compressed in the vacuum system, is minimized, thus reducing equipment size and power to drive the vacuum pumps.
Another device 11 for separating and breaking the large bubbles is shown in FIG. 4, which shows an impeller 50 with half-vanes projecting through the inner, liquid layer containing large air-steam bubbles. The outer half-annulus of water contains those micro-bubbles not coalesced in the CV as in FIG. 1, as 54. The impeller is driven through a shaft 56, which is supported and sealed with a combination bearing and seal, 58. Experience has shown that the large air-steam bubbles are stable when rotating rapidly and under centrifugal force. The half-surface impeller acts as a centrifugal pump, expelling the liquid in the septa forming the bubbles to the outer layer, leaving the gasses behind. These separated gasses proceed to the vacuum system through duct 60, which performs as does 20 in FIG. 1. For large systems, this design has powerful advantages justifying the additional complexity, in that one device, similar in some respects to a centrifugal pump, can handle the output of any number of stages, as each consisting of the apparatus shown in FIG. 1.
One very important benefit of the system disclosed here is that the permanent gasses and volatile contaminants can be separated from the main liquid stream at a pressure much lower than necessary to volatilize the contaminating volatiles. The pressure is then raised in the diffuser of the cavitating venturi to a pressure just below that required to keep them in the gas mixture in the bubbles. Since most volatile liquids do not have an exact evaporation point--gasoline, for instance, is a mixture of many compounds--the result is that we can achieve maximum separation of the volatiles at a very low pressure while then raising them to as high a pressure as practicable. This has the very important advantage that the pressure increase in the vacuum pump, and so the power to drive it, will be minimized. The size of the compressor, an important cost factor, also can be minimized. This is illustrated for discussion in FIG. 5, to approximate scale, where the pressure along the length of a cavitating venturi is shown. In section A, the converging nozzle section a large portion of the dissolved gasses to be released are moved to very small bubbles. In the center, or coalescing section, C, massive steam bubbles are formed by dropping the pressure to any chosen value below the saturation temperature of the liquid. Much of the gasses in the micro bubbles formed in section A are incorporated into the massive steam bubbles (which can attempt, unsuccessfully of course, to achieve diameters of infinity if the pressure is just below the saturation pressure of the liquid) In the diffuser section, C, the pressure is raised to any desired value according to Bernoulli's theorem, avoiding excessive condensation (if that is the correct term) that would re-incorporate the volatilize gasses into the liquid. By controlling the pressure at the exit of the diffuser by suitably dimensioning the diffuser and discharging it at the desired pressure in the vacuum system, we can compress, for instance at a low pressure, D, or over-expand to a too-high pressure E or in a correct design, to a preferred pressure F, just high enough to avoid recondensation or perhaps re-solution in the liquid. Note also that the coalescing section of the cavitating venturi, B, need not be straight nor the pressure constant, but can be adjusted to reach almost absolute zero pressure, then increased to just below the saturation pressure to achieve maximum steam bubble size and so coalescence of the micro-gas bubbles. The steam re-condenses very early in the diffuser, section C, when the pressure rises above the liquid's saturation pressure.
FIGS. 6A, 6B, and 6C show 3 combinations of novel components revealed in the earlier FIGS. 1 through 4. Each combination achieves the important functions of releasing micro bubbles of gas from solution, coalescing part of them, then breaking the large bubbles formed by coalescence and sending their contents to a vacuum system in such a way as to avoid excessive evaporation of the liquid being cleansed or stripped of its permanent gasses.
The strength of the system can be understood by considering a possible need for separating helium, a permanent gas, and one or more of the more volatile fractions, say benzene, naphtha, etc, from a stream of crude oil. In the first stage, the final pressure at the discharge of the cavitating venturi's diffuser might be so high that any light fractions would be re-condensed and returned to the main stream, while the helium and other permanent gasses(for instance, air) are separated. The next stage could be designed to separate a more volatile fraction, the third stage a less volatile component, etc. | A system is described for rapidly removing dissolved permanent gasses or dissolved volatile contaminants from a liquid, in which the liquid is forced through a cavitating venturi, designed and operated in a fashion to produce micro-bubbles in the high-shear, converging flow section at its entry, to coalesce a significant fraction of these micro-air bubbles in a nominally straight section of maximum restriction following the inlet section, then in a final section, a diffuser, the steam bubbles condense, having during their lives caused coalescence of a significant fraction of the micro air bubbles, which are then, with the water carrying them separated from the remaining stream and its micro-bubbles. The stream separated carries large, easily broken air bubbles which then are broken in a suitable device (four are shown, each with a proposed best design for a specific size of system). The bubbles' contents, a mixture of air, volatiles and vapor are then sent to a vacuum system for processing to the atmosphere. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a mouse as an input device of a computer with a monitor having a windows application, and in particular, to such a mouse having an additional manually-operating mechanism for inputting additional instruction or control signals such as, for example, scroll control signals.
In a computer with a monitor a windows application, there are displayed on a screen of a monitor identification marks which are referred to as icons for identifying programs, documents and other applications. A cursor or pointer is also displayed for selectively pointing to one of the icons to open a desired one of the programs or documents. A mouse is used for controlling movement of the cursor on the screen to point to one of the icons for indication or actuation of opening of the program or document identified by the icon that is pointed at by the cursor.
Therefore, the mouse includes a motion detector for detecting a two-dimensional motion of the mouse itself to produce a positional signal which is used for controlling movement of the cursor on the screen so that the cursor moves on the screen according to the motion of the mouse. As the motion detector, there are known various types in the art. In a typical one, a trackball is mounted in the mouse to be freely rotated and therefore rotates according to motion of the mouse on a plane. A converting mechanism including photo-electric encoders is also mounted in the mouse to be coupled with the trackball and convert the rotation of the trackball into X and Y quadrature signals as a position signal.
Further, the mouse has at least one, usually two, click switch mechanisms for indication or actuation of the icon pointed by the cursor. Each of the click switch mechanism comprises a micro switch mounted in the mouse and a click button for manually operating the micro switch from the outside of the mouse. Therefore, the click buttons are exposed outside of a housing of the mouse.
On the other hand, there are messages in bit-mapped memory which are partially displayed at one time in a window area opened on the monitor and scrolled continuously so that the messages are displayed one part after another part. The scrolling operation is usually performed by handling a mouse to point and indicate an icon representing the scroll by moving the mouse and manipulating the click button.
Recently, there has been proposed in, for example, U.S. Pat. No. 5,530,455 and actually used a scroll control system in which the scroll can be controlled directly from a mouse. Therefore, the mouse additionally has a scroll control mechanism for controlling the scroll operation directly from the mouse. In detail, the scroll control mechanism comprises an additional switch for selecting a scroll mode and a control wheel for controlling selection of up-scroll and down-scroll and a scrolling speed and/or distance. The control wheel is rotatably mounted in a housing of the mouse and partially exposed outside the housing to be capable of being manually operated or rotated. The control wheel is coupled to a photo-electric encoder for producing a scroll signal which comprises a speed and/or distance signal representing a rotation speed of the control wheel and a direction signal representing a rotational direction of the control wheel. As known in the art, the photo-electric encoder comprises a photo-coupler and a rotary disk with a plurality of small holes. The rotary disk is rotated together with the control wheel.
The control wheel is also elastically supported in the housing to be pushed down to actuate the scroll mode selection switch.
In operation of the scroll system using the mouse, when the control wheel is rotated without pushing down the control wheel, the messages displayed on the monitor are scrolled by rotating the control wheel. The up-scroll and down-scroll are determined by rotational direction of the control wheel and the scrolling speed is determined by rotational speed of the control wheel.
On the other hand, after selecting the scroll mode by pushing down the control wheel to actuate the scroll mode selection switch, the messages displayed on the monitor can be scrolled continuously once rotating the control wheel. The scroll direction and speed are dependent on the rotational direction and angle of the control wheel. When the control wheel is again pushed down to actuate the scroll mode selection switch, the scroll mode is cancelled.
In the scroll mode, the motion detector is also used for providing the scroll control signal. When the mouse is moved at a distance in a direction after selecting the scroll mode, the distance and the direction detected by the motion detector provide the scroll direction and speed.
In the mouse with the control wheel used in the scroll system, it is troublesome for users to manually rotate the control wheel for controlling the scroll.
Further, the mouse is complicated by provision of the photo-electric encoder in addition to the position detector.
SUMMARY OF THE INVENTION
Therefore, it is a specific object of this invention to provide a mouse having a scroll control mechanism which is simple in structure and in operation by users.
It is a general object of this invention to provide a mouse having an additional function control mechanism which is simple in structure and in operation by users.
This invention is applicable to a mouse for use in input to a computer having a monitor, the monitor displaying a cursor, icons, and messages, which comprises a housing having an inner bottom surface, a positional movement detecting mechanism mounted in the housing for detecting movement of the mouse to produce a position signal, at least one click switch mechanism mounted in the housing and having a click switch button exposed outside of the housing for producing a click signal when the click switch button is operated, and an additional function control mechanism for inputting additional instructions for controlling a function of the computer. According to this invention, the additional function control mechanism comprises:
a first switch element mounted in the housing for producing a first switch signal upon being actuated;
a second switch element mounted in the housing for producing a second switch signal upon being actuated;
a third switch element mounted in the housing for producing a third switch signal upon being actuated;
at least one operating button exposed outside of the housing to be manually operated to actuate the first, the second and the third switches independently from each other from outside of the housing.
According to an embodiment, the first and the second switch elements are disposed to face each other with an interspace therebetween, while the third switch is positioned adjacent to the first and the second switch elements away from the interspace. A switch operating lever is disposed in the interspace and elastically supported on the housing to be thereby possible to be inclined and moved down from a normal standing position. The switch operating lever has a first operating portion to be brought into contact with the first switch element to actuate the first switch element when the switch operating lever is inclined towards the first switch element, a second operating portion to be brought into contact with the second switch element to actuate the second switch element when the switch operating lever is inclined towards the second switch element, and a third operating portion to be brought into contact with the third switch element to actuate the third switch element when the switch operating lever is pushed down. In this embodiment, the operating button is a single and common button which is mounted on a top end of the switch operating lever and having a top surface exposed outside of the housing for manually operating the inclination and downward movement of the switch operating lever.
According to another embodiment, the first and the second switch elements are disposed to face each other with an interspace therebetween. The third switch is positioned adjacent to a side wall of the housing. A switch operating lever is disposed in the interspace and supported on the housing to be possible to be inclined from a normal standing position. The switch operating lever has a first operating portion to be brought into contact with the first switch element to actuate the first switch element when the switch operating lever is inclined towards the first switch element, and a second operating portion to be brought into contact with the second switch element to actuate the second switch element when the switch operating lever is inclined towards the second switch element. In this embodiment, the operating button comprises a first button which is mounted on a top end of the switch operating lever and having a top surface exposed outside of the housing for manually operating the inclination of the switch operating lever from the outside of the housing, and a second button mounted on the side wall of the housing to be movable inward to thereby push and actuate the third switch.
According to a further embodiment, the housing is generally in an egg shape in a plan view, and two click switch buttons are disposed in a top face at an end portion having a relatively large curvature of the egg shape and in parallel with a longitudinal direction of the egg shape. The first and the second switch elements are disposed adjacent to an inner surface of a side wall of the housing, and the third switch element is disposed between the two click mechanism. In this embodiment, the operating button comprises a first button and a second button mounted in the side walls to be pushed inwardly to actuate the first and the second switch elements, respectively, and a third button disposed in the top face between the two click switch buttons to be pushed inwardly for actuating the third switch element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a mouse according to an embodiment of this invention;
FIG. 2 is a side view of the mouse of FIG. 1;
FIG. 3 is a plan view of the mouse of FIG. 1 with an upper case being removed;
FIG. 4 is a sectional view of a portion of a control switch mechanism of the mouse of FIG. 1;
FIG. 5 is a perspective view illustrating the control switch mechanism disassembled;
FIG. 6 is a perspective view of a mouse according to another embodiment;
FIG. 7 is a sectional view of an manually operating button with actuator rod used in the mouse of FIG. 6;
FIG. 8 is a sectional view of another example of the manually operating button;
FIG. 9 is a plan view of a mouse according to another embodiment of this invention;
FIG. 10 is a side view of the mouse of FIG. 9;
FIG. 11 is a plan view of the mouse of FIG. 9 with an upper case being removed;
FIG. 12 is a sectional view of a portion of a control switch mechanism of the mouse of FIG. 9;
FIG. 13 is a perspective view illustrating the control switch mechanism disassembled;
FIG. 14 is a plan view of a mouse according to another embodiment of this invention;
FIG. 15 is a side view of the mouse of FIG. 14;
FIG. 16 is a plan view of the mouse of FIG. 14 with an upper case being removed;
FIG. 17 is a perspective view of a mouse according to another embodiment of this invention; and
FIG. 18 is an opposite side view of the mouse of FIG. 17.
DESCRIPTION OF PREFERRED EMBODIMENTS
Now, a mouse according to an embodiment of this invention will be described with reference to FIGS. 1-5, below.
Referring to FIGS. 1 and 2, the mouse 1 comprises a housing 11 in combination with an upper case 11a and a lower case 11b, first and second click switch buttons 12-1 and 12-2 exposed in the outer surface of the upper case 11a, and an additional switch button or a manual operating button 13 also exposed in the outer surface of the upper case 11a.
The housing is formed in an egg shape in the plan view. The first and second click switch buttons 11-1 and 11-2 are disposed in the top face of the housing 11 at the larger curvature end portion of the egg shape and in parallel with each other in the longitudinal direction of the egg shape. The additional switch button 13 is disposed in an interspace between the both click switch buttons 11-1 and 11-2.
Referring to FIG. 3, there is fixedly mounted a printed circuit board 14 in the lower case 11b. First and second click switches 12a and 12b are mounted on a surface of the printed circuit board 14 and are disposed under the first and second click switch buttons 12-1 and 12-2, respectively, so that they are actuated by the first and second click switch buttons 12-1 and 12-2 pushed down to produce first and second click signals, respectively.
In the housing 11, there is further mounted a motion detector of a known trackball type for detecting movement of the mouse 1 itself. The motion detector 15 comprises a ball 15a mounted to rotate in any rotational direction in the housing 11 and is partially projected out of an bottom surface of the lower case 11b. Accordingly, the ball 15a is rotated when the mouse 1 is moved or slid on a desk. Two photo-electric encoders 15-1 and 15-2 are mounted on the printed circuit board 14 and are engaged with the ball 15a for detecting the rotation of the ball 15a to produce X and Y signals, respectively.
The mouse 1 has an additional function control mechanism including the additional switch button 13.
Referring to FIGS. 4 and 5 in addition to FIG. 3, the additional function control mechanism comprises first and second switches 16-1 and 16-2 that are mounted on the printed circuit board 14 and that face each other with an interspace therebetween, a third switch 17 adjacent to the first and the second switches 16-1 and 16-2 away from the interspace of those first and second switches, and an actuator rod or a switch operating lever 18 for actuating those three switches 16-1, 16-2 and 17.
In the embodiment shown, tact switches are used for the first and the second switches 16-1 and 16-2 and a micro switch is used for the third switch 17. Each of these three switches has an actuator button of insulator (shown at 16a and 17a) which is elastically projected out of the switch. The actuator button has a movable contact (not shown) within the switch which has also a fixed switch contact. When the actuator button is pushed into the switch against the elastic projecting force by the actuating rod 18, the movable contact is brought into contact with the fixed contact in the switch. When a pushing force by the actuator rod 18 is cancelled, the actuator button is again projected outwardly. In other words, the switch 16-1, 16-2 and 17 can automatically restore to its normal condition when no external force is applied to the actuator button.
The printed circuit board 14 has an opening 14a in an area between the first and the second switches 16-1 and 16-2. The actuator rod 18 is elastically supported by coil springs 19 through the opening 14a on an inner bottom surface of the lower case 11b. Therefore, the actuator rod 18 can be pushed down against the coil springs 19 and can also be inclined from the standing condition. The actuator rod 18 has first and second actuating or operating portions 18a and 18b which are brought into contact with, and push, the actuator buttons 16a of first and second switches 16-1 and 16-2, respectively, when the actuator rod 18 is inclined toward first and second switches 16-1 and 16-2, respectively. The actuator rod 18 is further provided with a third actuating portion 18c which pushes down the actuator button 17a of the third switch 17 when the actuator rod 18 is pushed down.
Referring to FIG. 5, the actuator rod 18 comprises an upper part 18-1 and a lower part 18-2 both being assembled and combined by fitting keys 20 into key holes 21. Both parts can be molded of plastic resin into given forms by use of individual molds. The lower part 18-2 has holes for receiving the coil springs 19. On the other hand, the upper part 18-1 has a top end on which the additional switch button 13 is attached.
Now, description will be made as to operation of the additional function control mechanism of the mouse in use for controlling scroll operation in the scroll system.
The first and second click switches 12a and 12b accompanied with click buttons 12-1 and 12-2 and the motion detector 15 are operated and used in a usual manner as known in the art.
When the additional control button 13 is pushed down, the actuator rod 18 goes down against the coil springs 19 to push down the actuator button 17a of the third switch 17 by its third actuating portion 18c. Thus, the third switch 18 is turned on to produce an electric signal which is used as a scroll mode selection signal.
When the additional control button 13 is pushed forward (in the right direction in FIGS. 1 and 2) to incline the actuator rod 18 toward the first switch 16-1, the actuator button 16a thereof is pushed by the first actuating portion 18a, so that the first switch 16-1 is turned on to produce a first electric signal during a time when the first switch 16-1 is maintained on. The first electric signal is used as a first scroll signal. That is, the messages displayed on the monitor are up-scrolled at a constant scroll speed until the first scroll signal is stopped. On the contrary, when the additional control button 13 is pushed rearward (in the left direction in FIGS. 1 and 2) to incline the actuator rod 18 toward the second switch 16-2, the actuator button 16a thereof is pushed by the second actuating portion 18a, so that the second switch 16-2 is turned on to produce a second electric signal during a time when the second switch 16-2 is maintained on. The second electric signal is used as a second scroll signal. That is, the messages displayed on the monitor are down-scrolled at a constant scroll speed until the second scroll signal is stopped.
On the other hand, after selecting the scroll mode by pushing down the additional control button 13 to actuate the third switch 17, the messages displayed on the monitor can continuously be scrolled at a constant speed upward or downward once actuating the first switch 16-1 or the second switch 16-2, respectively. When the additional control button 13 is again pushed down to actuate the third switch 17, the scroll mode is cancelled.
In the scroll mode, the motion detector 15 is also used for providing the scroll signal in the similar manner known in the prior art as described in the preamble.
In the mouse 1 according to an embodiment shown FIGS. 1-5, the additional switch button 13 has a generally elongated rectangular shape in the plan view as shown in FIG. 1 and has a concave top surface where a center portion is depressed comparing with peripheries at both ends in the longitudinal direction as shown in FIGS. 2 and 4.
Referring to FIGS. 6 and 7, the mouse 1 shown therein is similar to that shown in FIGS. 1-5 except that the additional switch button 13 has a different shape. That is, it has a circular shape with a concave top surface where a center portion is depressed comparing with the circumferential periphery as shown in FIG. 7.
Referring to FIG. 8, a modified example of the additional switch button 13 shown therein has a convex top surface where a center portion projects comparing with the circumferential periphery.
Referring to FIGS. 9-13, the mouse 1 according to another embodiment shown therein has a similar structure as that shown in FIGS. 1-5 except some differences described below.
The additional switch button 13 in FIG. 1 is also shown as a first button 13-2 and used for operating the first and the second switches 16-1 and 16-2 except the third switch 17. Therefore, the actuator rod 18 does not have the third actuating portion (shown at 18c in FIGS. 3-5). Further, the actuator rod 18 is supported on the inner bottom surface of the lower case 11b without use of coil springs 19 but the lower end of the actuator rod is slidable for rotation to enable the actuator rod 18 to inline towards the first or the second switch 16-1 or 16-2.
The first switch button 13-1 can have any one of the different shapes as shown in FIGS. 6-9.
The third switch 17 is mounted at a position far away from the first and second switch 16-1 and 16-2 and adjacent to a side wall of the housing 11. Therefore, a side wall button 13-2 is mounted in the side wall of the housing 11, or in the lower case 11b. The micro switch 17 sits sideways although upwards in the mouse of FIGS. 1-5.
The other structures are similar to those in the embodiment of FIGS. 1-5. Therefore, they are only shown in the figures but are not described here for the purpose of simplification of the description.
In use of the mouse 1 of FIGS. 9-13, the first switch button 13-1 and the second switch button 13-2 can usually be handled by different fingers, for example, a forefinger and a little finger, respectively.
Referring to FIGS. 14-16, the mouse 1 shown therein is similar to the mouse of FIGS. 1-5 except that the three switches 16-1, 16-2 and 17 individually have first, second and third switch buttons 13-1, 13-2, 13-3, respectively, while the first and second switches 16-1 and 16-2 being disposed adjacent to a sidewall of the housing 11.
In detail, the first switch 16-1 and the second switch 16-2 are disposed adjacent to an inner surface of the housing 11, specifically, the upper case 11a and the lower case 11b, respectively. The upper case 11a and lower case 11b are provided with the first and the second switch buttons 13-1 and 13-2 for actuating the first and the second switches 16-1 and 16-2, respectively, as shown in FIGS. 15 and 16. Thus, when the first switch button 13-1 is pushed, the actuator button 16a of the first switch 16-1 is pushed by an inner wall of the first switch button 13-1. Therefore, the first switch 16-1 is turned on. Similarly, when the second switch button 13-2 is pushed, the actuator button 16a of the second switch 16-2 is pushed by an inner wall of the second switch button 13-2. Therefore, the second switch 16-2 is turned on.
The third switch button 13-3 is disposed between the two click switch buttons 12-1 and 12-2. This is similar to the button 13 in FIG. 1. The third switch 17 is disposed under the third switch button 13-3 so that the third switch 17 is actuated by the third switch button 13-3 pushed down.
The third switch button 13-3 is shown in an elongated rectangular shape similar to the button 13 in FIG. However, it can have different shape as shown in FIGS. 6-8.
In use of the mouse 1 of FIGS. 14-16, the third switch button 13-3 can be manipulated by the forefinger while the first and the second switch buttons 13-1 and 13-2 can be handled by the little finger.
Referring to FIGS. 17 and 18, the mouse 1 shown therein is a modification of the mouse 1 shown in FIGS. 14-16. In this modification, the first and the second switch buttons 13-1 and 13-2 are mounted in opposite side walls of the lower case 11b. Therefore, it will be easily noted that the first and the second switches 16-1 and 16-2 are also disposed adjacent to the opposite sidewalls of the lower case 11b, although it is not shown for the simplification of the drawing.
The third button 13-3 is shown to have a circular shape but has an elongated rectangular shape as shown in FIG. 14.
In use of the mouse 1 shown in FIGS. 17 and 18, the third switch button 13-3, the first switch button 13-1 and the second switch button 13-2 are handled by the forefinger, the thumb and the little finger, respectively. | In a mouse having two click switches with buttons, a motion detector and an additional control switch mechanism for a function of scrolling are provided. The additional control switch mechanism includes a first, a second, and a third switch for producing an up-scroll signal, a down-scroll signal, and a scroll mode selection signal, respectively when being actuated. A single actuator rod having a top push button is disposed to be able to incline opposite directions to selectively actuate the first and second switches and to be pushed down to actuate the third switch. The top push button is disposed between the click switch buttons. Alternatively, the third switch with a push button thereof is disposed at a sidewall of the mouse. In another arrangement, the third switch and the push button thereof are disposed between the two click switch mechanisms, and the first switch a push button thereof and the second switch with a push button thereof are disposed in a sidewall of the mouse. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. Provisional Application No. 61/406,532, filed Oct. 25, 2010, which is pending at filing of the present application, and which is incorporated by reference in its entirety herein.
BACKGROUND
[0002] 1. Field
[0003] Embodiments of the present invention generally relate to systems and methods for drainage of door, window and other fenestration systems, and more specifically relate to accessible adjustable height drainage systems configured for draining water or other liquid intrusion in to building structure openings, access routes, or fenestration products such as one or more doors, sliding doors, hinged doors, rotational door, revolving doors, jambs, windows, window sills, and other types of openings in a building or wall.
[0004] 2. Description of the Related Art
[0005] Various door, window and fenestration systems have long been a desirable option for providing access to residences, businesses and other structures as they can provide an opening for entry and exit. However, with environmental conditions, water, rain, snow, sprinklers, flooding, puddles or other liquids can also enter from the exterior to the interior of a structure through these systems, potentially causing cosmetic or structural damage to flooring, rugs, carpets, paneling, furniture, and other items inside the structure. Some drainage systems are fixed or non-adjustable, and some require removal of the door or window for accessibility for service, adjustment or cleaning purposes.
[0006] Some door, window or fenestration systems are difficult to seal. Some door systems include some type of weather stripping or a brush along a border or edge to form a seal with the floor, wall, and/or ceiling surface. However, in order to effectively seal, some types of weather stripping or brushes slide along the floor or other surface while the door system is being opened or closed. Accordingly, the weather stripping can wear rather quickly until it loses effectiveness at forming a seal. If the unit is adjusted downward in order to close the gap too much, the added friction will not allow the panel to slide freely. Many attempts to just add brushes to reduce the friction will allow water and air infiltration. Thus, many of these systems do not easily compensate for infiltration of non-desired liquids in to the interior of a structure.
SUMMARY
[0007] Several embodiments of the present invention relate to drainage systems for reduction or elimination of liquid infiltration in to a structure though an access point in or out of buildings or structures, such as commercial or residential homes, or other structures with doors or windows. In some embodiments, the drainage system is adjustable. In some embodiments, the drainage system is vertically adjustable to controllably place the height of the drainage system above, below or flush with one or more surrounding floor or fenestration portal surfaces. In some embodiments, the drainage system is readily accessible for service without removing or disassembling the door or window.
[0008] In various embodiments, the drainage system can be used with any door or window or other opening in a wall for any type of structure, such as a door, sliding door, hinged door, revolving door, rotating door, pet door, window or other portal structure. Although some embodiments will be described in the context of use on a sliding door system, some embodiments of the drainage system can be used on any type of door, window, or panel.
[0009] In various embodiments, a drainage system is configured to redirect water or other liquids or fluids from accumulation on or near a door or other structural entry point. In various embodiments, the drainage system includes a channel to collect liquid and redirect or drain the liquid to the exterior or to a drainage system, such as a sewer or rain gutter or other system for removing the liquid from the structure. In one embodiment, the drainage system includes an adjustable dimension component for vertically, horizontally, or otherwise moveably adjusting a drainage system component, such as a cap, to a position with respect to the surrounding floor, wall, or other structural feature. In various embodiments, the drainage system is accessible for service. In various embodiments the service is cleaning, adjusting, adjusting the height, or other action in relation to the drainage system.
[0010] In one embodiment, a door drainage system includes a base, an adjustable height cover and two or more adjustable members configured to controllably position the adjustable height cover. The base includes a channel configured for redirecting a liquid away from a door. The adjustable height cover is removably positionable on the base. In one embodiment, the adjustable height cover is configured to be readily removable from the base for service without removing or disassembling the door. In one embodiment, the adjustable member base is connected to the base. In one embodiment, the adjustable member is linearly positionable with respect to the adjustable member base. In various embodiments, the two or more adjustable members are configured to controllably position the adjustable height cover to be flush with, higher than, or recessed below an adjacent structural surface. In one embodiment, at least one adjustable member includes an elongate threaded member configured for controlled vertical positioning of the adjustable height cover. In one embodiment, the adjustable height cover includes a plurality of apertures configured to redirect flow of a liquid through the drainage system. In one embodiment, the body includes a first wall, a second wall and a base at least partially surrounding the channel. In one embodiment, the body includes a U-shaped extrusion. In one embodiment, the door drainage system also includes a filter configured to fit in the channel. In one embodiment, the drainage system also includes one or more exit ports in the base in fluid connection with one or more drainage ports configured to direct the liquid away from the base. In one embodiment, the drainage system also includes a valve for adjustable fluid control. In one embodiment, a valve is disposed on one or more drainage ports. In one embodiment, the drainage system also includes one or more sliding doors disposed on a track disposed in an exterior position with respect to the base.
[0011] 1. In one embodiment, a door drainage system includes a base, an adjustable height cover, an adjustable member base, two or more adjustable members, and one or more exit ports. The base includes a channel configured for redirecting a liquid away from a door. The adjustable height cover is removably positionable on the base, with the adjustable height cover including a plurality of apertures configured to redirect flow of a liquid through the drainage system. The adjustable member base is connected to the base, and the adjustable member is linearly positionable with respect to the adjustable member base. The two or more adjustable members are configured to controllably position the adjustable height cover to be flush with, higher than, or recessed below an adjacent structural surface. The one or more exit ports in the base is in fluid connection with one or more drainage ports configured to direct the liquid away from the base. The adjustable height cover is configured to be readily removable from the base for service without removing or disassembling the door. In one embodiment, at least one adjustable member includes an elongate threaded member configured for controlled vertical positioning of the adjustable height cover. In one embodiment, the drainage system includes a filter configured to fit in the channel. In one embodiment, the drainage system includes a valve for adjustable fluid control.
[0012] In one embodiment, a fenestration product drainage system includes a base, an adjustable height cover, and an adjustable member. The base includes a channel configured for redirecting a liquid away from a fenestration product. The adjustable height cover is removably positionable on the base. The adjustable member is configured to controllably position the adjustable height cover. In one embodiment, the adjustable height cover is configured to be readily removable from the base for service without removing or disassembling the fenestration product. In one embodiment, the fenestration product is a door. In one embodiment, the fenestration product is a window. In one embodiment, the adjustable member includes an elongate threaded member configured for controlled vertical positioning of the adjustable height cover. In one embodiment, the fenestration product includes one or more exit ports in the base in fluid connection with one or more drainage ports configured to direct the liquid away from the base. In one embodiment, the fenestration product includes a valve for adjustable fluid control. In one embodiment, the fenestration product includes a filter configured to fit in said channel.
[0013] The details of various embodiments are set forth in the accompanying drawings and the description herein. Other features and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and other aspects of embodiments of the present invention will now be described in detail with reference to the following drawings.
[0015] FIG. 1 is a schematic front partial cross sectional view of a drainage system according to an embodiment of the present invention;
[0016] FIG. 2 is a schematic front partial cross sectional view of a flush configuration drainage system according to an embodiment of the present invention;
[0017] FIG. 3 is a schematic front partial cross sectional view of an elevated configuration drainage system according to an embodiment of the present invention;
[0018] FIG. 4 is a schematic front partial cross sectional view of a recessed configuration drainage system according to an embodiment of the present invention;
[0019] FIG. 5 is a schematic front partial cross sectional view of a sliding door configuration drainage system according to an embodiment of the present invention;
[0020] FIG. 6 is a schematic front partial cross sectional view of a multiple sliding door drainage system according to an embodiment of the present invention;
[0021] FIG. 7 is a schematic front partial cross sectional view of a drainage system according to an embodiment of the present invention;
[0022] FIG. 8 is a schematic front partial cross sectional view of a compact height configuration of a drainage system according to an embodiment of the present invention;
[0023] FIG. 9 is a schematic front partial cross sectional view of the drainage system according to FIG. 7 with an adjustable height cover removed;
[0024] FIG. 10 is a schematic side view of the drainage system according to FIG. 7 ;
[0025] FIG. 11 is a schematic isometric view of the drainage system according to FIG. 7 with an adjustable height cover removed;
[0026] FIG. 12 is a schematic elevated isometric view of the drainage system according to FIG. 7 with an adjustable height cover removed;
[0027] FIG. 13 is a schematic elevated isometric view of the drainage system according to FIG. 7 ;
[0028] FIG. 14 is a schematic side isometric view of the drainage system according to FIG. 7 ;
[0029] FIG. 15 is a schematic side isometric view of the drainage system according to FIG. 7 with an adjustable height cover removed;
[0030] FIG. 16 is a schematic side isometric view of the drainage system according to FIG. 7 with an adjustable height cover removed;
[0031] FIG. 17 is a schematic isometric view of a cover according to an embodiment of the present invention;
[0032] FIG. 18 is a schematic side view of a cover according to FIG. 17 .
[0033] Like reference symbols in the various drawings indicate like elements. Throughout the figures, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components or portions of the illustrated embodiments. Moreover, while embodiments of the subject invention will now be described in detail with reference to the figures, it is done so in connection with the illustrative embodiments. It is intended that changes and modifications can be made to the described embodiments without departing from the true scope and spirit of the subject invention as defined by the appended claims.
DETAILED DESCRIPTION
[0034] Several embodiments of the present invention relate to drainage systems for access points to architectural building structures, such as commercial or residential homes, buildings, or other structures with doors or windows. In various embodiments, the drainage system can be used with any door or window or other opening in a wall for any type of structure, such as a door, sliding door, hinged door, rotatable door, revolving door, pet door, or window. Although some embodiments will be described in the context of use on a sliding door system, some embodiments of the drainage system can be used on any type of door, window, or panel. In various embodiments, the drainage system can be configured to be flush with, higher than, or recessed below a floor or jamb surface. In some embodiments, the drainage system is located inside, outside, or anywhere on the floor between interior to exterior jamb edges. In various embodiments, the drainage system can be configured to act as a stop on the interior or exterior of any door, window, or other fenestration product. In one embodiment, the drain system is configured to prevent liquid or moisture from entering the interior of a structure beyond an interior jamb line.
[0035] FIG. 1 illustrates one embodiment of the invention in which a drainage system 200 is configured to reduce or eliminate liquid infiltration in to a structure through a fenestration product 10 . In various embodiments, the fenestration product is a door, window, or other moveable closure device configured for providing access in to or out of a structure, building or wall. In various embodiments, the drainage system 200 comprises a body 210 and a cover 280 . In one embodiment, the body 210 is a U-shaped extrusion with a first wall 220 , a second wall 230 and a base 240 partially or completely surrounding a channel 215 . In one embodiment, the first wall 220 comprises a first wall channel surface 222 facing the channel 215 and a first wall floor surface 224 facing a floor 6 , 7 or a direction laterally outside of the body 210 . In one embodiment, the second wall 230 comprises a second wall channel surface 232 facing the channel 215 and a second wall floor surface 234 facing a floor 6 , 7 or a direction laterally outside of the body 210 . In one embodiment, the first wall 220 has a first wall height 226 (see FIGS. 7 and 8 ). In one embodiment, the second wall 230 has a second wall height 236 . In various embodiments, the first wall height 226 is the same or similar to the second wall height 236 , the first wall height 226 is greater than the second wall height 236 , or the first wall height 226 is less than the second wall height 236 . In various embodiments, the first wall height 226 and/or the second wall height 236 is less than 1 inch, 1 inch, 1.125 inches, 1.1875, 1.25 inches, 1.375 inches, 1.5 inches, 1.625 inches, 1.75 inches, 1.875 inches, 2 inches, 2.125 inches, 2.1875, 2.25 inches, 2.375 inches, 2.5 inches, 2.625 inches, 2.75 inches, 2.875 inches, 3 inches, 3.125 inches, 3.1875, 3.25 inches, 3.375 inches, 3.5 inches, 3.625 inches, 3.75 inches, 3.875 inches, 4 inches, or any dimension or range of dimensions between 0.5 inches and 1 foot or more.
[0036] In one embodiment, the first wall 220 is on an interior 120 side and the second wall 230 is on an exterior 122 side of the drainage system 200 with respect to a fenestration product 10 . In one embodiment, the first wall 220 is on an exterior 122 side and the second wall 230 is on an interior 120 side of the drainage system 200 with respect to a fenestration product 10 .
[0037] In one embodiment, the base 240 includes a base channel surface 245 facing the channel 215 . In various embodiments, the base channel surface 245 is sloped, slanted, angled, or configured to direct a liquid from the channel 215 to one, two, three, four, or more exit ports 250 . In various embodiments, the second wall 230 includes one, two, three, four, or more exit ports 250 . In various embodiments, the first wall 220 includes one, two, three, four, or more exit ports 250 . In various embodiments, the base channel surface 245 includes one, two, three, four, or more exit ports 250 .
[0038] In one embodiment, the exit port 250 is in fluid connection with one or more drainage ports 254 . In one embodiment, the drainage port 254 includes a drainage port lumen 256 configured to direct a liquid away from the channel 215 of the base 210 . In various embodiments, the drainage port 254 is directed toward the exterior 122 of the structure, the interior of the structure 120 , a sewer, a gutter, a rain gutter, piping, tubing, or other devices for diverting a fluid away from a structure.
[0039] In various embodiments, a valve 258 may be placed in or along the fluid drainage route. In one embodiment, one or more valves 258 are positioned to control the rate and/or direction of fluid (gas, liquid, etc.) flow. In one embodiment, one or more valves 258 is positioned in or along one or more exit ports 250 . In one embodiment, as shown in FIGS. 11 and 14 , one or more valves 258 is positioned in or along one or more drainage ports 254 . In one embodiment, one or more valves 258 is positioned in or along one or more drainage port lumens 256 . In one embodiment, one or more valves 258 is positioned in or along a structure, interior structure, exterior structure, drain, sewer, a gutter, a rain gutter, piping, tubing, or other devices for diverting a fluid away from a structure. In some embodiments, one or more valves 258 is readily accessible for service or actuation without removing or disassembling the door or window. In various embodiments, the valve 258 can be accessed through removal of the cover 280 . In various embodiments, a valve 258 can be directly or indirectly controlled through manual manipulation, electronic control, remote control, and other techniques. In one embodiment, a valve 258 can be altered or actuated to account for potential severe weather conditions, such as a storm, flooding, rain, high winds or other conditions. In various embodiments, a valve 258 can open, close, partially obstruct, and/or redirect flow within the drainage system 200 . In some embodiments, fluid flow moves in a direction from high to low pressure, and can use pressure or head to control fluid flow. In various embodiments, one or more actuators, handles, levers, pedals, switches, pistons, diaphragms, hydraulics, pneumatics, solenoids, motors, and/or materials can be used to respond to pressure, temperature, humidity or other measurable conditions. In various embodiments, a valve 258 may be a ball valve, butterfly valve, disc valve, check valve, one-way valve, two-way valve, choke valve, diaphragm valve, gate valve, globe valve, knife valve, needle valve, pinch valve, piston valve, plug valve, poppet valve, spool valve, thermal expansion valve, pressure relief valve, active valve, passive valve, or any other type of valve. In various embodiments, a valve 258 can connects to the drainage system 200 mechanically, chemically, magnetically, in threaded engagement, snap locked together, adhered, bonded, or with other connecting devices or methods.
[0040] In various embodiments, any components of a drainage system 200 can be manufactured from stainless steel, aluminum, metal, plastic, wood, hard wood or other materials and can be extruded, machines, cast, and/or completed with multiple finishes to accommodate specific needs of a customer whether for harsh weather conditions or more aesthetically pleasing to their tastes. In various embodiments, the drainage port 254 is rigid, flexible, malleable, bendable, PVC, copper, tubing, and can be circular, rectangular, square, or any other shape in cross section. In various embodiments, the drainage port 254 has a length in the range of 1-12 inches, 1-5 feet or more, the width of a door assembly, the width of a window assembly, the width of a jamb, configured to connect to a secondary drainage system, or other lengths. In one embodiment, the drainage port 254 is connectable to the base 210 with an exit port interface 252 . In various embodiments, the exit port interface 252 connects the drainage port 254 to the base 210 mechanically, chemically, magnetically, in threaded engagement, snap locked together, adhered, bonded, or with other connecting devices or methods.
[0041] In various embodiments, the body 210 can optionally include one, two, three, four or more flanges 270 . In various embodiments, the flanges 270 can structurally connect the body 210 to a fenestration product 10 or objects related to the fenestration product 10 , an interior floor 6 , an exterior floor 7 , a track 8 , channel, extrusion, or other structure. In various embodiments, the drainage system 200 is optionally configured to fit with or connect to a fenestration system, a door system, a window system, a track system, a cross member, flooring, interior flooring, exterior flooring, a shim, shim space, caulk, caulk line, seal, sill pan, flashing, insulation, stone, concrete, wood, foundation, framing, drywall, expansion joints, or other structures.
[0042] In one embodiment, a cover 280 is an adjustable cover. In one embodiment, the cover 280 is height-adjustable. In one embodiment, the cover 280 includes a cover top surface 283 . In one embodiment, the cover 280 includes a cover top surface 283 , a cover first wall 284 and a cover second wall 286 . In one embodiment, the cover 280 is a U-shaped cap. In one embodiment, the cover 280 has a cover width 281 and a cover height 282 and a cover length 287 (see FIG. 18 ). In various embodiments, the cover 280 can be configured with a cover width 281 and a cover height 282 and a cover length 287 to fit on top of a base 210 , inside a base 210 , around a base 210 , outside a base, have corresponding dimensions as a base 210 , have a dimension that is greater than a corresponding base 210 dimension, have a dimension that is less than a corresponding base 210 dimension, have a dimension that is the same as or similar to a corresponding base 210 dimension, or other dimensions. In various embodiments, the cover length 287 is 1 foot or less, 1-5 feet, 5-10 feet, 10 feet or more, or any range of sizes. In various embodiments, a drainage system 200 is straight, curved, arced, segmented, angular, or otherwise shaped to meet fenestration product 10 dimensions.
[0043] In one embodiment, the cover 280 includes one or more apertures 288 . In various embodiments, the cover 280 includes one, two, three, four, five or more, ten or more, twenty or more, fifty or more, a plurality, or multiple apertures 288 configured to redirect fluid from the cover 280 through the channel 215 of the body 210 to one or more drainage ports 254 . In various embodiments, the apertures 288 can be located on the cover top surface 283 , the cover first wall 284 and/or the cover second wall 286 . In one embodiment the cover has a cover width 281 (see FIGS. 7 and 8 ). In one embodiment the cover has a cover height 282 (see FIGS. 7 and 8 ). In one embodiment the distance of the top of the cover 280 to the top of a body wall 220 , 230 is a cover-to-body-wall height 292 (see FIGS. 7 and 8 ). In various embodiments, the cover-to-body-wall height 292 is less than 1 inch, 0.125 inches, 0.1875, 0.25 inches, 0.375 inches, 0.5 inches, 0.625 inches, 0.75 inches, 0.875 inches, 1.0 inches, 1.25 inches, 1.5 inches, 2 inches, or any dimension or range of dimensions between 0.125 inches and 3 inches or more. FIGS. 17-18 illustrate a cover 280 according to an embodiment of the present invention.
[0044] In various embodiments, the one or more apertures 288 is a slot, opening, hole, weep hole, a punch hole, a filter, or otherwise configured to redirect flow of a liquid away from a fenestration product 10 . In various embodiments, the one or more apertures 288 can have a circular, oval, rounded, rectilinear, square, rectangular, slanted, patterned or other shape. In one embodiment, the apertures 288 are configured to prevent the passage of insects or debris from clogging the drainage system 200 . In one embodiment, the cover 280 is configured to be readily accessible for servicing without removing or disassembling the fenestration product 10 .
[0045] In one embodiment, the drainage system 200 includes one or more adjustable members 260 configured to be movable with respect to an adjustable member base 262 to adjust a dimension or a position of the cover 280 . In one embodiment, the one or more adjustable members 260 are configured to alter, modify, adjust, move, or align a cover 280 . In one embodiment, an adjustable member 260 is configured to change the cover-to-body-wall height 292 . In various embodiments, the adjustable member 260 is a screw, bolt, nut, spring, lever, mechanism, solenoid, ratchet, gear, shim, elongate member, threaded member, or other device configured to be controllably altered to change and/or maintain the position of an adjustable cover 280 . In various embodiments, the adjustable member base 262 is a threaded hole, nut, screw, bolt, spring, lever, mechanism, solenoid, ratchet, gear, shim, elongate member, threaded member, or other device configured to be controllably change and/or maintain the position of the adjustable member 260 . In one embodiment, the adjustable member 260 is configured to be readily accessible for servicing without removing or disassembling the fenestration product 10 . In one embodiment, the adjustable member base 262 is configured to be readily accessible for servicing without removing or disassembling the fenestration product 10 .
[0046] In one embodiment, the first wall channel surface 222 includes one, two, three, four, or more adjustable member interfaces 264 . In one embodiment, an adjustable member interface 264 extends along a body length 213 of body 210 (see FIG. 14 ). In various embodiments, an adjustable member interface 264 is configured to connect the base 210 to an adjustable member 260 and/or an adjustable member base 262 through unitary construction, separate movable parts, welding, bonding, attaching, adhering, permanently attaching, temporarily attaching or some other type of interface. In one embodiment, the drainage system 200 is configured to conceal, contain, and/or route wires, connectors, cables, optical cables, lights, sensors, alarms or other apparatus in proximity to a fenestration product 10 .
[0047] As illustrated in FIGS. 2-6 , in accordance with various embodiments of drainage systems 200 , one or more drainage systems 200 includes can be used with one or more fenestration products 10 .
[0048] FIG. 2 illustrates a flush configuration drainage system 200 according to an embodiment of the present invention in which a cover 280 is configured to be substantially flush with an interior floor surface 6 , an exterior floor surface 7 , or both. In one embodiment, the cover 280 is an adjustable cover 280 set to a height to allow a fenestration product 10 to open or close inward and/or outward, in an interior 120 direction, an exterior 122 direction, and/or a direction parallel or substantially parallel to the body length 213 of the drainage system 200 .
[0049] FIG. 3 illustrates an elevated configuration drainage system 200 according to an embodiment of the present invention in which a cover 280 is configured to be elevated above an interior floor surface 6 , an exterior floor surface 7 , or both. In one embodiment, the cover 280 and/or body 210 of the drainage system 200 is configured to act as a stop to a fenestration product 10 , preventing motion in the direction impacting or abutting the drainage system 200 .
[0050] FIG. 4 illustrates a recessed configuration drainage system 200 according to an embodiment of the present invention in which a cover 280 is configured to be recessed below an interior floor surface 6 , an exterior floor surface 7 , or both. In one embodiment, the cover 280 is an adjustable cover 280 set to a height to allow a fenestration product 10 to open or close inward and/or outward, in an interior 120 direction, an exterior 122 direction, and/or a direction parallel or substantially parallel to the body length 213 of the drainage system 200 .
[0051] FIG. 5 illustrates a sliding door configuration drainage system 200 according to an embodiment of the present invention configured to operate with a sliding door. FIG. 6 illustrates a multiple sliding door drainage system 200 according to an embodiment of the present invention whereby the present invention configured to operate with multiple sliding doors. In various embodiments, any number of embodiments of one or more fenestration products 10 can be used to form a sliding door panel system 11 . In various embodiments, additional door panels can be denoted with a prime symbol, such as a first door panel 15 , a second door panel 15 ′, a third door panel 15 ″, etc. In various embodiments of sliding door systems, two or more sliding door panels 15 can be arranged, typically sliding on parallel tracks, to form a “multislide” door system that can span an opening. The individual door panels 15 of a multislide door system can include one or more transparent or translucent windowpanes 20 to provide access to a panoramic view or light even when the door system is closed. In some embodiments, some or all of the door panels of multislide systems can be retracted into a pocket of a door jamb in an adjacent wall, such that when the door system is open, an indoor/outdoor building space is created. In one embodiment, the fenestration product 10 is configured to open and close between an interior 120 and an exterior 122 . In one embodiment, the interior 120 is the inside of a building, house, room, or structure. In one embodiment, the exterior 122 is the outside of a building, house, room, or structure. In various embodiments, although the term interior 120 or exterior 122 is used, the names are being used in reference to a side of embodiments of the fenestration product 10 and can simply refer to a side of a wall or side of the fenestration product 10 whether one side is in or out of a structure or wall. In various embodiments the interior 120 and/or exterior 122 can be any combination of inside, outside, both inside or both outside of a structure, wall, etc. In various embodiments, a door panel 15 can comprise vertical stiles 12 , 14 and horizontal rails 16 , 18 . The stiles and rails can comprise a rigid material such as a wood, metal, plastic or polymer, composite, or other suitable material construction. In some embodiments, the stiles 12 , 14 and the rails 16 , 18 comprise a hardwood. In some embodiments, the stiles 12 , 14 and the rails 16 , 18 comprise aluminum. In some embodiments, the stiles 12 , 14 and the rails 16 , 18 comprise a wood reinforced with at least a metallic strip. Where the stiles 12 , 14 and the rails 16 , 18 are comprised of a metal, in some embodiments, they can be formed by extrusion. In various embodiments, any combination of materials can be used.
[0052] In one embodiment, a sliding door panel system 11 includes one, two or more door panels 15 , 15 ′ slideably disposed on one or more lower tracks 8 , 8 ′. In one embodiment, each door panel 15 is slideably disposed on a track segment 8 . It is contemplated that multiple door panels 15 , 15 ′ can be arranged (for example, including two, three, four, five, six, or more door panels 15 ) to form various sliding door systems. The sliding door panel system 11 can be configured to be slideably mounted to a jamb or door frame 1 having a header 2 and an upper track 4 (not illustrated here). In one embodiment, the door panels 15 can run on parallel tracks 4 , 4 ′, 8 , 8 ′. In one embodiment, one or more door panels 15 can be stored in a pocket 3 (not illustrated here) to the side of the door frame 1 or an upper track 4 (not illustrated here) or a lower track 8 . For example, in some embodiments, the door panel 15 can include one or more upper roller mechanisms 30 configured to ride in the upper track 4 to guide the door panel 15 along the upper track 4 (not illustrated). In one embodiment, the door panel 15 has adjustable rollers. In one embodiment, the door panel 15 has weather stripping. In one embodiment, both adjustable rollers and weather stripping are used together, and as the rollers are adjusted the weather stripping may or may not come into contact with the threshold or the ground.
[0053] In one embodiment, the door panel 15 can be configured to be slideably disposed on a lower track 8 . In various embodiments, the lower track 8 can be recessed below a floor surface 6 , even with a floor surface 6 , or raised above a floor surface 6 . In the one embodiment, the door panel 15 can further be configured to be slideably disposed on a lower track 8 recessed into a floor surface 6 . For example, in some embodiments, the door panel 15 can include one or more lower roller mechanisms 32 configured to ride on the lower track 8 . In some embodiments, the door panel 15 can be configured to run on a lower track 8 that is not recessed.
[0054] In several embodiments, the drainage systems described herein are particularly suitable for the sliding doors described in PCT/US2009/047540, filed on Jun. 16, 2009. This application incorporates the disclosure of U.S. application Ser. No. 12/999,433, filed Dec. 16, 2010 as a national phase application from PCT/US2009/047540 filed in English on Jun. 16, 2009, which claims the benefit of priority to U.S. Provisional Application No. 61/073,320, filed Jun. 17, 2008, and which is incorporated by reference in its entirety herein. In several embodiments, the drainage systems described herein are particularly suitable for the sliding doors described in PCT/US2008/050928, filed on Jan. 11, 2008. This application incorporates the disclosure of U.S. application Ser. No. 12/522,909, filed Jul. 10, 2009 as a national phase application from PCT/US2008/050928 filed in English on Jan. 11, 2008, which claims the benefit of priority to U.S. Provisional Application No. 60/880,255, filed Jan. 12, 2007, and which is incorporated by reference in its entirety herein.
[0055] FIG. 7 illustrates a drainage system 200 according to an embodiment of the present invention in accord with the embodiments of a drainage system 200 disclosed herein with respect to FIGS. 1-6 . As illustrated in FIG. 7 , the embodiment is shown at a location in which an adjustable member 260 is not visible. In one embodiment, a drainage system 200 is configured to fit within or between the interior jamb line of a wall and the fenestration product 10 . In one embodiment, an adjustable height cover 280 is configured with a cover width 281 that is less than the body width 212 to fit inside or between the walls 220 , 230 of the body 210 . In one embodiment, not illustrated here, an adjustable height cover 280 is configured with a cover width 281 that is greater than the body width 212 to fit over and around the body 210 . In various embodiments, the cover width 281 is less than 1 inch, 0.125 inches, 0.1875, 0.25 inches, 0.375 inches, 0.5 inches, 0.625 inches, 0.75 inches, 0.875 inches, 1.0 inches, 1.25 inches, 1.5 inches, 2 inches, or any dimension or range of dimensions between 0.125 inches and 1 foot or more. In various embodiments, the body width 212 is less than 1 inch, 0.125 inches, 0.1875, 0.25 inches, 0.375 inches, 0.5 inches, 0.625 inches, 0.75 inches, 0.875 inches, 1.0 inches, 1.25 inches, 1.5 inches, 2 inches, or any dimension or range of dimensions between 0.125 inches and 1 foot or more.
[0056] In various embodiments, the cover-to-body-wall height 292 is configured to be controllably adjustable or variable. As illustrated in FIGS. 7 and 8 , the first wall height 226 , second wall height 236 , cover height 282 , and cover-to-body-wall height 292 can be varied or produced in various fixed dimensions to meet any of the various configurations shown at least in FIGS. 2-6 or other configurations. FIG. 8 illustrates a compact height configuration of a drainage system 200 according to an embodiment of the present invention, wherein the body 210 is relatively shorter than the body 210 shown in the embodiment illustrated at FIG. 7 .
[0057] In optional embodiments, a cover 280 can comprise a filter 290 , 290 ′, 290 ″. In various embodiments, the filter 290 is a mesh, screen, matrix, fabric, sponge, porous medium or other material configured to fit outside, inside or within one or more apertures 288 . In various embodiments, the filter 290 is configured to prevent the passage of insects or debris from clogging the drainage system 200 . In one embodiment, the filter 290 is configured to be removable for cleaning or replacement from the drainage system 200 . In one embodiment, the filter 290 is roughly two-dimensional structure configured to extend across one or more or all apertures 288 . In one embodiment, the filter 290 is three-dimensional structure configured to fit within the cover 280 . In one embodiment, the filter 290 is three-dimensional structure configured to fit within the channel 215 of a body 210 . In one embodiment, the filter 290 is configured to be readily accessible for servicing without removing or disassembling the fenestration product 10 .
[0058] FIG. 9 illustrates the drainage system 200 according to FIG. 7 with an adjustable height cover 280 removed. In various embodiments, the adjustable height cover 280 can be configured to be disposable and maneuverable or adjustable with one, two or more adjustable members 260 . In one embodiment, a single adjustable member 260 is configured to adjust the height of the adjustable height cover 280 . In one embodiment, a two, three, four, or more adjustable members 260 are distributed along a length or a cover 280 are configured to adjust the height of the adjustable height cover 280 . In one embodiment, a first end adjustable member 260 and second end adjustable member 260 are configured to adjust the height, tilt, slant, slope, and/or position of the adjustable height cover 280 . In various embodiments, two or more adjustment members 260 can be distributed evenly or asymmetrically at any distance apart. In various embodiments, the distance between adjustment members 260 can vary depending on the length of the cover 280 , the body length 213 , interior floor surface 6 considerations, exterior floor surface 7 considerations, or other distances, including, but not limited to 6 inches, 12 inches, 18 inches, 24 inches, or anywhere in the range of 1 inch to six feet. In one embodiment, any adjustment member 260 can be set to the same or different height as adjacent or other adjustment members 260 in an attempt to flatten, tilt, slant, and/or configure a position of a cover 280 . FIGS. 10-16 illustrate the drainage system 200 according to FIG. 7 either with or without an adjustable height cover 280 shown.
[0059] It will be understood by those of skill in the art that numerous and various modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the forms of the present invention are illustrative only and are not intended to limit the scope of the present invention. Although a few embodiments have been described in detail above, other modifications are possible. For example, although several of the embodiments described herein discuss drainage systems used with linear movement of door panels along tracks that can be parallel or linear, it is also contemplated that drainage systems can be used with door panels, track, and related movement can be accomplished with rounded doors and or tracks, curves and/or arcs, or other shapes as well. Other embodiments may be within the scope of the following claims. It will be understood that the foregoing is only illustrative of the principles of the invention, and that various modifications, alterations, and combinations can be made by those skilled in the art without departing from the scope and spirit of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims. | A drainage system is configured for draining water or other liquid intrusion in to building structure openings, access routes, including fenestration, door or window products. Embodiments include adjustable height drainage systems that are vertically adjustable to controllably place the height of the drainage system above, below or flush with one or more surrounding floor or fenestration portal surfaces. One or more adjustable members controllably move and position the cover with respect to the drainage system body. Drainage systems are readily accessible for service and/or adjustment of the drainage system without removal or disassembly of a fenestration product. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a new method for managing a database. More specifically, it relates to a method for assuring atomicity of multi-row update operations such as in a relational database system.
2. Description of the Prior Art
In prior art data management systems, support is sometimes provided for assuring the atomicity of operations effecting a database. Such an operation is "atomic" if the operation either succeeds completely or it fails, in which latter case the state of the database is left unchanged.
The IBM Information Management System (IMS/VS) Version 1 provides support for assuring the atomicity of operations updating one record, or row of a table, at a time. However, there is no multi-row update facility in IMS/VS.
Database management systems which provide multi-row updating operations include those based upon the relational model, such as the IBM Research System R, an experimental database management system, and the IBM Sequel Query Language/Data System (SQL/DS). System R is described in M. W. Blasgen, et al, "System R: An Architectural Overview", IBM System Journal, Vol. 20, No. 1, 1981, pages 41-62. The IBM SQL/DS is described in "SQL/Data System Planning and Administration", IBM Publication SH24-5014-0, Program Numbr 5748-XXJ, August 1981, with the recovery considerations set forth at pages 9-1 to 9-19. Hereafter, reference to relational databases will be intended to include all database management models which allow multi-row update operations.
The SQL language, which is the external language for access to databases managed by System R or SQL/DS, provides operations for modifying the state of userdefined data, including UPDATE, DELETE, and INSERT operations which allow the SQL user to insert, update, or delete multiple rows (i.e., records) in a specified database table. As implemented in System R and SQL/DS, SQL allows partial success of such multi-row operations, such that a detected error in the middle of a multi-row UPDATE, for example, will cause termination of the operation with only a subset of the required records updated. This leaves the table in an inconsistent state, and the application program requesting the SQL operation has no practical means of determining exactly which records were or were not updated. If recoverable files are used, a rollback, or recovery operation must be performed when such an error is detected to cause all work within the entire unit of recovery (UR), i.e. transaction, to be undone. Unfortunately, this action not only cancels the effects of the operation causing the error, but also the effects of any other operation in the same unit of recovery. The problem is more serious if non-recoverable files are in use. In such a case the rollback process has no effect, and the application programmer must handle the recovery of the data.
Various proposals have been made to avoid the necessity for backing out a complete transaction in the event of an error during a sequence of multi-row update operations. Thus, it has been suggested to "begin each complex operation with a savepoint and backing up to this savepoint" in the event of a failure during the operation. See, for example, Grey, et al, "The Recovery Manager of a Data Management System", IBM Research Publication, Computer Science RJ 2623 (#33801), Aug. 15, 1979. (See also, ACM Computing Surveys, Vol. 13, No. 2, June 1981, pages 223-242.) Grey, in this discussion of the System R, notes that such a savepoint technique was not implemented, but was rather an unsolved language design problem.
SUMMARY OF THE INVENTION
This invention provides a method and apparatus for assuring atomicity of user requested multi-row update operations to tables such as in a relational database, guaranteeing that for any update operation that succeeds all stated effects will have occurred and that for any update operation that fails the system state as perceived by the user remains unchanged. This is accomplished by establishing, in response to a multi-row update operation request, an execution module containing machine language code instructions implementing the update operation request with a savepoint request at the beginning of the execution module. For each set of instructions in or called by the execution module which modifies the user perceived system state, undo information is logged selectively to a hard or soft log. Upon completing the execution module without error, the savepoint is dropped, causing all soft log information recorded since the savepoint to be deleted and releasing all resources held to guarantee restoration of the user perceived system state at the time of the savepoint request. Responsive to the detection of an error during execution of the module, the logged undo information is used to restore the user perceived state to that existing at the time of the savepoint request.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of a database management system including a relational data system, a data manager, and hard and soft logs.
FIG. 2 is a diagrammatic illustration of a typical unit of recovery, distinguishing recovery and restore operations.
FIG. 3 is a diagram illustrating a typical SQL statement.
FIG. 4 is a diagrammatic illustration of various control blocks and data areas comprising the apparatus of the invention and referenced in executing the method of the invention.
FIG. 5 is a flow chart illustrating the procedures executed by an execution module implementing an INSERT operation.
FIG. 6 is a flow chart illustrating the procedures executed by an execution module implementing an UPDATE or DELETE operation.
FIG. 7 is a flow chart illustrating the savepoint operation shown in FIGS. 5 and 6.
FIG. 8 is a flow chart illustrating the restore operation shown in FIGS. 5 and 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a high level storage map is shown illustrating, for example, two private address spaces in an IBM System/370 Multiple Virtual System implementing a database management system (DBMS) 10. The IBM System/370 architecture is described in IBM System/370 Principles of Operation. IBM Publication GA22-7000-6. In this embodiment, by way of example, DBMS 10 includes a master (MST) region 12 and a database manager (DBM) region 14. Hard log 22 is maintained under control of MST 12, as is described in patent applications of E. Jenner, "Method and Apparatus for Restarting a Computing System", Ser. No. 390,163, filed June 21, 1982, and of C. Mellow, et al, "Method and Apparatus for Logging Journal Data in a Continuous Address Space Across Main Storage, Direct Access, and Sequential Access Devices", Ser. No. 390,454, filed June 21, 1982.
Database manager 14 includes a relational data system (RDS) 16 and a data manager (DM) 17 which together manage the creation, modification, access, and deletion of data objects stored in database 24. Such operations may be performed in response to calls from applications or tasks running in allied address spaces (not shown). One approach to establishing connection between such allied address spaces and the facilities provided by DBMS 10 is described in R. Reinsch, "Method and Apparatus for Controlling Intersubsystem Access to Computing Functions and Data", application Ser. No. 393,244, filed June 29, 1982.
The manner in which RDS 16 performs its functions is set forth in further detail in M. W. Blasgen, et al, "System R: An Architectural Overview", IBM System Journal, Vol. 20, No. 1, 1981, supra, and in D. J. Haderle, et al "Method and Apparatus for Online Definition of Database Descriptors", application Ser. No. 393,902, filed June 30, 1982.
In FIG. 3 is set forth a typical SQL statement or request 36, illustrating a command field 50, showing that an UPDATE is to be made to the file named EMPLOYEE, an operation field 52, showing that the SALARY field is to be incremented by 10%, and the selection criteria field 54, showing that the salary field is to be updated for those employees in department M10. The selection field 54 includes one or more predicates, a term which will be further described hereafter.
RDS 16 processes a SQL statement received from an application running in an allied address space into control blocks necessary to invoke the data manager 17 component within DBM 14 and into an execution module. Each execution module comprises a set of machine language instructions which implement the SQL statement being processed. The execution module will include calls to a defined set of protocols in data manager 17 for retrieving and modifying the data in database 24. (This set of protocols means manipulative system input and is referenced as MSI.)
Referring now to FIG. 4, a description will be given of various control blocks of a program passed to the DBM 14 data manager from an execution module of a program for data manipulation operations, including SQL INSERT, UPDATE, DELETE operations. Illustrated in FIG. 4 are manipulative system input block (MSIB) 60, manipulative system input field (MSIFLD) 70, manipulative system selection block (MSISELL) 80, cursor block (CUB) 90, and pageset 100. MSIB 60 is the main anchor control block, and includes pointer 62 to CUB 90, pointer 64 to MSISELL 80, and pointer 66 to MSIFLD 70. CUB 90 contains information which identifies the position of the scan in the page set 100. This information includes, among other things, a code which identifies the type of cursor block, pageset 100 identifier 92, and record identifier (RID) number 92 which identifies the RID slot 112 of RIDs 100 which contains a pointer into page 102 to the record 106 to which the scan is positioned. MSISELL 80 specifies "sargable" predicates. Sargable predicates are predicates which have meaning to the data manager component of DBM 14. Non-sargable predicates are predicates which the data manager component cannot handle, and must be checked by RDS 16. MSISELL 80 includes the identifier of the field to which the predicate applies; the operation code of a comparison operator (greater than, less than, equal or greater than, equal or less than, not equal); a pointer to the value to be compared; and any boolean connectors, such as AND, OR. Each MSISELL 80 is used to specify one predicate. Multiple predicates are specified by using a plurality of MSISELLs and the boolean connector field. MSIFLD 70 specifies fields for which values are returned or supplied, and includes the identifier of the field; the field data type; the field length; and a pointer to related buffers 76, 78.
Referring now to FIG. 2, a transaction comprising a plurality of SQL statements 33, 34, 36, and 40 is illustrated as a unit of recovery 30. A unit of recovery (UR) is the work done by a process which affects the state of one or more recoverable resources 24 from one point of consistency to another. The scope of a UR may include multiple execution modules of a program. The UR 30 of FIG. 2 includes the execution modules which implement SQL statements 33, 34, 36 and 40. The start of the UR is at 32, the beginning of INSERT statement 33, and extends in time to a point beyond the current SQL DELETE statement 38, which begins at point 40. Assume that an error occurs at 42, during execution of a multi-row DELETE operation 38, which is not a system crash or some other loss of volatile storage (including soft log 20). By this invention, a restore operation is provided which restores the database to its point at the beginning 40 of the current SQL statement 40, without impacting changes made within this same UR 30 by, say, SQL UPDATE statement 36. Without this invention, a recovery operation 46 utilizing hard log 22, such as is described in the copending Jenner application, would be necessary. (If the error results in loss of soft log 20, then the recovery operation of Jenner would still be available to recover the database to its state at start UR 32.)
Thus, in performing the procedures of this invention, DM 17 utilizes soft log 20 in main storage and the hard log 22 on a direct access storage device (DASD). Each time a change is made to a data object in a database 24, DM 17 writes or stores a record or records in the hard or soft log. Hard log 22 is used if the pageset is recoverable and if the page containing the update may have been copied to DASD 24. The pageset is considered to be recoverable if the effects of committed changes are guaranteed to survive system failures by DBMS 10. Soft log 20 is used if the pageset is not recoverable or if the page is guaranteed not to have been copied to DASD 24. Each record on hard log 22 representing a change to database 24 includes the following three fields: (1) hard log header, (2) data manager log header, and (3) appendage. The hard log header includes a field specifying the log record type and a field containing a pointer to the previous hard log record. The data manager log header includes the following four fields:
1. A pageset identifier field which identifies the pageset to which the change is made. In this example, a pageset is a set of one to 32 data sets which are logically concatenated to form a linear address space of up to 2**32 bytes. A data set is a specific portion of DASD storage 24 which is read from and written to via the MVS operating system.
2. A page identifier field which identifies the page in the pageset being changed. In this example, a page is a 4096 or 32768 byte contiguous area in a pageset which begins on a 4096 or 32768 byte boundary.
3. A field identifying the DBM 14 data manager 17 procedure which is making the change.
4. A flag indicating whether the hard log record contains UNDO, REDO or UNDO/REDO information. UNDO information is that information required to reverse an update operation in order that it appear that the operation was never performed. REDO information is that information required to re-perform an update operation.
The appendage format depends upon the type of modification. In some cases the appendage will contain before and after images of the data object being changed, and in other cases the appendage will contain information necessary to conduct a reversing operation.
Each time a change is made to a data object in a non-recoverable database 24 and each time a savepoint is established, DM17 stores a soft log record in soft log 20. A soft log 20 record includes the following:
1. A soft log record header, which includes (a) a pointer to the previous soft log 20 record, (b) the length of this log record, and (c) an operation code identifying the log record type.
2. An appendage whose format depends on the log record type. If the log record is for a data change then the appendage will contain UNDO information. If the log record describes a savepoint, then the appendage will contain the following:
1. A user supplied savepoint name.
2. A pointer to the previous savepoint soft log 20 record.
3. The relative byte address (RBA) of the first hard log 32 record written by the savepoint module writing this soft log record.
4. A list of entries describing cursor blocks (CUBs) whose positions are to be saved, including (a) the record identifier (RID) contained the CUB and (b) the position of the CUB (i.e. CUB position WRT record: before, at, after). A cursor block (CUB) is a DM 17 control block used to maintain position on a row or record in a database. Each CUB represents, among other things, positions within data manager objects such as indexes and page sets 100.
Now, by way of explanation of the operation of the above control blocks and modules, the atomicity protocol of the invention is implemented using a savepoint/restore mechanism by the data manager component of DBM 14. These two operations enable any user of the data manager to return the state of database 24 to a predefined point 40 (a savepoint) within UR 30, negating any effects of any modifications which occurred after that point 40.
Each execution module which implements a SQL multi-row UPDATE, INSERT, or DELETE utilizes the savepoint and restore operations to guarantee atomicity. These execution modules are set forth in FIGS. 5 and 6. The execution module for update/delete of FIG. 6 is also set forth in pseudo code in Table 3. At the beginning of the execution module, before any database 24 change is made, a savepoint command 150 (see also FIG. 7) is issued to the data manager component of DBM 14. As input to this operation, a name, unique within the UR 30, is passed which identifies the savepoint 150 (for the example of FIG. 2, this would be point 40, at the start of the current SQL statement 38), and a list of cursor blocks 90 whose states are to be saved. Table 4 sets forth the create savepoint procedure in pseudo code.
If an error 160 (42) is detected by the execution module (FIG. 5 or 6), then a restore 162 is issued (as is illustrated in FIG. 8) in which the name specified on the savepoint operation 150 is passed as a parameter. Restore 162 returns the state of all user and system data to what it was at the point 40 at which the savepoint 150 was issued, according to the method set forth in FIG. 8 and Table 5, including the steps of getting 190 the soft log 20 savepoint 150 record; getting 192 from the soft log record the RBA of the hard log 22 savepoint 150 record; processing 194 hard log 22 UNDO records from failure 42, 160 back to the savepoint 150 RBA 40; and setting 196 CUBs 90 RDI 94 values to the positions which existed at the savepoint 40, 150.
All execution modules which implement SQL operations which change the state of database 24 use the savepoint 150 and restore 162 operations to insure atomicity. Other SQL operations which are interpreted (such as definitional and authorization statements) rather than having compiled code generated utilize the same approach. That is, a savepoint 150 is issued before any database 24 change is made and a restore 162 is issued if an error is detected after any such database change. The net effect of this implementation is that the SQL user perceives all operations to be atomic, either succeeding completely or leaving database 24 unchanged.
Thus, soft log 20 is created in volatile storage for each unit of recovery and is managed on a last-in first-out (LIFO) basis. When the data manager 17 component of DBM 14 is required to make any change to a CUB 90 or to a non-recoverable data page or to a recoverable page which is guaranteed not to have been copied to DASD 24, it inserts a record into the soft log 20 for the unit of recovery (UR) requesting the change. This record contains precisely the information required to undo the effects of the modification to the CUB 90 or data page 102. The name of the module to be invoked to accomplish the undo operation is also specified in the soft log 20 record. The hard log 22 is used to record both UNDO and REDO information for changes made to data pages 102 which may have been copied to DASD 24 and REDO only information for pages which are guaranteed not to have been copied to DASD.
If an execution module (FIG. 5 or 6) in a UR 30 issues a savepoint 150 command then a special record with the specified savepoint name is inserted into both soft log 20 and hard log 22. If a restore 162 is issued then the UNDO records are read and removed from both logs 20, 22 in LIFO order 44, and the described operations performed until the savepoint 150 record containing the name specified on the restore 162 is found.
It is also possible for multiple savepoints 150 to be stacked by a UR 30. Consider, for example, a UR which has issued two savepoint 150 commands with no restore 162 command between them. The contents of the soft log 20 would appear as in Table 1: Stacked Savepoints.
TABLE 1______________________________________STACKED SAVEPOINTS______________________________________ SAVEPOINT SP1 undo-record-1 undo-record-2 . . . undo-record-i SAVEPOINT SP2 undo-record-i+1 undo-record-i+2 . . . undo-record-k______________________________________
At this point, the UR could issue RESTORE SP2, which would back out all changes to the database 24 made since savepoint SP2. The soft log 20 would then contain the information set forth in Table 2: Stacked Savepoints With Restore.
TABLE 2______________________________________STACKED SAVEPOINTS WITH RESTORE______________________________________ SAVEPOINT SP1 undo-record-1 undo-record-2 . . . undo-record-i______________________________________
If, however, RESTORE SP1 was issued, then all records of soft log 20 are processed and deleted.
In order to enhance the efficiency of the UNDO process, the data manager component of DBM 14 may adopt the strategy that each soft log 20 record describes a change to a single page 102 of storage and that this change can be applied using only information contained in the page 102 and the log 20,22 record. Thus, no other pages, directories, or catalogs need to be accessed to accomplish UNDO.
The data manager component of DBM 14 simplifies the atomicity protocol of the invention by providing an operator which allows other components to write records in soft log 20 or in hard log 22. Thus, modifications to resources managed by other components can be backed out with this mechanism. The data manager component of DBM 14 also uses soft log 20 and hard log 22 to guarantee the atomicity of its own operations. Thus, any component using the data manager component of DBM 14 need not be concerned with the consistency of data 24 between calls.
Soft log 20 is the critical component for this preferred embodiment of the atomicity protocol of the invention because it provides a centralized mechanism for managing the information required to undo changes to user and system data.
TABLE 3______________________________________UPDATE/DELETE EXECUTUIN MODULE______________________________________10 Establish Savepoint (call DM)12 error=no;14 rnf=no;1618 DO UNTIL rnf=yes or error=yes;/*repeat until*/19 /*last record or error occurs*/20 fetch next record;/*call to DM passing MSIB*/22 If record not found24 THEN rnf=yes;26 ELSE28 IF error returned by DM30 THEN error=yes32 ELSE34 check non-sargable predicates;36 IF non-sargable predicates satisfied THEN38 DO; /*record satisfies all SQL predicates*/40 update/delete record /*call to DM*/41 /*passing MSIB*/42 IF error returned by DM44 THEN error=yes;46 ELSE;48 END;50 ELSE;52 END; /* or DO UNTIL rnf=yes or error=yes*/5456 IF err=yes58 THEN restore savepoint;/*call to DM passing SVPT block*/60 ELSE drop savepoint;/*call to DM passing SVPT block*/6264 RETURN;66 END;______________________________________
TABLE 4______________________________________CREATE SAVEPOINT (SVPT)______________________________________80 Compute length of appendage of soft log record.82 If some or all CUBs to be saved THEN83 DO.84 Case of all CUBs to be saved.85 DO for all CUBs.86 Add contribution to soft log record for CUB if88 it is recoverable.90 END.92 Change all lock durations to commit.94 END case.96 Case of some CUBs to be saved.98 DO for all CUBs to be saved.100 IF CUB to be saved and it is recoverable THEN102 DO.104 Add contribution to soft log record for CUB.106 IF page lock held by CUB change the lock108 duration to commit to guarantee the110 page can be re-accessed during restore.112 IF index leaf lock held by CUB change the114 lock duration to commit to guarantee the116 page can be re-accessed during restore.118 END.120 END.122 END case.124 END126 IF UR is recoverable THEN write a savepoint hard log128 record.130 Write a savepont soft log record.132 Increment count of outstanding savepoints.134 Add to the soft log the CUB flags and position136 information for all CUBs to be saved.______________________________________
TABLE 5______________________________________RESTORE SAVEPOINT______________________________________200 Search the chain of savepoint log records in the202 soft log backwards until the savepoint204 with the name = supplied name is found.206 DO for each record in the soft log UNTIL the208 savepoint record is reached beginning with210 the last record in the soft log.212 IF the record is not a savepoint record THEN214 Invoke the UNDO routine for the records.216 ELSE218 DO.220 DO for each CUB that was saved.222 IF the CUB has a buffer THEN224 Free it.225 Move from the soft log record to the226 CUB the flags and position information228 that was saved.230 Decrement count of outstanding savepoints.232 END.234 END.236 Get the address of the previous record in the238 soft log.240 END.242 IF the UR is recoverable THEN244 Save the log RBA of the hard log savepoint246 record.248 Reset the soft log to the beginning of the250 savepoint record which was restored to.252 IF the UR is recoverable THEN254 DO.256 DO for each UR-related record in LIFO order.258 UNTIL the log RBA - RBA of the hard log260 savepoint record.262 IF the record contains UNDO information263 THEN264 Invoke the UNDO procedure to process266 the record.268 END.270 END.______________________________________
TABLE 6______________________________________DROP SAVEPOINT______________________________________300 If no savepoint is outstanding then302 return error code.304 Locate the last savepoint log record.306 Reset the soft log to the beginning308 of the savepoint record.310 Decrement count of outstanding312 savepoints.______________________________________ | A method for assuring atomicity of user requested multi-row update operations to tables such as in a relational database, guarantees that for any update operation that succeeds all stated effects will have occurred and that for any update operation that fails the system state as perceived by the user remains unchanged. This is accomplished by establishing, in response to a multi-row update operation request, an execution module of a program containing sets of machine language code instructions implementing the update operation request with a savepoint request at the beginning of the execution module of the program. For each set of machine language code instructions in or called by the execution module which modified the user perceived system state, information is logged to a soft log. Upon completing the execution module of the program, the savepoint is dropped, causing all soft log information recorded since the savepoint to be deleted and releasing all resources held to guarantee restoration of the user perceived system state at the time of the savepoint request. Responsive to the detection of an error during execution of the execution module of the program, the soft logged information is used to restore the user perceived state to that existing at the time of the savepoint request. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a process of fabricating an elongated glass body, particularly a preform for optical waveguides on the basis of SiO 2 , in which a porous body is formed from powdery glass starting material and such body is sintered to obtain the glass body.
One such process is described in a copending commonly owned U.S. Pat. application Ser. No. 703,793, in which it is proposed to fill powdery glass starting materials with compositions changing in the radial direction under precompaction, into a compression mold from several coaxially disposed conveyor tubes. The fill-in pressure effecting the pre-compaction is effected therein either by screw conveyors or by a centrifugal force. In any case, the coaxial arrangement of various conveyor tubes and the simultaneous conveyance of different materials involves a considerable investment in appartus, which is a pronounced disadvantage.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to avoid the disadvantages of the prior art.
More particularly, it is one of the objects of the invention to provide a process of producing glass bodies from pulverulent material formed into porous bodies and then sintered, which avoids the disadvantages of the conventional processes of this type.
It is yet another object of the present invention to develop a process of this type which would render it possible to fabricate the glass bodies from such porous bodies with a high degree of reliability and dependability.
A concomitant object of the present invention is to provide a process of the above type which allows simplification of the apparatus used to perform the process so that this appartus is simple in construction, inexpensive to manufacture, easy to use, and reliable in operation nevertheless.
In pursuance of these objects and others which will become apparent hereafter, one feature of the present invention resides in a process of fabricating elongated glass bodies, particularly preforms for optical waveguides, from pulverulent starting materials, especially such including SiO 2 , comprising the steps of filling a plurality of pulverulent starting materials with different compositions one at a time into respective mutually adjacent coaxial confining zones of a confining space in such a manner as to be pre-compacted during the filling step and to form a pre-compacted composite body in the confining space; compressing the pre-compacted composite body subsequently to the filling step to convert the pre-compacted composite body into a porous composite body; and sintering the compressed porous composite body into the glass body.
BRIEF DESCRIPTION OF THE DRAWING
Above-mentioned and other features and objects of this invention will become more apparent by reference to the following description taken in conjuction with the accompanying drawing, in which:
FIG. 1 is a partially sectional side elevational view of a device for filling the powdery starting material into a compression mold illustrative of the type of apparatus usable in performing the process proposed by the invention; and
FIG. 2 is a longitudinal sectional view of a part of a conveying device for forming a tubular porous body that is usable in performing the inventive process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following, the invention will now be described as it is to be used for fabricating a preform for optical waveguides, with the starting material containing SiO 2 as its base material, which, for the purpose of changing the refractive index, contains, as a rule, one or more doping agents such as GeO 2 , P 2 O 5 , F, or B 2 O 3 . It should be pointed out, however, that the process according to the invention is also suitable for fabricating articles other than optical waveguides, so long as the starting material which comes in question therefor is capable of being manufactured in powder form and of being compressed into a porous body, and the latter is capable of being sintered into a glass body.
The device as shown in FIG. 1 which is identical to that disclosed in the above-mentioned U.S. Pat. application Ser. No. 703,793 and is shown and described here for illustrative purposes only, comprises a storage bin 1 containing the powdery glass starting material, with the interior of the bin 1 being sealed against the ambient atmosphere.
Inside the storage bin 1, near its bottom, there is arranged a screw conveyor 3 which is driven by an external motor 2, with the aid of which the powder material contained in the stroage bin 1 can be conveyed through an elongated conveying tube 4 out of the storage bin 1. The conveying tube 4 projects into a compression mold which is to be filled with the powder material. In the given example, the compression mold is a flexible hose 5 which, at its end lying in the conveying direction, is closed by a cover 6. The fill-in pressure is produced in that the screw conveyor 3 passes the material by the conveying force produced by its motor 2 in direction toward the cover 6, and in that the cover 6 is acted upon by a counterforce in opoosition to the conveying direction.
A shape-stabilizing rigid body 7, constructed as a double-walled tube whose inner wall is perforated as shown in the drawing, and whose inner space between the two walls is capable of being subjected to either an increased or a reduced pressure, surrounds the hose 5 and thus forms a support for the hose 5 in the radially outward direction. To effect a pressure variation, an opening with a tubular joint (or socket) 8 is provided for in the outer wall of the tube 7, on which a conduit leading to a vacuum pump can be slid. The vacuum pump, such as a water-jet pump, produces in the interspace between the walls of the tube 7 a suction pressure which, through the perforated inner wall, acts upon the hose 5, pulls it in direction toward the inner wall and expands it to such an extent as to be smoothly applied to this inner wall. The thus constructed rigid shape retaining body 7, accordingly, simultaneously permits preexpansion of the hose 5 and a shape stabilization of the hose 5 during the fill-in process.
For sealing the interspace between the conveying tube 4 and the pre-expanded hose 5, the outlet end of the conveying tube 4 is surrounded by a sealing ring 9 which is attached to the conveying tube 4 and is operative for providing a constant frictional force between the conveying tube 4 and the pre-expanded hose 5, which force is not dependent on just how far the conveying tube 4 projects into the compression mold 5.
The end of the compression mold 5 lying in the conveying direction is sealed by the already mentioned cover 6 which, on its side facing the compression mold 5, is provided with a truncated cone-shaped extension 10 which is pushed to the end of the tube 7 that is covered by the hose 5, in such a manner that its jacketing surface is firmly applied to the tube end, thus sealing the latter. The cover 6 is attached to the tube 7 with the aid of holding means that is not shown, such as a clamp, which is capable of being mounted to the outside of the tube 7, or by a cap surrounding the cover 6 and capable of being screwed on to the outside of the tube 7.
When filling the powder material into the described compression mold 5, the material is pre-compacted by the action of the fill-in pressure. In the course of this operation, the conveying force of the screw conveyor 3 pushes the entire compression mold 5 inclusive of the shape retaining body 7 in opposition to the counterforce acting upon the cover 6, away from the conveying tube 4 in the conveying direction until, in this way, almost the entire interior space of the hose 5 is filled with the pre-compacted powder material. The motion of the compression mold 5 relative to the conveying tube 4 during the feed operation is indicated by an arrow shown below the compression mold 5, pointing in the conveying direction.
Following the fill-in operation, the vacuum pump is turned off and the air conduit is removed from the tube joint or socket 8. The pre-expanded hose 5, owing to the filled-in pre-compacted powder material, remains in its expanded state. The compression mold 5, inclusive of the shape retaining bod 7 surrounding it, is now removed from the fill-in device and is inserted into the hydraulic fluid of an isostatic press after its other end has also been closed by a cover corresponding to the cover 6 described hereinbefore. The hydraulic fluid of the isostatic press enters through the tube joint or socket 8 into the interspace of the double-walled tube 7, with the air contained therein escaping either through this joint or socket 8 as well, or through a further opening which is additiobally provided but has not been shown. Thereupon, the isostatic press subjects the hydraulic fluid to a pressure ranging between 100 and 300 bar, with this pressure acting through the perforated inner wall of the tube 7 upon the outer side of the pre-expanded hose 5 for pressing the latter together in the radial direction, so that the desired porous body will result. Although the isostatic press exerts a uniform pressure from all sides upon any structure contained in its hydraulic fluid, the pressure, in the present case, owing to the tube ends being closed by rigid covers 6, only acts in the radial direction upon the compression mold 5, so that during the compression process the longitudinal dimension of the filled-in material remains unchanged.
Upon completion of the pressing operation, the tube 7 is removed from the isostatic press, one or both covers 6 are opened, and the compressed body surronded by the hose 5, is removed from the tube 7. After this, the hose 5 is again expanded and the pressed porous body is removed therefrom. Prior to any further processing, it may become necessary to mechanically process the porous body on its surface until it shows to have the desired geometrical shape, for example, by way of grinding the surface.
The porous body is next subjected to a physical and/or chemical cleaning. As a physical cleaning there may be used cleaning in an electric arc or in a high-voltage plasma, and as a chemical cleaning there may be used heat treatment in a chlorine-containing atmosphere in order thus to remove from the porous body an possible impurities in the form of hydroxyl groups and transition metals.
The porous body which, owing to the described process, has a homogeneous material composition, can now be further processed into an optical waveguide, for example, in that it, by way of sintering, is transformed into a glass body, with the latter then being drawn out into a glass fiber.
In principle, the fill-in operation as described with reference to FIG. 1 can also be applied to such cases in which the porous body to be formed has no homogeneous composition, but a material composition changing in the radial direction. This is possible in that, in contradistinction to the foregoing part of the specification, where the compression mold 5 was described as having the shape of a hollow cylinder, so that the subsequently following compression would in any case result in a rod-shaped porous body, is designed in such a way that the resulting formed porous body is of tubular shape. For this purpose there is used a screw conveyor which, unlike the screw conveyor 3 as shown in FIG. 1, does not convey the material within the area of its axis, but within an area having a circular ring-shaped cross section disposed coaxially in relation to its axis of rotation. One such screw conveyor is shown in FIG. 2.
This type of screw conveyor 20 rotates in the interspace between an inner tube 21 and an outer tube 22 disposed coaxially in relation thereto, about the inner tube 21, so as to convey the powdery glass starting material through this interspace into the compression mold 3 and into an area coaxially distant from the axis.
At its front end, the arrangement as shown in FIG. 2 comprises two sealing rings 23 and 24 for sealing the area within which the powdery material is conveyed into the compression mold and which, just like the sealing ring 9 in the arrangement as shown in FIG. 1, provide for a constant position-independent frictional force. The inner sealing ring 23 is mounted to the inside of the inner tube 21 and is applied to the outer side of the rod-shaped or tubular base body, whereas the outer sealing ring 24 is mounted to the outer side of the outer tube 22 and is applied to the inner side of the hose 5 in the case of the compression mold 5 as shown in FIG. 1.
As the compression mold 5 for forming a tubular body there may be used either the type of compression mold 5 as shown in FIG. 1, which would have to be slightly modified, or else a compression mold as shown in FIG. 2. The modification of the compression mold 5 as shown in FIG. 1 consists in that, along its longitudinal axis and extending from one to the other end thereof, there is disposed a rod or a tube, for example, of silica glass which can be mounted e.g. at the cover 6 in a central recess and, following the fill-in process, in a corresponding recess of the other cover. The screw conveyor of the type as shown in FIG. 2 now conveys the powdery material in a way corresponding to that described hereinbefore with reference to FIG. 1, into the interspace between this rod or tube and the pre-expanded hose 5. Following the compression process, the rod-shaped or tubular base body can be easily removed from the center of the compressed porous body.
According to the invention, the filling of the compression mold which is shown in FIG. 1, is carried out as follows: as proposed above with respect to the fabrication of a tubular body, also with the process according to this invention, a rod-shaped base body, that is, a rod or a tube, for example, of silica glass, is disposed in the compression mold which is modified to accommodate such base body along the longitudinal axis by extending in the center from the one end to the other, and a powdery glass starting material is filled in such a way into the interspace between this base body and the inside wall of the compression mold with the aid of a screw conveyor, as to be pre-compacted in the course of this filling operation. The filled-in material, for example, has a composition which is suitable for the cladding of an optical waveguide. By the pre-compaction, the filled-in material is given such a consistency that the base body, upon completion of the fill-in process, can be removed without the filled-in material dropping into the resulting hollow space. It was surprisingly discovered that it is indeed possible to give the particulate material during the filled-in process such a consistency that the thus formed tubular body will be self-supporting and will thus serve to externally delimit the internally located confining zone, thus in effect serving as a mold for the following filled-in operation. Upon removal of the base body, a further powdery glass starting material in a different composition, such as core material, and likewise under a pre-compaction, is filled into the hollow space.
When this last mentioned material is to have a composition which is constant throughout the cross section, it is filled in in the way as shown in FIG. 1, with the aid of a centrally disposed screw conveyor and with the previously filled in tubular body serving to externally delimit the space being filled. When the composition of the material is to vary throughout the cross section, as is necessary for an optical waveguide having a graded index profile, then, following the removal of the base body, another base body of smaller diameter is disposed in the center of the hollow space along the longitudinal axis, and a powdery glass starting material of a still different composition is filled into the interspace with the aid of a screw conveyor of the type as shown in FIG. 2 which is adapted to the interspace, and under a precompaction, with the base body thereafter being removed and the next base body being introduced, etc., until finally the remaining hollow space is filled with a material suitable for the central area, with the aid of a centrally disposed screw conveyor. Accordingly, the first fill-in process is repeated several times with a varying material composition, with respectively a different base body and a screw conveyor adapted thereto, until the remaining hollow space is filled.
The process described hereinbefore, in which the adjacent coaxial areas of the compression mold are filled one at a time in turn, offers the advantage that each of the different fill-in steps can be controlled individually and independently of the others with respect to the fill-in pressure and the fill-in speed.
It should still be mentioned that in every phase of the described process, from the stage of fabricating the powdery starting material to the sintering into an elongated glass body suitable for use as a preform, care must be taken for preventing the material from becoming contaminated.
For this purpose, it is preferable for the storage bins containing the powder material to be always airtightly sealed, and for the feeding of the material into the compression mold to be carried out in a sealed atmosphere, for example, in an evacuated glove box. Into this glove box, the one conveyor tube or a plurality of such conveyor tubes projects from the outside through a vacuum-sealed passage. The compression mold is removed from this glove box only after it has been closed on both sides with a cover, and is then placed into the isostatic press.
A further measure for avoiding contaminations resides in that the heat treatment of the porous body is carried out in a chlorine-gas atmosphere, with the subsequent sintering into a glass body being carried out in an apparatus which is constructed to keep the porous body, during the heat treatment in the chlorine-gas atmosphere, for example, in that the porous body is moved from a low elevation toward a higher elevation through a first zone in which the heat treatment is carried out, and from there immediately into a second zone in which the sintering is carried out.
While we have described above the principles of our invention in connection with specific apparatus, it is to be clearly understood that this description is made only by way of example and not as a limitation to the scope of our invention as set forth in the objects thereof and in the accompanying claims. | For fabricating porous bodies from a glass starting material, particularly in connection with the fabrication of an optical waveguide preform, it is proposed to fill powdery glass starting material under a pre-compaction into a compression mold, and to compress it thereafter. When the porous body to be formed is to have a varying composition in the radial direction, as is necessary with a view to step index optical fibers or optical waveguides having a graded index of the refractive-index profile, then differently composed powdery glass starting materials are filled one at a time, in adjacent coaxial areas, into the compression mold. This is effected with respect to each of the individual areas with the aid of a screw conveyor under a continuous, adjustable pressure and at an adjustable conveying speed. If more than two coaxially disposed areas of different composition are to result, the corresponding material is filled several times in succession into the interspace between a base body disposed in the center of the compression mold in the longitudinal direction thereof, and the inside wall of the deposited material, before the central area is filled. | 2 |
BACKGROUND OF THE INVENTION
1. Technical Field
This device relates to blast suppression enclosures that limit or confine the blast effects for safety and health reasons.
2. Description of the Prior Art
Prior art devices of this type have relied on a variety of different structural enclosures to limit blast effects. See for example U.S. Pat. Nos. 4,325,309, 4,248,342 and 3,800,715.
In U.S. Pat. No. 4,325,309, a device is disclosed that comprises a shield system having multiple paneled configurations of alternate layers of steel grating, steel perforated plates and steel louvered panels or wire screening. The shield reduces blast over pressure and heat and will contain flying debris.
U.S. Pat. No. 4,248,342 discloses an improved version of the shield system that was disclosed in U.S. Pat. No. 4,325,309 having almost an identical structural configuration.
In U.S. Pat. No. 3,800,715, a bomb recovery shield apparatus is shown having a support cage covered with rigid high strength material, such as steel, with the ends of the enclosure being open and covered with mesh and a lid to help suppress the blast force directed outwardly from the ends.
SUMMARY OF THE INVENTION
A blast suppression device for use in a confined area provides a yielding structure to absorb and dissipate the blast effects without damage to itself for repeated reuse. The device consists of a rigid support frame with multiple flexible panels movably secured thereto. The device is buried in sand or the like to stabilize and restrict movement of the flexible panels under the force of the blast.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the blast suppression device;
FIG. 2 is a perspective view of flexible flaps removed from the device;
FIG. 3 is an alternate form of the invention;
FIG. 4 is a side elevation of the alternate form of the invention seen in FIG. 3; and
FIG. 5 is an end view of the alternate form of the blast suppression device buried in sand as it would be used.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A blast suppression device for use with explosive hardening techniques that comprises a support frame 10 having a pair of base support tubular members 11 and 12 in spaced parallel relation to one another.
An upper support tubular member 13 is vertically spaced between said support tubular members. Pairs of longitudinally angularly aligned oppositely disposed interconnection member 14 extend between said upper support member 13 and said base support tubular members 11 and 12 respectively forming a generally elongated triangular frame configuration.
An end base tubular connection member 15 is positioned on either end of said support frame 10 removably secured between the free ends of said base support tubular members 11 and 12. A plurality of resilient flap configurations 16 comprised of individual flaps 17, each secured to the base support tubular members 11 and 12 by attachment bars 18 and fasteners F as will be well understood by those skilled in the art.
The resilient flap configurations 16 have a plurality of flaps located on either side of the elongated triangular frame configuration in side to side abutting relationship. Each pair of oppositely disposed flaps 17 overlap their respective free ends 19 on one another equally across the upper support tubular member 13 forming a tent-like enclosure resilient and yieldable in nature.
Referring to FIGS. 2,3 and 4 of the drawings, an alternate form of the invention is disclosed having a plurality of arcuate upstanding plates 20 aligned longitudinally in spaced relation to one another. Each of the plates 20 has a series of radially spaced notches 21 in its outermost edge to receive longitudinally extending interconnecting fastner bands 22 defining a ribbed enclosure 23A. Pairs of oppositely disposed resilient rubber flaps 23 are secured to the lowermost band 22 at 21 by a support plate 24 and multiple fasteners 25. The flaps 23 abut one another in side to side relationship as seen in FIG. 2 of the drawings overlapping their free ends of the oppositvely disposed flap pairs on the ribbed enclosure 23A. The arcuate upstanding plates 20 provide a stable frame for the interconnecting bands 22 and expose only a small edge surface area to the blast force improving durability and reuse factors.
In operation, the blast suppression device is positioned directly over the material to be hardened (M) on a bed of sand (SB). The material to be hardened (M) has been prepared with appropriately placed and configured blasting charges (not shown) positioned as will be well understood by those skilled in the art of blast hardening. The multiple flaps 23 are overlapped on the structure as hereinbefore described. End retainers (R) shown in broken lines in FIG. 4 of the drawings are secured to either end of the support frame. The end retainers (R) can be of any one of a variety of different materials and are used solely to prevent the filling in or the enclosure ends by sand (S) that is used to cover the entire structure to a depth of approximately three to four feet.
Once the blasting charges are fired, the resulting blast force is confined within the blast suppression device which absorbs and dissipates the blast force by flanging back the flaps 17 and 23 under the weight of the sand S.
This unique flexible absorbent action allows such blast hardening to be used in an indoor relatively confined space, unlike blast hardening methods used heretofore that require a large outdoor blast area consisting of many acres.
After the blast, the blast suppression device is removed and reused in tact with only the addition of new end retainers (R).
It will be evident from the above description that the principal object of the invention is to contain and dissipate blast force in a reuseable structure which is most desirable in the blast hardening techniques of metal articles, such as railroad frogs. The ability to contain and dissipate the blast allows use of the blast hardening in confined areas such as indoors where it was heretofore impossible to do allowing blasting on site of production greatly reducing the cost and time consuming factors of shipping material to a blast site. | A blast supression device for use in explosive hardening in a relatively confined enclosed area. The device absorbs and dissipates the explosive force by utilizing a containment frame covered with overlapping multiple flexible resilient flaps that dissipate the explosive force by yielding during the blast within the device. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a jack for returning the wheels of a derailed rail car to the track and, more particularly, to a re-railing jack adaptable for removable connection and pivotal movement in the receiver for the coupling of the rail car.
2. Description of the Prior Art
Lifting jacks, as disclosed in U.S. Pat. No. 1,088,236, are known for replacing a derailed rail car upon a track. The lifting operation requires vertically raising the wheels of the rail car above the upper level of the track and then laterally moving and simultaneously permitting the car to fall in a downward arc about the base of the jack onto the track. The above referenced patent discloses a bearing secured to the underside of the rail car adjacent and separate from the rail car coupler. The bearing receives a support for a lifting screw in which the support and the lifting screw are pivotally supported by the bearing. The upper end of the lifting screw is slidably connected to the upper edge of the car body, and the lower end is provided with a swivel base. A hand operated ratchet is provided for rotating the screw in either direction to raise and lower the car.
U.S. Pat. No. 1,062,871 discloses a lifting jack which is movable along the track. The lifting jack is connected to the car body in a manner to permit the jack to be swung about a horizontal axis into and out of an operative position. In this manner, the jack is carried on the rail car in a position where it is entirely out of the way when not in use. U.S. Pat. Nos. 862,609; 981,617; 1,099,405 and 1,107,706 also disclose lifting jacks movable into and out of position for re-railing a derailed rail car or for transferring a rail car from one set of tracks to another.
Lifting jacks, which are not connected to the rail car which is lifted and moved into position on the track, are considered hazardous to operating personnel because of the tendency for the jack to be displaced and fly out in a random direction when the vehicle is moved laterally and downwardly with the jack extended. Even though the lifting jacks which are not connected to the car body are provided with swivel bases in most cases, when the vehicle has to move laterally at an angle for a considerable distance, the base has a tendency to shift and move out of contact with the ground resulting in a sudden downward, uncontrolled movement of the vehicle which can result in serious bodily injury to operating personnel.
While the above-described lifting devices, which are attached to the vehicle, have attempted to solve the problem of uncontrolled shifting movement of the jack and prevent resultant injury which may occur, major modifications are required to the jack and the vehicle so that the jack can be connected to the vehicle in a manner to be easily moved to an out-of-way position on the vehicle. Due to the expense and lack of versatility of lifting jacks which are permanently secured to vehicles, they have not been generally accepted for use on rail vehicles operated either above or below ground, as for example on locomotives and rail cars used in underground mining operations. Furthermore, permanently securing a lifting jack to a vehicle limits that lifting jack to that specific vehicle, thereby requiring every vehicle to have a lifting jack. This constitutes a substantial expenditure to the operator. Consequently, the separate jacks which are known to be inherently dangerous are still being commonly used, particularly with underground track equipment.
There is a need for a jack for lifting a derailed vehicle upon a track where the jack is removably secured to the vehicle to be lifted in a manner which prevents the jack from flying out in a random direction and can be easily connected and disconnected from the vehicle without requiring major modifications to be made to the vehicle or requiring detailed construction of the jack. While it has been suggested to provide lifting jacks which are either removably connected to the vehicle or are connected to the vehicle for movement into and out of an operative position, the prior art lifting jacks require either that the jack be permanently secured to the vehicle or the vehicle by extensively modified to receive the jack in a manner that it can be connected and disconnected to the vehicle.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a lifting jack that includes a jack housing. The jack housing has an internally threaded portion and a support portion integral with the housing. A receiver is fixedly positioned to receive the jack housing support portion. Means is provided for removably connecting the jack housing support portion to the receiver to permit pivotal movement of the jack housing support portion relative to the receiver. A threaded jack screw is threadedly positioned in the jack housing internally threaded portion. A swivel base supports the threaded jack screw. Means is provided for turning the threaded jack screw in a selected direction to raise and lower the jack housing while permitting pivotal movement of the jack housing support.
Further in accordance with the present invention, there is provided a lifting jack for a rail car that includes a rail car coupler receiver. A jack housing has a first portion with an internally threaded bore and a second portion is positioned in the rail car coupler receiver for pivotal movement relative to the rail car coupler receiver. Means is provided for releasably connecting the jack housing second portion to the rail car coupler receiver for pivotal movement of the jack housing. A threaded jack screw is threadedly positioned in the jack housing internally threaded bore. Base support means supports the threaded jack screw for pivotal movement. Power means is provided for actuating rotation of the threaded jack screw in a selected direction to raise and lower the jack housing together with the rail car coupler receiver secured thereto.
The second portion of the jack housing has a configuration adapted for efficient movement into and out of the rail car coupler receiver. The rail car coupler receiver is normally operable to receive the automatic coupler of the rail car. Accordingly, by removing the automatic coupler from the coupler receiver, the coupler receiver is available for use to support the jack housing on the rail car. The jack housing second portion is pivotally movable within the coupler receiver.
The jack housing second portion is provided with slotted means to receive a pin of the coupler receiver that is normally utilized to hold the automatic coupler in the coupler receiver. With the jack housing second portion operatively positioned in the coupler receiver, the pin of the coupler receiver is extended down through the aligned slots of the coupler receiver and the jack housing second portion to connect the jack housing to the coupler receiver while permitting the jack housing to pivot about a horizontal axis relative to the coupler receiver. With this arrangement, the lifting jack is removably connected to existing equipment on the rail car and is pivotal about its point of connection on the rail car to permit the vehicle to be raised to a preselected height and move downwardly in an arc onto the rail.
Accordingly, the principal object of the present invention is to provide a lifting jack for a rail car that is secured to the rail car to permit both vertical and lateral movement of the car to safely return the car to the track.
Another object of the present invention is to provide a jack for re-railing a vehicle without encountering risk of injury to operating personnel.
An additional object of the present invention is to provide a lifting jack that is removably connected to the coupler receiver that is provided on a track vehicle to receive an automatic coupler for connecting adjacent track vehicles.
A further object of the present invention is to provide a lifting jack for a rail car in which the jack is adapted for pivotal connection to the receiver for the automatic coupler on the car.
These and other objects of the present invention will be more completely disclosed and described in the following specification, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in side elevation of a re-railing jack of the present invention, illustrating the pivotal connection of the jack housing to the receiver of an automatic coupler for a rail vehicle to be lifted by the re-railing jack.
FIG. 2 is a front elevational view taken along line II--II of FIG. 1, illustrating in phantom lateral, pivoted positions of the jack.
FIG. 3 is a fragmentary, schematic illustration of the various pivoted positions of the jack when the jack housing is pivoted in the coupler receiver on the vehicle.
FIG. 4 is a schematic view, illustrating a rail vehicle derailed from the track, and the automatic coupler which is normally retained in the coupler receiver on the vehicle.
FIG. 5 is a view similar to FIG. 4 of the derailed vehicle, illustrating the automatic coupler removed from the coupler receiver on the vehicle and the lifting jack secured to the coupler receiver and anchored in position to return the vehicle to the track.
FIG. 6 is an operational, schematic view, illustrating the lifting jack in a pivoted position where the vehicle has fallen downwardly onto the track.
FIG. 7 is an operational, schematic view, illustrating the lifting jack in a pivoted position where the vehicle has fallen downwardly onto the trace.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings and, particularly to FIGS. 1, 2 and 4-7, there is illustrated a re-railing jack generally designated by the numeral 10 for replacing a derailed rail vehicle 12 upon the track 14. The jack 10 is adaptable for use on any type of vehicle that is track mounted, such as rail cars, and particularly for both above and below ground track equipment, such as locomotives and personnel carriers movable on track in underground mining operations. As illustrated in FIGS. 4-7, the rail vehicle 12 includes a body portion 16 which is supported on the track 14 by conventional wheels 18 and axle 20. As illustrated also in FIG. 1, the rail vehicle body 16 includes a bumper 22 formed by spaced apart plate members secured to the body 16 at the ends of the body 16. Positioned within the space between the plates forming the bumper 22 is a conventional coupling member 24, illustrated in FIG. 4.
The coupling member 24, as well-known in the art, is operable to automatically connect adjacent cars or vehicles to one another to form a continuous string of vehicles for movement on the track 14. The operation of the coupling member 24 is well-known in the art and will not be described herein in detail. The coupling member 24 is received in a coupler receiver or a coupler pocket 26 which is shown in FIG. 1 and in accordance with the present invention is adaptable to receive and connect the re-railing jack to the rail vehicle 12.
The coupler pocket 26 is conventional in design and is formed by plates 28 which are secured to the bumper 22. The plates 28 of the coupler pocket 26 form an opening 30 for receiving the coupling member 24 as shown in FIG. 4, as well as, the re-railing jack 10 of the present invention, as illustrated in FIG. 1. The coupler pocket plates 28 include aligned slots 32 shown in FIG. 1 for receiving a connecting pin 34, conventionally used to releasably connect the coupler member 24 to the coupler pocket 26 as shown in FIG. 4. As it will be explained later in greater detail, the connecting pin 34 used to connect the coupler member 24 to the coupler pocket 26 is also adaptable to releasably connect the re-railing jack 10 to the coupler pocket 26.
The re-railing jack 10, as illustrated in detail in FIGS. 1 and 2, includes a jack housing generally designated by the numeral 36 adapted for positioning in the coupler pocket 26. The jack housing 36 is pivotal in the pocket 26 as illustrated in FIG. 3 to position the re-railing jack 10 in inclined positions. The jack housing 36 includes an internally threaded portion 38 and a support portion 40. The internally threaded portion 38 extends down through the support portion 40. The housing portions 38 and 40 are integrally formed so that internally threaded portion 38 extends in substantially perpendicular relationship to the support portion 40.
The support portion 40 is removably positioned in the coupler pocket 26. The internally threaded portion 38 extends outwardly from the coupler pocket 26 and the bumper 22. The internally threaded portion 38 includes an upper end portion 42 and a lower end portion 44 and has a tubular configuration. The jack housing support portion 40 also has a tubular configuration as seen in FIG. 2. The diameter of the support portion 40 is greater than the diameter of the internally threaded portion 38 because the support portion 40 is received within the coupler pocket 26 and the internally threaded portion 38 threadedly receives a threaded jack screw 46. The internally threaded portion 38 of the jack housing 36 has an internally threaded bore 48 that extends from the upper end portion 42 to the lower end portion 44. With this arrangement, the threaded jack screw 46 is threadedly positioned in the jack housing 36.
The threaded jack screw 46 includes a lower end 52 supported by a bearing 54. A transverse bore 56 extends through the bearing 54. The bearing 54 is positioned between plates 58 of a clevis-type base 60. The clevis-type base 60 has a lower surface engageable with the ground for supporting the re-railing jack 10 to carry out the re-railing operation. The plates 58 have aligned holes which when aligned with the bore 56 of the bearing 54 are adaptable to receive a pin 62 to pivotally connect the threaded jack screw 46 to the clevis-type base 60, as illustrated in phantom in FIG. 2 and further in operation in FIG. 7.
Rotation of the threaded jack screw 46 is actuated by a suitable means, as for example, by a ratchet generally designated by the numeral 64 engaging the threaded jack screw 46. The ratchet 64 includes a conventional nut 66 for engaging the jack screw 46 and a ratchet handle 68. Rotation of the ratchet handle 68 in a preselected direction turns the nut 66 to raise and lower the jack housing 36 on the threaded jack screw 46. A hydraulic jack or lever operated ratchet jack can also be used in place of the ratchet 64.
As illustrated in FIG. 1, the jack housing support portion 40 includes a pair of elongated slots 70 and 72 that open into a bore 74 (shown in FIG. 2) of the jack housing support portion 40. The slots 70 and 72 are positioned in overlying relation. When the jack housing support portion 40 is positioned in the coupler pocket 26, the slots 70 and 72 are aligned with the slots 32 of the coupler pocket 26. The connecting pin 34 extends through the aligned slots 32, 70 and 72 to connect the jack housing 36 to the coupler pocket 26.
With the above described arrangement, the jack housing 36 together with the jack screw 46 is pivotal about a horizontal axis 50 (FIG. 3) through the coupler pocket 26 at the point where the jack housing support portion 40 is connected to the coupler pocket 26. The degree of pivotal movement of the jack housing 36 is schematically illustrated in FIG. 3. Accordingly, the length of the slots 70 and 72 is selected to provide the desired degree of pivotal movement of the jack housing 36 and threaded jack screw 46. In this manner, the jack housing 36 and the jack screw 46 can be inclined at a preselected angle to facilitate the lateral movement of the rail vehicle 12 in an elevated position back on to the track 14 as illustrated in FIG. 7 and described hereinafter in greater detail.
The ratchet 64 is a hand-operated means for turning the threaded jack screw 46 is a selected direction to raise and lower the jack housing 36. This type of means is applicable for returning a light rail vehicle to the track 14 of the type illustrated in FIGS. 4-7. However, for heavier rail vehicles the hand-operated ratchet 64 can be substituted for a power-assisted device, such as an electric motor or an internal combustion engine through mechanical, hydraulic, pneumatic or other transmission medium. Therefore, it should be understood that the raising and lowering of the jack housing 36 together with the rail vehicle 12 can be accomplished by means other than the ratchet 64 and the present invention is not confined to the ratchet 64 as the means for raising and lowering the jack housing 36 on the threaded jack screw 46.
Now referring to FIGS. 4-7, there is illustrated the method of operation of the re-railing jack 10 for replacing a derailed vehicle 12 upon the track 14. In order to replace the derailed vehicle 12 upon the track 14 the automatic coupling member 24 retained in the coupler pocket 26 between the plates 28 of the bumper 22 is removed by first pulling the connecting pin 34 from connection of the coupling member 24 to the coupler pocket 26. When this is accomplished, the coupling member 24 is taken out of the coupler pocket 26 and the jack housing 36 is positioned in the pocket 26. The jack housing support portion 40 is positioned in the pocket 26 so that the slots 70 and 72 are aligned with the slots 32 to receive the connecting pin 34.
As illustrated in FIG. 4, the derailed vehicle 12 is tilted from a horizontal plane, and therefore, before the clevis-type base 60 is positioned on the ground the jack housing 36 is pivoted in the coupler pocket 26 to substantially, vertically position the threaded jack screw 46. Then the threaded jack screw 46 is firmly supported on the ground by the clevis-type base 60. Further in accordance with the present invention by utilizing the coupler pocket 26 for connecting the jack housing 36 to the rail vehicle 12, the lifting point of the re-railing jack 10 is on the longitudinal centerline of the rail vehicle 12. This substantially balances the raised vehicle to facilitate lateral movement of the rail vehicle 12 in a raised position back on to the track 14.
Once the re-railing jack 10 is firmly supported by the clevis-type base 60 engaging the ground, the jack housing 36 is advanced upwardly on the threaded jack screw 46 by rotation of the ratchet handle 68. Accordingly, as the jack housing 36 is raised the end of the vehicle is lifted to the desired height so that the wheels 18 are positioned above the track 14. After the vehicle 12 is raised to where the wheels 18 clear the track 14, the rail vehicle 12 is shifted laterally and by the pivotal support of the threaded jack screw 46 to the clevis-type base 60 the vehicle is permitted to fall in a downward arc on to the track 14.
With light rail vehicles, manpower can be used to push the vehicle laterally and downwardly on to the track. However, with heavier rail vehicles, mechanical or power actuated jacks can be utilized to laterally move the vehicle into position on the track 14. For those instances where a derailed vehicle is displaced a considerable distance from the track 14 it may be necessary to repeat the steps of lifting and laterally moving the vehicle to move the vehicle the required lateral distanced to return the wheels 18 to the track 14.
By pivotally connecting the jack housing 36 to the coupler pocket 26 the lateral movement of the vehicle is controlled so as to prevent the threaded jack screw 46 and the clevis-type base 60 from losing traction with the ground and thereby preventing the clevis-type base 60 from becoming displaced and flying out in a random direction in a hazardous manner. Furthermore, by lifting the vehicle about the longitudinal center line of the vehicle, greater control is provided in the lateral downward movement on to the track 14. It is well known that the rail vehicle 12 includes coupler pockets 26 at both ends of the vehicle so as to permit operation of the jack 12 at both ends of the vehicle to return all wheels of the vehicle 12 on to the track 14.
According to the provisions of the patent statutes, I have explained the principle, preferred construction and mode of operation of my invention and have illustrated and described what I now consider to represent its best embodiments. However, it should be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically illustrated and described. | A re-railing jack for returning derailed track vehicles to the track includes a threaded jack screw pivotally mounted in a ground supported swivel base. A jack housing is longitudinally movable on the jack screw in response to rotation of the jack screw by a ratchet which engages the jack screw. The jack housing includes a first portion threadedly engaged to the jack screw and a second integral portion positioned in the coupler pocket which normally receives the automatic coupler of the track vehicle. The housing second portion is retained in the coupler pocket by the same pin which holds the coupler in place. The pin extends through transverse slots of the jack housing permitting the housing to pivot within the coupler pocket about the point of connection of the housing to the vehicle. The jack is thus safely connected to the vehicle in an efficient manner which facilitates lifting and combined downward lateral movement of the vehicle back on to the track. | 1 |
RELATED APPLICATIONS
This application claims the benefit of U.S. provisional patent application No. 60/388,832 filed on Jun. 13, 2002.
FIELD OF INVENTION
The present invention relates to a computer method and system for simulating an online session while offline, and more particularly, to such a method and system in the field of customer relationship management.
BACKGROUND OF THE INVENTION
The Internet provides the capability to provide services to customers without requiring them to install additional software on their local computers. Specifically, by exploiting the customer's web browser, all functional logic and all data can reside at a remote server rather than at the customer's local computer (i.e., the client). As such, the customer, via instructions submitted through web pages that are displayed in the web browser, can remotely invoke the functional logic to view, create, update, delete or otherwise modify the data residing on the remote server.
In the field of customer relationship management (“CRM”), the foregoing use of the Internet is ideal for enabling sales, customer support, and marketing teams and individuals to organize and manage their customer information. For example, all leads, opportunities, contacts, accounts, forecasts, cases, and solutions can be stored at a secure data center but may be easily viewed by any authorized sales-person (e.g., with a proper username and password) through a web browser and Internet connection. One key benefit of such an online CRM solution is the ability to share data real-time and enable all team members to leverage a common set of information from one accessible location. For example, sales managers can track forecast rollups without requiring each sales representative to submit individual reports, as well as instantly access aggregated sales data without requiring each sales representative to manually submit such data. Similarly, reseller sales representatives and other external partners can be granted secure access to a company's sales data by providing them a username and password for the web site.
Nevertheless, such an online CRM solution suffers from the requirement that a user must have access to an Internet connection in order to access and manipulate the data residing on the remote server. For example, when a sales representative or manager is working in the field, such an Internet connection may not be readily available. As such, what is needed is a method for simulating an online session while the user is offline (e.g., without a network connection). Furthermore, it would be advantageous if such a method minimized the amount of user training and client-side installation and customization by taking advantage of pre-existing interfaces and technologies on the client computer.
SUMMARY OF THE INVENTION
The present invention provides a method and system for simulating an online session between the client and a remote server when the client is offline. The client includes a local interface that can communicate with the remote server. During an online session, the data and the functional logic that is invoked to manipulate the data reside on the remote server. As such, the user transmits instructions to view, create, update, delete, or otherwise modify portions of data through the local interface and subsequently through the underlying network. These instructions are ultimately received at the remote server, which then invokes the proper functional logic to perform the instructions in order to manipulate the data.
In preparation for simulating an online session when the client is offline, when the client is online, it imports at least a subset of the data that resides at the remote server. Furthermore, the client imports at least a subset of the functional logic used to manipulate the data as an embedded portion of a format or document that is capable of being interpreted and performed by the local interface. To initiate an offline session, the user invokes the local interface (as in the online session). However, rather than accessing the remote server, the local interface accesses local documents formatted with the embedded functional logic. As in the online session, the user transmits instructions to view, create, update, delete, or otherwise modify portions of data through the local interface. However, rather than transmitting the instructions through an underlying network, the local interface invokes the embedded functional logic in the documents to manipulate the imported data in response to the instructions. As such, the present invention provides an offline simulation of an online session between the client and a remote server. Because the same local interface that is used in the online session is also used in the offline session, user training for the offline session is minimized or even eliminated. Furthermore, since functional logic is embedded into a format capable of being interpreted and performed by the local interface, the need to install additional standalone software applications is also minimized or eliminated. Further objects and advantages of the present invention will become apparent from a consideration of the drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating an online session between a client with a local interface and a remote server with a relational database and functional logic.
FIG. 2 is an example of a client initiation of an online CRM session with a remote server.
FIG. 3 is an example of the presentation of CRM data on a client's web browser during an online CRM session.
FIG. 4 is a diagram illustrating an offline session.
FIG. 5 is a expanded block diagram illustrating one embodiment of the various phases used to provide a client with the capabilities of engaging in an offline CRM session.
FIG. 6 is a flowchart illustrating one embodiment of a process for conducting an offline CRM session.
FIG. 7 is an example of a login session to connect to a remote server during a synchronization process.
FIG. 8 is an example of a visual representation of a synchronization process with the remote server.
FIG. 9A is a first example of the presentation of CRM data during an offline session (Home View).
FIG. 9B is a second example of the presentation of CRM data during an offline session (Home View).
FIG. 9C is a third example of the presentation of CRM data during an offline session (Home View).
FIG. 9D is a fourth example of the presentation of CRM data during an offline session (Home View).
FIG. 9E is a fifth example of the presentation of CRM data during an offline session (Home View).
FIG. 10A is an example of the presentation of “Accounts” CRM data during an offline session (Home View).
FIG. 10B is an example of the presentation of “Accounts” CRM data during an offline session (All Accounts View).
FIG. 10C is an example of the presentation of “Accounts” CRM data during an offline session (Specific Account View).
FIG. 10D is an example of the presentation of “Accounts” CRM data during an offline session (New Account View).
FIG. 11A is an example of the presentation of “Contacts” CRM data during an offline session (Home View).
FIG. 11B is an example of the presentation of “Contacts” CRM data during an offline session (All Contacts View).
FIG. 11C is an example of the presentation of “Contacts” CRM data during an offline session (Specific Contact View).
FIG. 11D is an example of the presentation of “Contacts” CRM data during an offline session (New Contact View).
FIG. 12A is an example of the presentation of “Opportunities” CRM data during an offline session (Home View).
FIG. 12B is an example of the presentation of “Opportunities” CRM data during an offline session (All Opportunities View).
FIG. 12C is an example of the presentation of “Opportunities” CRM data during an offline session (Specific Opportunity View).
FIG. 12D is an example of the presentation of “Opportunities” CRM data during an offline session (New Opportunity View).
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description will first describe the structure of an online session that may be simulated by an offline session in accordance with the invention. The structure of the offline session, itself, is then detailed. Following the description of the offline session, preparation of the client prior to conducting such offline sessions (e.g., installation and synchronization phases) is described.
Online Session
Referring to the drawings, FIG. 1 illustrates an online session between a client 100 and a remote server 200 . The client includes a local interface 110 while the remote server 200 includes a database 210 and functional logic 220 that is invoked to manipulate the data residing in the database 210 . The client 100 establishes communication channels through a network 150 that connects the client 100 to the remote server 200 .
In one environment, the network 150 used by the online session may be the Internet. In such an environment, the client 100 may be a laptop or desktop computer and the local interface. 110 may be a web browser such as Internet Explorer or Netscape Navigator. The functional logic 220 at the remote server 200 may be invoked through an underlying application or specification such as a CGI program (including, for example, scripts such as Perl), Java servlet (including, for example, JavaServer Pages, or JSP, technology), daemon, service, system agent, server API solution (including, for example, ISAPI or NSAPI) or any other technique or technology known in the art. The database 210 may be a relational database management system such as Oracle or DB2. The communication channels between the local interface 110 and the remote server 200 may be governed by the HTTP protocol. For example, by selecting various options from a web page, a user transmits instructions in the form of an HTTP message through the Internet to the remote server. Upon receiving the HTTP message, the underlying program, component, or application at the remote server performs the pertinent functional logic to interact with and manipulate the data in the database in accordance with the instructions. Those skilled in the art will recognize that the foregoing general online client-server scheme is merely illustrative and that various alternatives, possibly exploiting different technologies, standards and specifications, may also be utilized to create an online session over the Internet in accordance with FIG. 1 . Those skilled in the art will also appreciate that functional logic, program, service, agent, API or other computer code and/or data referred to herein or otherwise utilized may be stored, loaded and/or executed from or otherwise embodied in a suitable computer-readable medium, in accordance with the requirements of a particular implementation.
In the field of customer relationship management (“CRM”), such an online client-server scheme can provide the capability to track contacts, leads and customer inquiries without needing a complex software solution on the client-side. For example, in one instance of an online CRM session, the user securely logs into the remote server by entering a username and a password through his local web browser, as shown in FIG. 2 . Once the user successfully logs into the remote server, he may be presented with an initial home page that provides access to further features and information. As shown in FIG. 3 , for example, the initial home page may provide the user with a brief synopsis of his upcoming events 310 and tasks 320 . Furthermore, the initial home page provides access 330 to further pages that enable the user the track, manage and organize other data including campaigns, leads, accounts, contacts, opportunities, forecasts, cases, and reports. Those skilled in the art will recognize that FIGS. 2 and 3 are merely examples of one way of presenting CRM information on a local interface and that there exist innumerous ways (e.g., look and feel) to present CRM information on a local interface in accordance with the online client-server scheme presented herein. Furthermore, those skilled in the art will recognize that the online CRM session described herein is merely an example of one area in which the online client-server scheme may be exploited and that there exist innumerous fields and areas in which this online client-server scheme may be exploited.
Offline Session
As shown in FIG. 4 , during an offline session, in contrast to an online session as described earlier and illustrated in FIG. 1 , the client 100 can no longer establish a communications channel through the network 150 to connect to the remote server 200 . As such, at least portions of the data from the database 210 and portions of the functional logic 220 at the remote server 200 are imported to the client 100 so that the client 100 can conduct an offline session in isolation. In FIG. 4 , at least a subset 130 of the data 210 is imported to the client 100 . Similarly, at least a subset 120 of the functional logic 220 is also imported to the client. This imported functional logic 120 is embedded into a format capable of being interpreted and performed by the local interface.
In an embodiment of an offline session in which the local interface 110 is a web browser, both the data 130 and functional logic 120 may be stored according to an open standards formatting protocol. For example and without limitation, the data 130 may be stored in a single or a series of documents in XML (Extensible Markup Language), possibly including, for example, XSL stylesheets (which are XML documents, themselves) for rendering the data into HTML documents. As is known to those skilled in the art, XML may be considered a markup language (or a specification for creating markup languages) that is used to identify structures within a document. Similarly, the functional logic 120 may be embedded in a document utilizing a markup language and may be expressed as a scripting language within the document. For example and without limitation, the functional logic 120 could be expressed as JavaScript or VBScript that is embedded in an HTML (HyperText Markup Language) document. As used herein, the term “embedded” may mean either actually embedding the JavaScript (or any other functional logic in a format capable of being interpreted and performed by the web browser) code in the HTML document, or alternatively, accessing a separate JavaScript document by, for example, providing the URL (relative or full address) of the JavaScript source code file in the HTML document. As such, when the HTML document is rendered by the web browser, depending upon certain actions taken by the user, certain portions of the functional logic 120 (e.g., JavaScript) may be interpreted and performed by the web browser. Such functional logic 120 may interact with the data 130 expressed as XML. For example and without limitation, a user may request to view portions of the data 130 on the web browser. In response to the request, by calling an XSLT (Extensible Stylesheet Language for Transformations) processor that is incorporated into the web browser (e.g., MSXML Parser) or any other comparable XSLT technology residing at the client, the functional logic 120 may access the appropriate portions of the data 130 (e.g., in XML documents) in conjunction with the appropriate XSL stylesheets, in order to transform or render such data 130 into an HTML document that is visually presented on the web browser.
Preparation of Client for Offline Session
Prior to conducting an offline session as described in the foregoing, an initial installation phase and subsequent synchronization sessions may be needed to prepare the client 100 for such an offline session. During the installation phase, an installation or setup executable may be downloaded from the remote server 200 to the client 100 . As depicted in FIG. 5 , during the installation phase 500 , the executable prepares the client for conducting an offline session by, for example and without limitation, (1) establishing a directory structure in the client's file system (Step 510 ), (2) downloading navigational markup documents with embedded functional logic (e.g., HTML files with embedded JavaScript code or HTML files and related separate JavaScript files) (Step 520 ); (3) downloading other miscellaneous installation components possibly including static HTML files, stylesheets, XSL templates, ActiveX controls, system shortcuts, local language components and, if not already available, an XML parser that may be integrated into the web browser (e.g., MSXML Parser) (Step 530 ).
Furthermore, prior to going offline, a user may synchronize the imported subset of data 130 at the client with the data residing in the database 210 . For example, if synchronization is occurring for the first time, all data residing in the database 210 that is needed for conducting an offline session may be downloaded from the database 210 to the client 100 (Step 550 ). This downloaded data may, for example, be defined and customized according to the user's criteria for conducting an offline session. In one implementation, the synchronization process may download this data as XML documents (e.g., according to data type such as accounts, contacts, opportunities, etc.). Once such XML documents are downloaded, XSL templates that are used to visually render the data (e.g., 130 in FIG. 4 ) on the web browser may be constructed at the client by utilizing the formatting instructions provided by the XML documents. Alternatively, such XSL templates might also be generated at the server and subsequently downloaded to the client. During subsequent synchronization processes prior to going offline 540 , as depicted in FIG. 5 , modified data records and data records created since the previous synchronization may be downloaded to the client (Step 560 ). Furthermore, the synchronization process 540 may also provide the opportunity to download (or modify) user customizations (e.g., XML layout information used to construct XSL templates at the client or the XSL templates themselves) for the visual representation of data and other information on the web browser (Step 570 ). Similarly, upon reestablishing a connection with the remote server 200 , the user may also desire to conduct a synchronization process 580 in order to upload any modified or newly created data records to the remote database 210 (Step 590 ). In one implementation of the synchronization process, the communication channel between the client 100 and the remote server 200 may be established through the HTTP protocol using XML-RPC and a related HTTP/HTTPS server based XML API. Those skilled in the art will recognize that there are alternative synchronization processes other than the one presented in FIG. 5 that may be conducted in accordance with the present invention. For example and without limitation, all synchronization processes, regardless of whether the subsequent activity is an offline session or the re-establishment of an online connection, may simultaneously download modified and newly created data records from the server database to the client as well as upload modified and newly create data records from the client to the server database. Additionally, those skilled in the art will recognize that any variety of techniques and models known in the art may be used implement the synchronization process in order to maintain consistency and coherency while accessing data (e.g., atomic, sequential or causal consistency, etc.).
FIG. 6 illustrates one embodiment of a process for initiating and conducting an offline CRM session. As depicted, in this embodiment, an initial installation process should be conducted before an offline session can begin (e.g., Steps 610 , 510 , 520 , 530 ). After installation, a user may initiate an offline session by opening an HTML page downloaded to the client during the installation phase (Step 620 ). While still online, the user may then synchronize local client data with the remote database before going offline (Step 630 and expanded in Steps 632 , 634 , 550 , 560 , 590 ). As shown in FIG. 6 , this may involve downloading data from the remote server (Step 550 ) as well as uploading data to the remote server (Step 590 ), and if necessary, an initial download of all offline session data (Step 550 ). As previously discussed, one implementation of such downloading and uploading may be implemented through HTTP communications channels using XML-RPC. Once synchronization is complete, the user may go offline and manipulate, view, and modify his customer relationship data by selecting from various options through the web browser (Step 640 ). For example and without limitation, the user may view his calendar, tasks, and activities (Step 642 ). Additionally, data may be organized into certain categories such as accounts, contacts, and opportunities. The user may be able to maneuver through the web browser to access, edit, create, delete, or otherwise modify data within these categories (Steps 642 , 644 , 646 , 648 ).
FIGS. 7 to 12D represent examples of the local interface 110 as a web browser that may serve as visual examples for certain steps in the flowchart of FIG. 6 . For example, FIG. 7 illustrates a login interface to access the remote server to initiate a synchronization corresponding to 632 of FIG. 6 . Similarly, FIG. 8 illustrates the synchronization process of downloading modified and newly created records from the remote database as in 560 of FIG. 6 (and possible uploading of any modified or newly created records to the remote database as in 590 of FIG. 6 ). Corresponding to Step 642 in FIG. 6 , FIG. 9A illustrates one example of an offline home page and FIGS. 9B to 9E illustrate various other alternative “Home” views that may be accessed by the user during an offline session. Similarly, corresponding to Step 644 in FIG. 6 , FIGS. 10A to 10C illustrate various views of data organized into an Accounts category. Corresponding to Steps 646 and 648 in FIG. 6 , FIGS. 11A to 11D illustrate various views of data organized into a Contacts category and FIGS. 12A to 12D illustrate various view of data organized into an Opportunities category, respectively.
The various embodiments described in the above specification should be considered as merely illustrative of the present invention. They are not intended to be exhaustive or to limit the invention to the forms disclosed. Those skilled in the art will readily appreciate that still other variations and modifications may be practiced without departing from the general spirit of the invention set forth herein. For example and without limitation, those skilled in the art will recognize that there exist alternative proprietary technologies, languages and open standards (e.g., other than JavaScript, XML, XSLT, XML-RPC, HTML, HTTP, etc.) that may be practiced in the context of the Internet and World Wide Web in accordance with the invention set forth herein. Furthermore, while much of the foregoing discussion has been described in the context of the World Wide Web and the Internet (e.g., local interface 110 is a web browser), those skilled in art will recognize that the invention disclosed herein may be implemented in other network environments as well. Similarly, while much of the foregoing discussion utilized the CRM area as an example, those skilled in the art will also recognize that other fields and areas may exploit the invention disclosed herein. Therefore, it is intended that the present invention be defined by the claims that follow. | Systems and Methods for conducting an offline session simulating an online session between a client and server in a network environment. The client imports data and functional logic from the server prior to going offline. The imported functional logic is embedded into a format or document that is capable of being interpreted and performed by the local interface at the client that is used to interact with server when online. Whether offline or online, the user utilizes the same local interface at the client to transmit instructions to the functional logic to manipulate the data. In an offline session, such instructions cause the imported and embedded functional logic to execute, thereby manipulating the data imported at the client. Known synchronization methods may also be used to maintain consistency and coherency between the imported data at the client and the database at the server. | 7 |
[0001] This invention relates to gas turbine combustor technology generally, and to an apparatus and related method for cooling the aft end of a transition pieces or duct that extends between a combustor and the first stage of the turbine.
BACKGROUND OF THE INVENTION
[0002] Typically, transition ducts have an aft frame which is attached, or integrated into, the aft end of the duct, facilitating attachment of the duct to the inlet of the turbine first stage. The aft frame is often cooled by means of controlled seal leakage and small cooling holes that allow compressor discharge air to pass through the frame. It has proven difficult, however, to cool the aft end of transition ducts which do not have an aft frame integrally formed with, or attached to the duct body. In accordance with exemplary but nonlimiting implementation of this invention, forced convection and potentially impingement cooling are used as a means to directly cool a transition duct which does not have an aft frame structure.
[0003] Accordingly, in one aspect, the present invention relates to a transition duct for a gas turbine comprising: a tubular body having a forward end and an aft end; a plurality of cooling channels formed on an exterior surface of the tubular body at the aft end; a closure band surrounding the aft end, covering at least a portion of the plurality of cooling channels; and a seal attached to the closure band, surrounding the aft end of the tubular body.
[0004] In another aspect, the present invention relates to a method of providing cooling air to an aft end of a gas turbine transition duct comprising: forming plural open cooling channels on an exterior surface of the transition duct at the aft end thereof, the plural cooling channels extending from an aft edge of the duct in an upstream direction; closing at least a portion of the plural open cooling channels with a peripheral closure band to thereby form cooling passageways; and incorporating a seal into the closure band.
[0005] The invention will now be described in greater detail in connection with the drawings identified below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a partial aft end perspective view of a turbine transition duct with cooling channels formed therein; and
[0007] FIG. 2 is a perspective view similar to FIG. 1 but with a band enclosing portions of said cooling channels, and with a seal attached to the band.
DETAILED DESCRIPTION OF THE INVENTION
[0008] In a typical can-annular combustor configuration in a gas turbine, an array of combustors surrounding the turbine rotor supply hot combustion gases to the turbine first stage via a corresponding array of transition ducts that extend between the combustors and the first stage inlets. With reference to FIG. 1 , one such transition duct 10 connects at a forward end to a combustor liner (not shown). The aft end 12 of the transition duct in the exemplary embodiment has no integral or attached aft frame surrounding the outlet 14 , thus making it difficult to adequately cool the aft end. The aft end 12 is received within a bracket (not shown) fixed to first stage turbine nozzle and formed with a correspondingly-shaped aperture. In this kind of arrangement, cooling techniques commonly employed to cool the aft end of a transition piece that does utilize an aft frame (which provides a ready vehicle for incorporating cooling geometry), are not available.
[0009] Accordingly, in one nonlimiting implementation, an array of cooling channels or grooves 16 are formed on the exterior surface of the aft end 12 of the transition duct 10 . The cooling channels 16 provide cooling air outlets 18 at the aft edge 20 of the duct 10 , extending toward the opposite end of the duct. The channels terminate at respective tapered inlets 22 , the axial location of which may be varied as dictated by combustor and duct design, cooling requirements, etc.
[0010] The cooling channels 16 may be provided on one, all or any combination of the exterior top surface 24 , side surfaces 26 , 28 , and bottom surface 30 of the duct, and the number of channels or grooves in each of those surfaces may also vary as desired. The channels 16 may be formed by means of any acceptable manufacturing process, e.g., milling, casting, laser etching, drop forging, etc.), and may be of any suitable cross-sectional shape including rectangular as shown in FIGS. 1 and 2 , but also including semi-circular, oval, V-shaped etc.
[0011] The channels 16 are substantially closed at the top by a metal wrap or closure band 32 ( FIG. 2 ) that surrounds the transition duct, thus forming closed-periphery passageways having substantially rectangular-shaped cross sections. The band 32 extends axially from the aft edge 20 to the tapered inlets 22 , leaving the latter exposed for facilitating entry of air into the channels. The band 32 may be fastened to the duct by any suitable process including bolting or welding.
[0012] The interior surfaces of the cooling channels may also be formed or provided with any of several known heat transfer enhancement mechanisms applied to one, all, or any combination of bounding walls of the cooling channels. Such surface enhancements include turbulators, fins, dimples, cross-hatch grooves, sand-dune shapes, chevrons or any combination thereof. The arrangement and number of such enhancements may be varied as desired among the various channels. Cooling air may be delivered to the channels 16 in any number of ways. For example, the channels 16 may be exposed, via inlets 22 , at their upstream ends to compressor discharge flow, or they may be fed directly from a separate inlet or manifold. Alternatively, or additionally, the cooling channels 16 may be fed from any number of cooling apertures 36 (three shown in FIG. 2 ) provided in the band 32 . For example, one or more cooling apertures could be provided in overlying relationship with any one or more of the channels 16 .
[0013] It is also a feature of the exemplary embodiment to combine a seal 36 with the closure band 32 . The seal 36 is shown schematically in FIG. 2 to include a pair of brush seal bands 38 , 40 but the seal may also be composed of may any of a variety of other conventional seals such as leaf seals, cloth seals, rope seals hula seals and the like. As noted above, the aft end of the transition piece will be received within a bracket assembly that is correspondingly-shaped aperture in a fixed to the stage 1 nozzle of the turbine. By incorporating a seal into the wrap or closure band 32 , air in the compressor discharge chamber will be prevented from leaking into the cavity between the bracket and the turbine first stage inlet.
[0014] Note that the above-described aft end cooling arrangement can be used with or without conventional impingement cooling sleeves that are used to impingement cool areas of the duct upstream of the aft end.
[0015] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A transition duct for a gas turbine includes a tubular body having a forward end and an aft end; a plurality of cooling channels formed on an exterior surface of the tubular body at the aft end; a closure band surrounding the aft end, covering at least a portion of the cooling channels; and a seal attached to the closure band, surrounding the aft end of the tubular body. | 5 |
RELATED APPLICATIONS
This application is a continuation application of, and hereby claims priority under 35 U.S.C. §120 to, pending U.S. patent application Ser. No. 11/054,508, entitled “Using Versioned Pointers to Facilitate Reusing Memory with a Reduced Need to Reclaim Objects through Garbage Collection,” by inventor David R. Chase, filed on 9 Feb. 2005.
BACKGROUND
The present invention relates to the process of allocating memory in a computer system.
One of the major problems with some programming languages arises from the process of allocating and de-allocating memory. Having the programmer allocate and de-allocate memory provides many advantages when done correctly. However, programmers routinely fail to de-allocate memory when it is no longer needed, and programmers commonly re-use memory that has been de-allocated. Both of these actions can cause a program to behave incorrectly, and can lead to erroneous results or to a “crash” of the computer system.
In order to obviate these problems, designers have created so-called “safe” languages, such as the JAVA™ programming language, Lisp, Modula-3, Perl, Smalltalk, ML, BASIC, C#, and the SafeC programming language. Safe programming languages typically do not trust programmers to recycle storage, because allocation errors can break the language abstraction. Instead, they either make use of a garbage collection mechanism, or use restrictive type systems to ensure that memory is recycled properly. Garbage collection generally runs quickly enough, but often has a substantial storage overhead, which can reduce the amount of storage that is available to do useful computing.
SUMMARY
One embodiment of the present invention provides a system that uses versioned pointers to facilitate reusing memory without having to reclaim the objects solely through garbage collection. The system operates by first receiving a request to allocate an object. Next, the system obtains the object from a pool of free objects, and sets an allocated/free flag within the object to indicate that the object is allocated. The system also increments a version number within the object, and also encodes the version number into a pointer for the object. The system then returns the pointer, which includes the encoded version number. In this way, subsequent accesses to the object through the pointer can compare the version number encoded in the pointer with the version number within the object to determine whether the object has been reused since the pointer was generated.
In a variation of this embodiment, the system receives a request to write data in the object. In response to the request, the system starts a memory transaction that ensures atomicity of a defined group of memory operations. Next, the system reads the object's header, compares the encoded version number in the object's pointer with the version number in the object's header, and determines if the allocated/free flag indicates the object is allocated. If the allocated/free flag indicates the object is allocated, and the encoded version number and the version number match, the system writes the data in the object and completes the memory transaction.
In a further variation, if the encoded version number and the version number do not match, the system reports a failed write.
In a further variation, if the memory transaction fails to complete, the system retries the memory transaction.
In a further variation, the system receives a request to read data from the object. In response to the request, the system reads the object, compares the encoded version number in the object's pointer with the version number in the object's header, and determines if the allocated/free flag indicates the object is allocated. If the allocated/free flag indicates the object is allocated, and the encoded version number and the version number match, the system returns the data. Otherwise, the system returns an error.
In a further variation, the system receives a request to free the object. In response to the request, the system sets the allocated/free flag to free, and if the object's version number is less than a maximum value, the system returns the object to the free pool.
In a further variation, the system receives a request to perform a garbage collection of the pool of free objects. In response, the system sequences through the objects in the pool of free objects and compares the encoded version number in each object's pointer with the version number in the object's header. If the encoded version number in the pointer and the version number in the header match, the system resets the encoded version number in the pointer to zero.
In a further variation, if the encoded version number in the pointer and the version number in the header do not match, the encoded version number in the pointer is either reset to an error value that will never be valid, or the pointer is modified to reference a special error object. All header version numbers on objects that survive garbage collection are reset to zero. Mark-and-sweep collectors accomplish this during their sweep phase; copying collectors accomplish this during their copying phase.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a computer system in accordance with an embodiment of the present invention.
FIG. 2 illustrates a memory organization in accordance with an embodiment of the present invention.
FIG. 3 illustrates a container in accordance with an embodiment of the present invention.
FIG. 4 illustrates an object in accordance with an embodiment of the present invention.
FIG. 5 illustrates a pointer in accordance with an embodiment of the present invention.
FIG. 6 presents a flowchart illustrating the process of creating a container in accordance with an embodiment of the present invention.
FIG. 7 presents a flowchart illustrating the process of allocating an object in accordance with an embodiment of the present invention.
FIG. 8 illustrates a flowchart illustrating the process of writing data to an object in accordance with an embodiment of the present invention.
FIG. 9 presents a flowchart illustrating the process of reading data from an object in accordance with an embodiment of the present invention.
FIG. 10 presents a flowchart illustrating the process of de-allocating an object in accordance with an embodiment of the present invention.
FIG. 11 presents a flowchart illustrating the process of performing garbage collection 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 intended to be 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. Computer system includes processor 102 , bridge 104 , and memory 106 . Processor 102 can generally 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.
Memory 106 includes random-access memory (RAM) which is used to store program instructions and data during execution of a program by processor 102 . Bridge 104 couples processor 102 to memory 106 and controls the flow of instructions and data between processor 102 and memory 106 .
Memory
FIG. 2 illustrates a system memory organization in accordance with an embodiment of the present invention. Memory 106 includes heap 202 . Heap 202 provides storage for containers 204 and 206 . Each container provides storage for a pool of objects, which are the same size. Different containers provide storage for objects of different sizes.
Container
FIG. 3 illustrates a container 204 in accordance with an embodiment of the present invention. Container 204 provides storage for objects 301 - 309 . Note that container 204 can provide storage for more or fewer objects than shown. The structure of each object is described in more detail in conjunction with FIG. 4 below.
Object
FIG. 4 illustrates an object 302 in accordance with an embodiment of the present invention. Object 302 is exemplary of the objects stored within the various containers in heap 202 . Object 302 includes header data 402 , allocated/free flag 404 , new/old flag 406 , version number 408 , and data 410 . Header data 402 and data 410 are commonly found in objects and will not be discussed further herein.
Allocated/free flag 404 indicates whether object 302 is allocated or not, while new/old flag 406 is a standard flag that is commonly used during garbage collection operations. Version number 408 indicates the version number for the current allocation of object 302 . Allocated/free flag 404 , new/old flag 406 , and version number 408 are described in detail in conjunction with FIGS. 6-11 below.
Pointer
FIG. 5 illustrates a pointer in accordance with an embodiment of the present invention. The pointer includes stale flag 502 , new/old flag 504 , version number 506 , and address 508 . Note that for the immediate future, four petabytes (2 52 ) is probably a reasonable upper limit on the memory that might be directly addressed in a computer. Given 64-bit pointers, this provides 12 bits for tagging (1 bit each for stale flag 502 and new/old flag 504 and 10 bits for version number 506 ).
After masking off stale flag 502 , new/old flag 504 , and version number 506 in the pointer, the pointer includes only address 508 , which is the address where the related object is stored.
Creating a Container
FIG. 6 presents a flowchart illustrating the process of creating a container in accordance with an embodiment of the present invention. The system starts by determining the size and quantity of objects needed for the program to execute efficiently (step 602 ). Next, the system creates a container within the heap for each size of object (step 604 ).
After the containers have been created, the system initializes each object in each container (step 606 ). This initialization includes setting the allocated/free flag to free, the new/old flag to new, and the version number to zero. Finally, the system initializes a pointer to each object in each container (step 608 ). This initialization involves clearing the stale flag, setting the new/old flag to new, setting the version number to zero, and setting the address to point to the object.
Allocating an Object
FIG. 7 presents a flowchart illustrating the process of allocating an object in accordance with an embodiment of the present invention. The system starts by incrementing the version number in the object's header (step 702 ). Next, the system sets the allocated/free bit to allocated (step 704 ). Finally, the system copies the version number from the object header to the tag area of the pointer (step 706 ).
Writing Data
FIG. 8 illustrates a flowchart illustrating the process of writing data to an object in accordance with an embodiment of the present invention. This process assumes that the computer system includes transactional memory to ensure that given memory transactions are either committed as a block or failed as a block to maintain memory coherence.
The system starts by starting a memory transaction (step 802 ). Next, the system reads the version number from the object (step 804 ). After reading the version number from the object, the system compares this version number with the version number stored in the pointer (step 806 ). If the version numbers are equal, the object has not been reallocated and the system next checks the free/allocated flag to see if the object is allocated (step 806 ).
If the free/allocated flag is set to allocated in step 808 , the system writes the data to the object (step 810 ). Next, the system commits the transaction (step 812 ). After committing the transaction, the system determines if the transaction has failed (step 814 ). If not, the process is complete. Otherwise, the process returns to step 802 to make another attempt.
If the version numbers do not match at step 806 or the free/allocated flag is equal to free at step 808 the system throws an exception (step 816 ).
Reading Data
FIG. 9 presents a flowchart illustrating the process of reading data from an object in accordance with an embodiment of the present invention. The system starts by reading the object including the header (step 902 ). Next, the system determines if the version number in the header matches the version number in the pointer (step 904 ). If the version numbers match, the system returns the data (step 906 ). Otherwise, the system throws an exception (step 908 ).
De-Allocating an Object
FIG. 10 presents a flowchart illustrating the process of de-allocating an object in accordance with an embodiment of the present invention. The system starts by setting the allocated/free flag to free in the object's header (step 1002 ). Next, the system determines if the version number is less than a maximum allowed version number (step 1004 ). If not, the system places the object on a free list of objects (step 1006 ). Otherwise, the system marks the object as unusable (step 1008 ). Note that this can be accomplished in any number of ways—for example, by setting the version number to a specific reserved value. Note also that object marked as unusable can be reclaimed during a garbage collection as described below in conjunction with FIG. 11 .
Garbage Collection
FIG. 11 presents a flowchart illustrating the process of performing garbage collection in accordance with an embodiment of the present invention. Note that the garbage collection operation can be performed by any available technique, one of which is described herein. A practitioner with ordinary skill in the art can readily adapt this invention to other garbage collectors. The system starts by reversing the meaning of the new/old flag (step 1102 ). Since all of the objects were marked as new, by reversing the meaning of the new/old flag, all objects become old. Next, the system sets the stale flag in each pointer in the root set (step 1104 ).
The system then examines a pointer as part of any object read or write operation (step 1106 ). Next, the system reads the object associated with the pointer (step 1108 ). After reading the object, the system compares the state and version of the object with the state and version of the pointer (step 1110 ). This comparison involves masking the header so that only the allocated/free flag, the old/new flag, and the version number are present. It also involves arithmetically shifting the stale flag, the new/old flag, and the version number to the right most position in the pointer. Note that using an arithmetic shift ensures that no stale pointer will match.
If there is no match (step 1112 ), the system copies the object, resets the stale flag, and sets the new/old flag to new (step 1114 ). Note that the only way for a match to occur is for the pointer to be not stale, the object to be allocated, and the version number to match. After copying the object at step 1114 or if there is a match at step 1112 , the system determines if all pointers have been visited (step 1116 ). If not, the process returns to step 1106 to select another pointer. Otherwise, the process is terminated.
Garbage Collection Techniques
The following garbage collection techniques are based on existing techniques for mark-and-sweep, copying-compacting, and Appel-Ellis-Li-like garbage collectors. Modifications necessary to support versioned pointers are underlined.
Common Code
The following examples provide pointer operations that are common to several garbage collection implementations. Note that other bit assignments may be more efficient for specific garbage collections implementations.
Return true if and only if a pointer is obsolete with respect to the object it references.
obsolete(P:pointer):pointer
version(P) !=header version(*P)∥freed(P)
Construct a version-tagged pointer from an address and tag value.
tagged pointer(A:address, T:tag):pointer=A+(T<<52)
Extract the version number (bits 52 - 63 ) from a pointer.
version(P:pointer):tag=P>>>52
Extract the version number (bits 0 - 11 ) from an object header word.
header version(W:word):tag=return P&)0xfff)
Extract the freed bit ( 12 ) from an object header word
freed(W:word):Boolean=(P>>12)&1
Allocate memory from the free list for a particular size.
allocate(size:integer):pointer
transactionally
I = frelists[size]
if I empty then refill I
remove o from I
set freed(o) = false
return 0
end
Free a previously allocated object and return it to the appropriate free list.
free(P:pointer) =
transactionally
O = Ps object
size = size of O
v = version(P)
if v < MAXIMUM VERSION then
if not obsolete(P) then
version(O) = version(O) + 1
freed(O) = true
put O on freelists[size]
else report error
else set freed(o) = true
end
Write barrier for all three collectors (new with versioned pointers). Translation of P.f=X.
write barrier(P:pointer) =
transactionally
A = addrbits(P)
To = otagbits(*A)
Tp = ptagbits(P)
if To != Tp then
if version(To) != version(Tp) then throw error
if freed(To) != freed(Tp) then throw error
*(A+f) = X
return
Read barrier for mark-sweep and copying-compacting. Translation of X=P.f.
read barrier(P:pointer):data = transactionally A = addrbits(P) X = *(A+f) To = otagbits(*A) Tp = ptagbits(P) if To != Tp then if version(To) != version(Tp) then throw error if freed(To) != freed(Tp) then throw error return X
Concurrent Collector Operations
Extract tag bits from an object header.
otagbits(W:word)=W&0x3fff
Extract tag bits from a pointer.
ptagbits(W>>>52)+(W>>(51-13) & 0x2000)
Extract the age bit ( 13 ) from an object header word or a tag.
age(W:word or tag):Boolean=(W>>13) & 1
Extract the age bit ( 51 ) from a pointer.
age(P:pointer):Boolean=W>>51) & 1
Invert an age.
flip(b:Boolean)=b XOR 1
Copying Collector Operations
Has the object been forwarded?
forwarded(W:word):Boolean=(W>>14) & 1
The address to which the object was forwarded (assume 8-byte alignment).
forward(W:word):Address=(W>>>12) & 0xffffFFFFffffFFF8
Mark-and Sweep garbage collection with versioned pointers.
mark_sweep_gc( ) =
bag = new Bag
//process registers
foreach register R
R = process_ms(R, bag)
//process every pointer in bag
while bag not empty
take P from bag
foreach pointer index I of Ps object
P[i] = process_ms(P[i], bag)
//sweep
foreach object(o) in heap
version(o) = 0
if visited(o) then reset viited(o)
else
set freed(o) = true
put o on freelists[size(o)]
end
process_ms(P:pointer, bag:Bag):pointer =
if obsolete(P) then return error pointer
else if not visited(P) then
set visited in Ps objects header
put P in bag
return tagged pointer(address(P), o)
Copying-compacting collection with versioned pointers.
scanned:address
unscanned:address
copy_compact_gc( ) =
scanned = unscanned = address of new memory
foreach register R
R = process_cc(R)
while scanned < unscanned do
P = scanned
O = object at P
scanned = scanned + size(O)
foreach pointer index I of O
P[i] = process_cc(P[i])
end
process_cc(P:pointer):pointer =
if obsolete(P) then return error pointer
else if forwarded(P) then
return tagged pointer(forward(*P), 0)
else
O = object at P
size = size(P)
F = unscanned
unscanned = unscanned + size
copy O form P to F
set version of copied object at F to 0
set forward(*P) to F
return tagged pointer(F, 0)
end
Appel-Ellis-Li-style concurrent collection with versioned pointers.
scanned, unscanned:address
ael_integrated_gc( ) =
scanned = unscanned = address of new memory
foreach register R
R = process_ael(R) //old pointer become new
end
process_ael(P:pointer):pointer =
if obsolete(P) then return error pointer
else if forwarded(*P) then
return age_tagged_pointer(forward(*P),
0, flip(age(P)))
else
O = object at P
size − size(O)
F = unscanned
unscanned = unscanned + size
copy O from P to F
set version of copied object at F to 0
set age of copied object at F to age(P)//old age
set forward(*P) to F
return age_tagged_pointer(F, 0, flip(age(P)))
end
Translation of X=P.f.
read_barrier(P:pointer):data =
transactionally
A = addrbits(P)
X = *(A + f)
To = otagbits(*A)
Tp = ptagbits(P)
if To != Tp then
if version(To) != version(Tp) then throw error
if freed(To) != freed(Tp) then throw error
if age(To) != age(Tp) then promote_object(A, Tp)
return X
promote_object(A:address, T:tag) =
foreach pointer index I of object at A do
A[i] = process_ael(A[i])
set age of object at A to age(Tp)
The foregoing descriptions of embodiments of the present invention have been presented for purposes of illustration and description only. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Additionally, the above disclosure is not intended to limit the present invention. The scope of the present invention is defined by the appended claims. | One embodiment of the present invention provides a system that uses versioned pointers to facilitate reusing memory without having to reclaim the objects solely through garbage collection. The system operates by first receiving a request to allocate an object. Next, the system obtains the object from a pool of free objects, and sets an allocated/free flag in the object to indicate that the object is allocated. The system also increments a version number in the object, and also encodes the version number into a pointer for the object. The system then returns the pointer, which includes the encoded version number. In this way, subsequent accesses to the object through the pointer can compare the version number encoded in the pointer with the version number in the object to determine whether the object has been reused since the pointer was generated. | 6 |
TECHNICAL FIELD
[0001] The present application relates to casing centralizers, and more specifically to a casing centralizer with improved material properties that is formed by compression molding a bulk molding compound.
BACKGROUND OF THE INVENTION
[0002] Non-metallic casing centralizers for use in casing oil and gas wells are known in the art, but suffer from material deficiencies that render them unacceptable for the downhole environment where they are used. The material properties required for such applications are not defined.
SUMMARY OF THE INVENTION
[0003] A casing centralizer is provided that includes a cylindrical base and a plurality of blades extending from the cylindrical base, wherein the plurality of blades and the cylindrical base are compression molded as a single piece from a mineral filled, glass and specialty fiber reinforced polyester molding compound, such as ST-20250 (Bulk Molding Compounds, Inc., West Chicago, Ill.).
[0004] Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0005] Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which:
[0006] FIG. 1 is a diagram of a casing centralizer in accordance with an exemplary embodiment of the present disclosure; and
[0007] FIG. 2 is a diagram of a casing centralizer with curved blades in accordance with an exemplary embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0008] In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures might not be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness.
[0009] FIG. 1 is a diagram of a casing centralizer 100 in accordance with an exemplary embodiment of the present disclosure. Casing centralizer 100 includes a cylindrical base 102 that fits around the well casing that is to be centralized within a bore hole, and has five straight blades 104 A through 104 E (of which four are shown) that are used to centralize the well casing in the bore hole with the casing centralizer. Each blade has a curved slope 106 from the base 102 to the top of the blade as opposed to a step, in order to avoid creating any surfaces that can get caught on discontinuities in the bore hole. Each blade also includes a flat portion 108 along the top of the blade, where flat portion 108 is in contact with the bore hole as the section of casing on which casing centralizer 100 is deployed is moved down the bore hole. Likewise, a multiple part base, a base that has a non-uniform cross-section, a greater or lesser number of blades, blades having a different shape or other suitable configurations can be used for the base or blades.
[0010] Casing centralizer 100 is compression molded using a bulk molding compound, unlike prior art non-metallic centralizers that are injection molded or extruded. Compression molding using a bulk molding compound allows casing centralizer 100 to have superior material properties for use within the harsh environment that casing centralizers are exposed to in oil and gas wells. In one exemplary embodiment, the bulk molding compound can be a mineral filled, glass and specialty fiber reinforced polyester molding compound suitable for compression and stuffer injection molding.
[0011] Typical properties for the molding operation can include a temperature of 270 to 370° F., with mold shrinkage of 0.001 to 0.004 mil/in, and a molded specific gravity of 1.65 to 1.95. The mechanical/physical properties of the bulk molding compound that make centralizer 100 suitable for use in oil and gas wells include a flexural strength of 18,000 to 28,000 psi, a flexural modulus of 1.4 to 2.2*10 6 psi, a tensile strength of 5,000 to 12,000 psi, a compressive strength of 18,000 to 28,000 psi, an impact strength, notched Izod, of 6 to 14 ft-lb/in and a shear strength of 2,800 to 6,800 psi. The electrical properties include an arc resistance of greater than 180 seconds, a comparative tracking index of greater than 600 volts, and a short time dielectric strength of 325 to 425 volts/mil. The thermal properties include a heat deflection temperature at 264 psi of greater than 450° F.
[0012] In one exemplary embodiment, the unsaturated polyester bulk molding compound can be formed by combining 31% resin system with 37.5% filler System and 31.5% chopped strand reinforcement. The molding process can include using a 400 ton press for compression molding, with temperatures of 300 to 330° F. and less than 10 minutes for the cure cycle. In another exemplary embodiment, the unsaturated polyester bulk molding compound can comprise a suitable combination of the following: <17% styrene; (10% vinyl toluene; <20% unsaturated polyester; <2% zinc stearate; <2% divinyl benzene; <70% calcium carbonate; <70% alumina trihydrate; <29% kaolin; <2% calcium stearate; <65% calcium metasilicate; <35% fibrous glass; <2% zinc sulfide; <2% iron oxide black; <3% carbon black; <4% titanium dioxide; <4% polyethylene; <3% talc and <5% . polystyrene. In another exemplary embodiment, casing centralizer 100 can be made from ST-20250, available from Bulk Molding Compounds, Inc., 1600 Powis Court, West Chicago, Ill. 60185.
[0013] FIG. 2 is a diagram of a casing centralizer 200 with curved blades in accordance with an exemplary embodiment of the present disclosure. Casing centralizer 200 includes cylindrical base 202 and five curved blades 204 A through 204 E (of which three are shown). Each blade also includes a curved transition 206 from the base 202 to the top of the blade, and a flat segment 208 that will be in contact with the bore hole as the casing section with casing centralizer 200 is move down the bore hole. Casing centralizer 200 can be made from the same material as casing centralizer 100 or other suitable materials.
[0014] It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims. | A casing centralizer comprising a cylindrical base and a plurality of blades extending from the cylindrical base, wherein the plurality of blades and the cylindrical base are compression molded as a single piece from a mineral filled, glass and specialty fiber reinforced polyester molding compound. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to the field of waste disposal and, more specifically, to an apparatus (comprising a frame and a bag) and to a preferred bag for packaging waste for disposal.
Under the so-called "pooper scooper" laws, those responsible for a dog (usually, the owner) must promptly remove any solid or semi-solid waste material left by the dog on sidewalks, etc. Thus, a person wishing to obey such a law has the problems of removing the offending material and then of its disposal.
There have been various attempts to deal with those problems. For example, those who can reason with their dogs often ask the dogs to consider using a circumscribed area on the ground upon which a substrate such as newspaper has been placed. If there are no mishaps, the newspaper may be folded to wrap the waste and the entire package thereafter disposed of. Those who cannot reason with their dogs as to the location but have quick reflexes sometimes attempt to place the substrate/wrapping material into position on the ground before the waste hits the ground.
For those with slower reflexes who still wish to comply with the law, a shovel may be employed to remove the waste material from the ground after the fact. The waste can then be put into a bag or placed on a substrate for wrapping and disposal. Some individuals have been known to place one of their hands inside a bag made of flexible material as if it were a glove, pick up the waste material using the "gloved" hand, and pull the end of the bag off the hand in a manner so as to invert the bag and package the waste material inside the bag for later disposal.
One device that has been used for attempting to scoop up waste after it is on the ground consists of a framework having a rectangular opening at its front end and a bag that is attached to the framework with the opening of the bag congruent with the rectangular front opening of the framework. The framework with the bag attached is placed on the ground with one side of the rectangular opening touching the ground. The device is pushed forward towards the waste material on the ground to scoop up the waste and have it pass through the rectangular opening into the rest of the attached bag. The bag is removed from the framework for disposal.
Each of those methods and devices has drawbacks. One problem with the apparatus just described is that the opening of the bag and the frame become contaminated with waste material. That is because the opening of the bag is at the leading edge of the framework and contacts the waste on the ground during the scooping maneuver. This makes closing the bag and disposal somewhat tricky. Other drawbacks of the various apparatus and methods used are obvious. Shovels become contaminated; the "gloved hand" method is aesthetically unpleasing, not to mention the problems encountered if the "glove" (i.e., bag) breaks at an inopportune moment.
SUMMARY OF THE INVENTION
A new apparatus that avoids the above-noted problems and has numerous other advantages has now been developed. Broadly, the device facilitates the disposal of the waste by packaging it in a rapid and reliable manner and with a minimum of handling and comprises:
(a) a bag having an open end, a periphery, a central portion, an inner surface, and an outer surface; and
(b) a frame having sides and having an inversion point, the frame being at least partially within the bag thereby to support it and having an open area located near the central portion of the bag; the bag being larger than the frame to provide sufficient slack so that after waste is placed on the outer surface of the central portion of the bag, the waste and that portion of the bag nearest the waste are pulled down by gravity at least partially into the open area of the frame and sections of the bag are drawn snug towards the frame, the frame and bag thereafter cooperating so that as a portion of the open end of the bag is moved towards the inversion point to remove the bag from the frame, the portion of the bag lying near the inversion point becomes inverted and further movement of the end of the bag in a direction to remove the bag from the frame results in inverting the rest of the bag, thereby placing the outer surface of the bag on the inside and packaging the waste inside the bag.
In other aspects of the invention, the frame comprises at least two members (and preferably three in the approximate shape of a triangle), and/or the bag carries closure or locking means so that it may be tied shut after the waste material is inside, and/or a plurality of bags may be stacked or nested one inside the other on the frame, and/or a handle portion is attached to the frame and the handle has grippers or other securing means for preventing the bag or bags from sliding off or otherwise being removed from the frame until such removal is required. Sticks or other disposable members may be carried within the handle and the sticks employed to help position the waste material on the device.
Another aspect of the invention concerns a preferred bag having integral flaps for tying the bag closed. The two major faces of the bag are attached directly or indirectly (i.e., through an intervening edge panel) to each other at their corresponding edges.
The frame itself need not be rigid and may be comprised of pieces that can rotate with respect to one another. Accordingly, in one embodiment the frame is collapsible and may be collapsed and retracted into or around or about the handle of the device to provide a small readily portable device. In another embodiment, the frame members may be rotated with respect to one another to form a "V" shape to provide an inversion point at what becomes the lowest vertical point of the "V" frame rather than at the lateral sides of the flat (unrotated) frame.
Devices of this invention may be used to efficiently and effectively scoop waste material off a variety of substrates (for example, concrete, carpeting, sand, grass, snow, leaves) or the device may be used to catch the waste in mid-air, before it hits the ground. The frame of the device remains clean because it is covered by the bag, and the open end of the bag is not contaminated with waste either during the scooping procedure or later. The leading edge of the bag, which does become contaminated during the scooping procedure, is placed inside by the inversion procedure. Thus, what becomes the outer surface of the bag after packaging is complete and the open end of the bag remain free of waste. Other advantages, aspects, and embodiments of the invention will be described below.
BRIEF DESCRIPTION OF THE DRAWINGS
To facilitate further description of the invention, the following drawings are provided in which:
FIG. 1 is a perspective view of the device being held in a position to scoop up waste material on the ground;
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a side elevational view of the device of FIG. 1 before waste material is on the device;
FIG. 4 is a detail view of FIG. 3 after the waste material has been placed on the device;
FIG. 5 is a perspective view showing the first stage in removing the bag from the frame of the device of FIG. 4 to package the waste material;
FIG. 6 is a perspective view of the device showing a further stage in the removal of the bag from the device;
FIG. 7 is a cross-sectional view of the device of FIG. 6 taken along line 7--7 of FIG. 6;
FIG. 8 is a perspective view showing a later stage in the removal of the bag from the frame of the device;
FIGS. 9 and 10 are detail views showing subsequent steps in the removal of the bag from the frame;
FIG. 11 shows the waste material in the bag after the bag has been completely inverted and is no longer supported by the frame;
FIG. 12 is a view showing the two integral strips on the bag tied together to securely close the bag;
FIG. 13 is a plan view of the preferred bag of the invention;
FIG. 14 is a plan schematic view of the preferred frame and handle of the invention;
FIG. 15 is a perspective view of another embodiment of the invention in which the two frame members are rotatably connected to one another;
FIG. 16 is a view of the device of FIG. 15 after the two frame members have been rotated up towards one another;
FIG. 17 is a view of a third embodiment of the device in which the frame members are rotatably connected to one another to permit the frame to be collapsed for storage and portability;
FIG. 18 is a view of the device of FIG. 17 showing the frame being collapsed for storage within the handle of the device; and
FIG. 19 is a view of the device of FIGS. 17 and 18 in which the frame has been collapsed and is being retracted into the handle of the device.
These drawings are provided for illustrative purposes only and should not be construed to limit the scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, handle 40 of device 20 is being held in left hand 22. The device comprises frame 24 and bag 26 having periphery 28 and two integral flaps 38 at open end 168 (or rear extent) of the bag. Frame 24 comprises side 32, side 34, and side 36, which is located at the leading or front edge of the device. The three sides lie substantially in the same plane and in substantially the shape of a triangle. Optional securing means 44 prevents bag 26 from sliding down and off the frame while the device is downwardly disposed towards waste 30, which is on the ground. The device need not have securing means 44. In that case, left hand 22 could hold the rear portion of the bag against handle 40 to prevent the bag from sliding off the frame. Central portion 42 of bag 26 is located in gap (or space or void) 84 between frame members (or sides) 32, 34, and 36.
In the cross-sectional view of FIG. 2, central portion 42 of bag 26 lies below the plane of frame members 32 and 34. Bag 26 has two major faces, upper face 50 and lower face 52, each of which has an inner surface 54 and an outer surface 56. Bag 26 may be thought of as having one continuous inner surface (or inside) 54 and one continuous outer surface (or outside) 56. Pressure pad 64, which is attached to front end 72 of securing means 44 (as more clearly shown in FIG. 3), temporarily secures bag 26 in place. The pad may be of any material that provides the required friction, such as rubber or flexible foam.
In FIG. 3, the device has been positioned with its leading edge on ground 74 so that it can be moved in the direction indicated by arrow 70 to scoop up waste material 30, which is also on the ground. Handle 40 has front end 46 and rear end 48. The frame is attached to the front end of the handle, and cylindrical cavity 66 terminates at rear end 48. Elongate sticks 68 (for example, ice cream sticks or tongue depressors) are stored within cavity 66. A stick 68 may be removed from cavity 66 and used to help push and position waste 30 on central portion 42 of the bag (see FIGS. 1 and 2).
Each of the two securing means 44 is rotatably connected to the handle, here by a pivot pin 62 in ears 60. The two securing means 44 are biased (spring biasing means not shown) so that pressure pads 64 connected to front ends 72 frictionally retain reinforced areas 88 of bag 26 against the outer portion of front end 46 of handle 40. (Reinforced areas 88 on bag 26 are better seen in FIG. 13.)
In FIG. 4, waste 30 is positioned adjacent central portion 42, both of which have been pulled down by gravity so that much of waste material 30 lies below the plane defined by the frame members. Arrow 78 indicates the direction of travel of the front end of the device for subsequent use.
As best seen by comparing FIGS. 1 and 2 with FIGS. 4 and 5, before waste 30 is positioned on central portion 42 of bag 26, the bag fits somewhat loosely on the frame because the bag is larger than the frame, that is, there is some slack. In FIG. 2 periphery 28 is seen to extend beyond frame members 32 and 34. In contrast, in FIGS. 4 and 5, the weight of waste 30 has pulled central portion 42 of the bag downward so as to take up the slack by pulling various portions of periphery 28 of the bag against the frame. For example, a portion of the front or leading edge of the bag has been drawn snug against a corresponding portion of leading side 36 of the frame and sections of the periphery of the bag have been drawn snug against corners (or shoulders) 80, which are located at the approximate places where lateral side members 32 and 34 meet front side member 36. In FIG. 5, left hand 22 is holding the device and right hand 76 is commencing the bag-removal and wrapping (or packaging) procedure.
During the removal procedure, the bag is inverted so that the outside of the bag becomes the inside and the waste material thereby becomes packaged inside the bag. Inversion of the bag may be facilitated by the frame increasing in transverse size from the rear of the frame to the front. For example, the device of FIG. 5 increases in lateral width from near handle 40 to a maximum at the imaginary line connecting the two corners 80. Inversion is also made possible in the embodiments shown by the periphery of the bag or at least certain sections of the periphery of the bag being pulled or drawn snug towards the inversion point and at least one other point on the frame. Usually, the weight of the waste material will pull the central portion of the bag down sufficiently to take up the slack in the bag provided the bag is sufficiently flexible and is not too big.
In FIG. 5, right hand 76 is grasping a portion of the open end of the bag towards the rear of the device. Right hand 76 then moves in a direction towards the front side 36 of the frame. The bag is usually manipulated at or near the beginning of this procedure to partially invert the small section of the opening of the bag between the thumb and forefinger of hand 76. That part of the bag is then drawn forward (i.e., towards front side 36 of the frame). Whether or not such preliminary inversion is carried out, at some point along the frame at or before corner 80, the bag will not be able to slide off the frame (because the bag lies so tightly against the frame) and the outer surface of the bag immediately adjacent to that point will be forced to fold over on itself as the open end of the bag continues to be pulled forward. Alternatively, gripping means (for example, adhesive) may be placed on a small section of the side portion of the frame to prevent the bag from sliding off the frame and thereby to cause inversion to occur at that point as the opening of the bag is being pulled forward. In that case, the lateral sides of the frame need not be diverging and may be parallel or converging.
In FIG. 6, arrow 82 indicates the direction in which the end of bag 26 is pulled to continue the removal procedure. Left hand 22 is holding the device by handle 40 and at the same time it is pushing release mechanism handles 58 towards main handle 40 to move pressure pads 64 away from the bag, thereby to release the bag and allow the inversion and removal procedure to continue. In many cases it will not be necessary to push release handles 58 because the act of pulling inverted portion 170 of the bag forward will pull the temporarily secured portions of the bag out from under pressure pads 64.
At some point during the inversion/removal procedure, the part of the opening of the bag lying at the bottom of the bag-frame combination must pass below the lowest point of central portion 42. If that does not occur, the edge of the already inverted portion of the opening of the bag will not clear the waste material and central portion of he bag that are located below the plane of the frame, and the inversion and removal procedure will not be able to continue. Thus, FIG. 7 shows a section of inverted portion 170 of the bag positioned below the bottom most part of central portion 42 and waste material 30 to enable the opening of the bag to clear (pass below) them at their lowest point. The top section of inverted portion 170 must pass above waste 30, and FIG. 7 shows this too. Finally, FIG. 7 shows that the weight of waste material 30 on central portion 42 has drawn part of periphery 28 of the bag against frame sides 32 and 34.
In FIG. 8 the bag has cleared corner 80 between frame members 34 and 36 and the inversion process is essentially complete: outer surface 56 is now the inside of the bag in contact with waste material 30. Void (or space or gap) 84 between the three frame members is no longer completely covered by the bag. The full completion of the inversion/removal procedure is then accomplished as leading edge 168 of the inverting bag clears the remaining shoulder between frame members 32 and 36. This occurs with continued travel along the direction of arrow 166.
FIGS. 9 and 10 show further stages of removing the bag from the frame. Arrow 86 indicates the direction of travel of the bag to complete removal.
FIG. 11 shows the completely inverted bag containing the waste material situated freely within void 84 of the frame at the conclusion of the removal/inversion procedure. Inner edge 164 of integral flaps 38 define U-shaped cutout 90. Two reinforced areas 88 (only one of which is shown) are located at the bottom of the U-shaped cutout. It is those two portions of the bag that securing means 44 contacts to temporarily secure the bag to the frame. Reinforced areas 88 are optional; any non-reinforced area of the bag may serve as the contact area of the bag for the gripping means.
FIG. 12 shows integral flaps 38 tied together so as to close and secure the opening of the bag to prevent waste material from leaving the bag.
FIG. 13 is a plan view of the preferred bag. The dimensions of the bag will depend principally on the dimensions of the frame: the bag must be larger than the frame so that the bag can fit onto the frame but should not be so large that too much slack is provided. FIG. 14 is a schematic diagram of a preferred frame and handle of the invention in which the frame is generally triangular in shape. Various combinations of bag and frame shapes and sizes may be used. For the shapes shown in FIGS. 13 and 14, three preferred size combinations are shown below.
______________________________________Dimension Approximate Size In InchesLine Set I Set II Set III______________________________________A 20 16 12B 12.5 10.5 8.5C 12.5 10.5 8.5D 10.5 8.5 5.5E 8.25 6.5 5F 10.5 8.5 6.5G 9.5 7.5 5.5______________________________________
The bag may be made of any material that has the required physical properties. Important physical properties include abrasion resistance, drapability, deformability, resilience, and strength. Preferred bags are of thin (about 0.5-2.5 mils in thickness) plastic film. Any size and shape bag and any bag material may be used so long as the bag in combination with the frame and rest of the device is capable of performing the desired function. Shapes and features other than that shown in FIG. 13 may be used, for example, the bag may be square or rectangular or have no U-shaped cutout or have no reinforced areas.
Similarly, the frame and handle may be made of any materials that have the required properties such as strength and resilience. Usually, the frame and handle will be made of metal and/or plastic. The particular size and shape of the frame are not important so long as the frame can interact with the bag to perform the desired function. Thus, the frame will generally have one or more frame members that provide a point along the frame at which inversion of the bag can take place (usually because of the bag being pulled taut in a transverse direction by a transverse frame size that increases towards the front of the device). Desirably, the frame will have a leading side to facilitate scooping up waste material that is on the ground and the leading member will be thin and not easily bent or deformed. The leading side may be straight or concave in, concave out (as shown in FIG. 14) being preferred. The bag must be sufficiently abrasion resistant so that the integrity of the bag is not compromised by the bag's being pushed along the ground (see FIGS. 3 and 4).
The location of the inversion point for a given bag/frame combination will vary depending on what means are used to retard the forward motion of the bag and hinder its sliding on the frame, e.g., adhesive on a lateral side of the frame, the bag's being pulled taut against the frame by the weight of the waste, etc. If the bag is pulled taut by the frame (as in the embodiments of FIGS. 1-19), the location of the inversion point will depend on the sizes of the bag and the frame, the physical characteristics of the bag employed (for example, the resistance of the bag to stretching, its tensile strength, and its flexibility and resilience), and on how tightly the bag's periphery is pulled against the frame and where. The increase in the lateral size of the frame of FIG. 14 towards the front of the frame and use of a bag not too much larger than the frame insures that inversion will occur at or before corner 80. If the bag is too large, inversion will not occur, regardless of the weight of waste material 30.
Two or more bags may be nested within one another and the frame placed within the innermost bag of the nested stack. In that case, the user would employ only the outermost bag, thereby leaving the rest of the stack of bags on the frame for subsequent use.
Other shapes may be employed for the frame. For example, the frame may be a polygon of more than three sides or the frame may be circular. The particular shape is not important so long as the device is able to perform the desired function. A frame with parallel or even converging sides may be used if adhesive or other such means is located on one section of a side for causing the inversion.
The frame need not lie in only one plane. For example, the front or leading edge of the frame and the forward sections of the two side frame members of the device of FIG. 1 may be bent upwards. Even if the frame members lie in a single plane at the start of the scooping and disposal operation, the frame need not remain in that one plane. For example, FIGS. 15 and 16 illustrate frame members that can rotate with respect to one another. The frame comprises side pieces 92 and 96, front piece 94 (which itself is comprised of segments 94a and 94b) and pivot 100. Corners 98 are located between the side pieces and the front pieces. Side pieces 92 and 96 are connected to straight portions 102 and 104, which are rotatably mounted in block 132. Extensions 102 and 104 terminate in bent portions 106 and 108, which prevent the frame from being pulled out of block 132.
FIG. 16 shows the two halves of the frame rotated up out of the plane they define when they are in their normal (or down) position. In FIG. 16, corners 98 have been rotated up out of the plane and towards one another.
To use this device, waste material is again positioned on the central portion of the bag (not shown), which is within gap (or void) 84 between the frame members. The two frame members are then rotated u into the position shown in FIG. 16 either manually or by spring-loaded or other means (not shown). At this point, most or all of the waste material hangs down below the two corners 98. To remove and invert the bag of this device, the bottom portion of the bag near its opening, which is pointed towards the rear of the handle, is grasped and pulled forward. That portion of the bag must be low enough to clear the bottom of the waste material and the central portion of the bag adjacent to it at their lowest point while they are hanging from the frame. Pivot point 100, which as shown in FIG. 16 is a low point for the frame, may help invert the bag. However, inversion may start before the lower open end of the bag is brought forward enough to meet pivot point 100. The top of the open end of the bag must also pass over the high points of the frame, corners 98 in FIG. 16.
FIGS. 17, 18, and 19 illustrate another embodiment of the invention, namely, a collapsible device. This device may be used in the same manner as the devices previously described except that it has the advantage that the frame can be collapsed. All of the frame or a substantial portion of it can be stored inside or around or about the handle so that the device may be carried in, for example, a pocket or pocketbook.
The frame comprises side piece 110, front piece 112 (which comprises portions 112a and 112b), side piece 114, corners 116, straight extension portions 124 and 126 (which are slidably mounted within block 134), and bent portions 128 and 130 (which prevent the frame from being pulled forward out of slidable block 136). The frame pieces are rotatably connected to one another at pivot points 120, 118, and 158. Extension or tab 122 on frame member 112b prevents sections 112a and 112b from rotating with respect to one another to move pivot point 120 forward beyond its forwardmost location shown in FIG. 17. Sliding block 136 is slidably mounted in path 138 of handle 40. Block 136 is biased towards the rear of the handle by spring 140, which is attached at its forward end to block 136 and at its rear end to fixed point 142.
Release mechanism 144 is rotatably mounted to handle 40 on ears 150. The forward end of release mechanism 144 carries pin 146, which passes through the outer surface of handle 40 into hole 148 located at the top of sliding block 136. As long as pin 146 lies within hole 148, block 136 is prevented from moving back under the force of spring 140. When trigger 152 of release 144 is pushed down in the direction shown by arrow 160, pin 146 is withdrawn from hole 148 and spring 140 pulls block 136 back in the direction shown by arrow 162. Prior to depressing trigger 152, pivot 120 is moved towards the rear of the device in the direction shown by arrow 154. That in turn causes rotation of the frame members with respect to one another and movement of side pieces 110 and 114 towards one another in the directions shown by arrows 156. When trigger 152 is depressed, the collapsed frame will be drawn into the front hollow storage section of handle 40. (A similar type of spring-powered mechanism may be used to rotate the two frame halves of the device of FIG. 15 when a trigger is depressed.)
To use this device, the front end of the collapsed frame is pulled forward and pivot 120 is moved to its forwardmost position (FIG. 17). A spring (not shown) biases trigger 152 up, thereby pushing pin 146 down into hole 148 when the hole is brought into registration with the pin. That prevents the frame from collapsing and being moved inward by spring 140. A bag may be stored in a rear hollow section of handle 40. Regardless of where the bag is stored, it is placed on the frame and the device is used in the same manner the device of FIG. 1 is used. After disposal of the waste, the device may be collapsed and stored again in a pocket or pocketbook.
The collapsible frame and bag may have any shapes and be of any materials that allow them to perform the desired function. The frame may be circular, oval, rectangular, etc. so long as it can be collapsed or folded into or around or about the handle. Means may be present to push out or unfold or erect the collapsed frame. For example, spring-biased means similar to those in FIGS. 17-19 may be used to push the collapsed frame out of the handle when a trigger is depressed. Other means dissimilar to those of FIGS. 17-19 may also be used. The frame need not fold only but could also have telescoping members.
Other variations and modifications may be made in this and all other embodiments shown herein, and the claims are intended to cover all variations and modifications that fall within the true spirit and scope of the invention. | Apparatus (including a frame and a bag), a preferred bag, and a method for packaging waste for disposal are disclosed. The frame fits into the bag at the open end of the bag. The frame has a central open area, and when waste material is placed on the outside of the bag corresponding to the open area of the frame, the waste material and the adjacent portion of the bag are pulled by gravity down through the open area of the frame. That pulls the bag tightly around the frame, which in turn facilitates the inversion of the bag as the bag is removed from the frame. Inversion of the bag results in the waste being trapped inside the bag, which may then be securely closed for disposal of the waste. The sizes and shapes of the frame and bag are not critical. The device finds particular use as a so-called "pooper scooper" for dogs. | 4 |
This is a division of application Ser. No. 625,586, filed Oct. 24, 1974, now U.S. Pat. No. 4,032,775, issued June 28, 1977, which is a divisional of application Ser. No. 496,879, filed Aug. 12, 1974, now U.S. Pat. No. 3,936,671.
BACKGROUND OF THE INVENTION
In the horizontal run-through utility and service system illustrated and described in Bobrick U.S. Pat. No. 3,354,301, elongated lighting fixtures are shown as positioned on either side of a central curtain track, to provide illumination on either side of a central curtain to permit the division of a room into two private areas with identical overhead lighting. No provision is suggested in the Bobrick arrangement for a travelling reading and examination light.
One of the objects of this invention is to provide, in a horizontal run-through type system, low-profile lighting fixtures with improved means for providing low brightness down lighting and higher brightness side lighting.
Another object is to provide, in a horizontal run-through system, either one or a pair of lengthwise travelling reading-examination light-carrying booms mounted at their upper ends for rotation and adapted to be self-supporting within a wide arc.
Still another object is to provide such a system in which an improved reading-examination lamp is mounted on the outer end of the telescoping boom, and so constructed as to permit two levels of illumination from a single light source.
Other objects will become apparent to those skilled in the art in the light of the following description and accompanying drawings.
BRIEF SUMMARY OF THE INVENTION
In accordance with this invention, generally stated, in an illumination system, particularly adapted to use in hospital rooms wherein a central curtain track is flanked by lighting boom-carrying tracks, and two, spaced, elongated fluorescent lighting fixtures are positioned one on either side of the carriage tracks, an elongated enclosure is provided with an open-topped primary enclosure having translucent high brightness light transmitting side and bottom walls and an L-shaped diffusing insert, mounted within the primary enclosure, having low brightness light-transmitting side and bottom walls, the side wall of the diffusing insert extending along the side wall of the primary enclosure next to the lighting boom carriage track. A four-wheeled, elongated carriage is mounted in at least one of the carriage tracks, the carriage carrying a telescoping boom swingably mounted at one end on a boom mount carried by the carriage. The boom mount is mounted for limited rotation and clutch means are provided for holding the boom mount and boom in any desired position within the limits of rotation of the boom.
A yoke, mounted on the outer end of the boom in such a manner as to be self-leveling carries a light head or reading-examination light. The yoke is mounted for rotation and the light head is mounted for rotation within the yoke. Means are provided for making electrical connection between the yoke and light head. The light head is provided with a deeply recessed color-correcting filter, an effective heat sink structure, and an arrangement whereby the power supply to a lamp is automatically disconnected when the light head is disassembled for relamping.
Electrical power supplied to the lamp in the light head by means of a flexible conductor enclosed within the boom, which is electrically connected to a flat tape conductor one end of which is carried by the boom carriage and the other end of which is fixed, the flat tape conductor being so arranged as to provide a positive electrical connection through the full longitudinal travel of the carriage on its track.
DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a fragmentary view in perspective of one embodiment of system of this invention with the fluorescent lighting fixtures removed to show portions of a carriage assembly in exploded condition;
FIG. 2 is a somewhat diagrammatic view in end elevation illustrating the rotation of the lighting boom in one plane;
FIG. 3 is a transverse sectional view showing a carriage track and curtain track arrangement, and one of two fluorescent enclosures;
FIG. 4 is a view in side elevation of one carriage, partly broken away;
FIG. 5 is a view in end elevation of the carriage shown in FIG. 4;
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 5;
FIG. 7 is a sectional view taken along the line 7--7 of FIG. 6;
FIG. 8 is a view partly in end elevation and partly in section taken along the line 8--8 of FIG. 4, the opposite end from that shown in FIG. 5;
FIG. 9 is a sectional view taken along the line 9--9 of FIG. 6;
FIG. 10 is a view in side elevation, partly in longitudinal section and partly broken away of the boom shown in FIGS. 1 and 2;
FIG. 11 is a sectional view taken along the line 11--11 of FIG. 10;
FIG. 12 is an enlarged fragmentary view, partly in section, of a part of the mounting assembly of the end of the boom adjacent the carriage;
FIG. 13 is an enlarged fragmentary detailed view, partly in section, of a slip joint of the telescoping boom;
FIG. 14 is a view in end elevation, partly broken away, of the yoke and reading-examination light assembly at the outer end of the boom;
FIG. 15 is a fragmentary sectional view taken along the line 15--15 of FIG. 14;
FIG. 16 is a sectional view taken along the line 16--16 of FIG. 14;
FIG. 17 is a view in perspective of the inner side of the light head housing closure of the reading-examination light assembly;
FIG. 18 is a bottom plan view of a yoke fitting at the lower end of the boom;
FIG. 19 is a view in side elevation of the inner side of one of two identical parts of a boom fitting at the upper end of the boom;
FIG. 20 is a top plan view in the direction indicated by the line 20--20 of FIG. 19;
FIG. 21 is a view in side elevation of part of the yoke assembly;
FIG. 22 is a view in rear elevation in the direction indicated by the line 22--22 of FIG. 21;
FIG. 23 is a view in side elevation of a yoke swivel boss insert;
FIG. 24 is a view in front elevation in the direction indicated by the line 24--24 of FIG. 23;
FIG. 25 is a view in rear elevation of a closure for the yoke assembly; and
FIG. 26 is a sectional view taken along the line 26--26 of FIG. 25.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIGS. 1 and 3, reference numeral 1 indicates an illumination system of this invention which includes a track and mounting system 2, fluorescent lighting fixtures 3, boom-carrying carriages 4, telescoping booms 5, self-leveling yoke assemblies 6 and reading-examination lights 7. The system illustrated is described as applied to hospital rooms, in which a horizontal run-through core is provided and vertical take-off consoles extend down the wall of each room at the head of beds, sometimes referred to as the reference wall.
The track and mounting system 2 is supported by rails 12, extending transversely of the length of the track and mounting system. In the embodiment shown, the track and mounting system consists of long aluminum extrusions formed to provide wireways 13 which not only serve as housings for electrical conductors for hospital electrical wiring, nurse calls, telephone lines and the like but also serve as means for mounting ceiling panels 16 shown in phantom lines in FIG. 3, sockets 17 for fluorescent lamps, and enclosures 20 for the fluorescent lighting fixtures 3. Medical gas pipelines 14 are mounted on the rails 12, above and parallel to the wireways, as shown in FIG. 3. In this embodiment, the track and mounting system is clamped to the rails by means of levers 18, pivotally mounted on a vertical web of rails 12, and hooks 19, arranged to overcenter with respect to the pivot arm of the levers and to engage channels on the wireways. The tracks are mounted to the wireways in a similar way as shown in FIG. 3. The track and mounting system includes a central curtain track 25, with spaced, oppositely directed feet defining a slot of conventional construction. Flanking the curtain track 25 on either side, is a carriage track 30. Each of the carriage tracks 30 has an inner ledge 31 and an outer ledge 32. The inner ledge 31 has at its outboard edge an upstanding rim 33, which, with an upstanding rim 34 along the free edge of the outer ledge 32 defines a carriage channel 35. Extending along an inner wall 36 at the inner ledge 31 are conductor tabs 37. Vertically aligned but spaced guide rails 40 and 41 are positioned inboard of the rim 33 of the inner ledges 31. An outer guide rail 42, positioned symmetrically with respect to the center line of the carriage channel 35, depends from a top wall above the outer ledge 32.
As seen in FIG. 3, the lighting fixtures 3 are positioned outboard of and on either side of the outer ledges 32. The enclosures 20 are made up of two parts, a primary enclosure 21 and an L-shaped diffusing insert 22. The primary enclosure 21 is preferably made of clear plastic such as acrylic, and has an inside side wall 23, an outside wall 24 and a bottom 26 with smooth, planar inner and outer broad surfaces. In the embodiment shown, the side wall 24 is indicated as being provided with transverse prisms on the outside and longitudinal prisms on the inside. The diffuser 22 has a side wall 27 and a bottom wall 28, both of a translucent, light-diffusing plastic such as pigmented acrylic with a transmission of approximately ten percent. It has been found that the best light control, for providing low brightness down lighting and lighting through the inside side wall is obtained by merely mounting the diffuser 22 loosely within the primary enclosure 21, as indicated in FIG. 3. As shown in that figure, the upper edge of the diffuser side wall 27 may be trapped between the inside side wall of the enclosure and a wireway cover 29.
It will be understood that, depending upon the length of fluorescent tubes, the primary enclosure and diffuser will be in convenient lengths, and can be supported at their ends on straps, preferably inverted T-shaped in cross section, carried by the mounting system.
Referring now particularly to FIGS. 1 and 3 through 9, the carriages 4 in this embodiment include a near or clutch end casting 45 and a far or retard end casting 46. The terms "near" and "far" are used to signify the positions of the ends with respect to the reference wall, both carriages being mounted in tracks with the clutch end nearer the reference wall. The clutch and retard end casting 45 and 46 have upstanding end blocks 47, with vertically spaced and lengthwise aligned holes in them, to receive throughbolts 48. The throughbolts 48, with nuts on their threaded ends, serve to fasten wheel blocks 49 to the outboard faces of the end blocks 47. The wheel blocks 49 carry four carriage supporting wheels 50, which are journaled on axles projecting from opposite sides of the wheel blocks 49, as shown in FIG. 6. The wheel blocks 48 also carry vertical axles 51, upon which guide wheels 52 are revolvably mounted.
The end blocks 47, hence the clutch and retard end castings, are spaced by a spacer body 55, against the ends of which the inboard faces of the end plates 47 are drawn by the throughbolts 48.
The clutch end casting 45 includes a cylindrical end bell 54 with a heavy annular wall 56 extending radially inwardly intermediate the ends of the end bell 54. The inside surface of the end bell 54 at both axial ends is rabbeted.
The retard end casting 46 includes a cylindrical end bell 60, which has a radially inwardly extending annular wall 61, and axial splines 62. The inner wall at both ends of the retard end casting end bell is also rabbeted at both axial ends of the cylindrical end bell. Cover caps 63 and 64 are friction mounted in the rabbeted outer ends of the end bells 54 and 60 respectively.
Carried by and between the facing ends of the end bells 54 and 60 is a boom sleeve or mount 70. In the embodiment shown, the boom mount 70 is a heavy aluminum extrusion. The boom mount 70 is generally cylindrical on its outside, with a rectangular slot 71 extending through its full length. The rectangular slot 71 is bounded along its long sides by heavy chordal sections 75 chamfered at their outer edges and terminating in a ledge 115 on their inside edges, all as best shown in FIG. 7. In the assembled mount, the slot 71 is bounded at its axial ends by heavy sectioned boom stops 72, with which inwardly convergent but spaced cross walls 73 are integral. The stops 72 and cross walls 73 are, in this embodiment, plastic inserts.
The cylindrical boom mount 70 is closed at its ends by boom mount end plates 76 and 77, which in this embodiment are made of steel, mounted on the ends of the boom mount by means of screws extending into tapped holes in the end faces of the heavy chordal sections 75, as indicated in FIG. 9. The plastic inserts which include the stops 72 are fastened by screws to the end plate, as indicated in FIGS. 7 and 9. The end plates 76 and 77 are round in front elevation, as indicated in FIG. 9, and fit rotatably within the channels formed by the rabbeting of the facing ends of the end bells 54 and 60. The end plate 77 has a central opening in which a bushing 78 is mounted, and the bushing in turn is revolvably mounted on the inner end of a hollow stop end shaft 79. The shaft 79 has a stepped inner end on which the bushing 73 is journalled, an annular collar 80 integral with the shaft, and an externally threaded outer end 81. The shaft 79 is mounted in the end bell 60 by means of a nut screwed onto the threaded end 81 against a lock washer which bears against the outer face of the annular wall 61, while the collar 80 bears against the inner face of the wall 61, clamping the shaft firmly in place. A retard-stop disc 90 is mounted on the shaft 79, in close engagement with the inside wall of the end bell 60 between the end plate 77 and the annular wall 61. The retard-stop disc 90 has a pair of grooves 91, as illustrated in FIG. 8, into which the splines 62 extend, to fix the disc 90 against rotation relative to the end bell. The disc 90 has a hub 92, a rim 93 which is axially wider than the hub 92, a web 94 between the hub and the rim, and heavy arcuate spaced ribs 95 and 96. The ribs 95 and 96 define oppositely disposed arcuate passages extending axially entirely through the disc 90. The passages are not uniformly wide radially, being, in the embodiment shown, wider by approximately one thousandths of an inch through about 55° of arc from an end 97 than through approximately 35° of arc from the other end 98. The meeting edges of the two sections are relieved to provide a short inclined transition area.
Rollpins 100 and 101 are fixed in and extend axially from the end plate 77 diametrically opposite one another as shown in FIG. 8. The rollpins 100 and 101 fit snugly in the wider part of the passages defined by the ribs 95 and 96, respectively, but tightly in the narrower part.
The end plate 76 has a square hole in its center, through which a square shaft 82 of a one-way roller clutch 83 extends. The roller clutch 83 is of conventional construction, with spring biased rollers mounted to roll along inclined planes on the periphery of a plate secured to the shaft 82, and engaging the inner surface of a cup 84 secured to a hollow shaft 85 threaded at its outer end to receive a nut.
The retard-stop disc 90 and the one-way roller clutch 83 must be oriented and constructed respectively for use with right and left hand carriages. The rest of the carriage and boom mounting assembly elements are symmetrical with respect to a vertical center plane.
In this embodiment, a clutch disc 86 is mounted on the shaft 85 between the bottom of the cup 84 and the annular inner wall 56, and clutch disc 87 is mounted on the shaft between the opposite radial face of the clutch ring 56 and a clutch plate 88. The clutch plate 88 has a non-circular opening complementary to flats on opposite sides of the shaft 85 extending between the outer end of the shaft 85 and the inner wall 56. The clutch plate 88 is biased against the clutch disc 87, and the radial surface of the cup 84 is biased against the clutch disc 86, which in turn is biased against the inner wall 56 by Belleville washers 89, against which a stopnut 98 is screwed down to the desired degree of tightness.
Referring now to FIGS. 6 through 11, as shown in FIG. 10, passages 74 aligned at right angles to the radial center plane of the slot 71 extend transversely through the heavy chordal sections 75 of the mount 70. The boom 5 is mounted in the boom mount 70 by means of a pintle 105, the ends of which are within the passages 74. A boom mount end fitting 106 is made in two parts, as indicated in FIG. 10. Each of the parts of the boom fitting has a skirt 103 extending all the way around it except for its lengthwise outer ends which are open, the edges of the skirts abutting when the two parts are assembled. The two parts are mirror images, and each has an integral sleeve 107, and a stem 108, with a screw boss 109. Bushings 104, mounted in the sleeve 107 and on the pintle 105, have an annular flange at their outer ends, which engage the periphery of holes in brake discs 110. The brake discs 110 are circular in front elevation, but have a chordal boss 111 at one end, which engages the ledge 115 of the section 75 on either side of the boom mount 70. The fitting 106 has a circular face bounded by a rim 116, in which a clutch washer 112 is seated. The clutch washers 112 have projections on one side which extend into shallow indentations in the circular faces of the fitting. The other face of the clutch discs engages a flat face of the brake discs 110. The pintle 105 has a head at one end, between which and the outer end of one of bushings 104 is a group of spring washers 113. Similarly, the pintle has a nut on the other end, between which and the other end of the bushings 109 is a group of spring washers 113. The bushings, spring washers, head and nut are all of a lesser diameter than the passages 74 in the boom mount. Tightening of the nut on the pintle will provide whatever degree of bias is required to give the desired amount of clamping of the clutch discs 112 between the brake discs 110 and the circular faces of the fitting.
A square seamless hollow upper boom tube section 120 is mounted on the stem 108 of the fitting 106 by means of screws 121 screwed into the screw bosses 109 of the fitting. In the embodiment shown, the boom 5 is made in two telescoping sections. A lower tubular section 125 is dimensioned to slide within the section 120. A plastic sleeve bushing 126 with a lip at its outer end and a projection on its inner side which takes into a hole in the lower tubular section 125 near its upper end and a sleeve bushing 127 with a lip on its outer end and a projection taking into a hole in the upper section 120 near its lower end, serve to make the movement of the inner section 125 and the outer section 120 quiet, and to insulate the two metal tubular sections electrically from one another. A button 128 with a stem projecting into a hole in the wall of the inner section 125 serves as a stop. An arm glide brake 130 in this embodiment consists of an externally and internally threaded nipple 131 screwed into an internally threaded hole near the lower end of the upper section 120 immediately contiguously the outer surface of the sleeve bushing 127. A helical compression spring 132 bears at one end on the outer surface of the sleeve bushing 127, and at the other end on the inner face of a threaded plug 133, as shown in detail in FIG. 13.
At its lower end, the boom 5 carries a yoke fitting 140. The yoke fitting 140 has a square block 141 with a passage 142 through it, and terminates at its lower end in a parallel flat sided ring 143, the block 141 is mounted in the lower end of the boom section 125 by means of screws 134 extending through holes in the side walls of the section 125 and into the block. A yoke hinge 145, made in two mirror image parts, forms a wire housing, hinge knuckle and swivel bearing. Each of the parts of the yoke hinge 145 has a skirt 146, shown in FIGS. 10 and 11, edges of which abut when the yoke hinge is assembled, as shown in FIG. 11. The skirt terminates just short of the ring 143, as shown in FIG. 10. The yoke hinge also includes rotating-bearing circles 147, which project within the compass of the ring 143 as shown in FIG. 11 revolvably to mount the yoke hinge on the ring part of the yoke fitting 140. Pintle bosses 148, concentric with the rotating-bearing circles 147 project inboard from the circles 147, and are provided with a passage extending entirely through the bosses and circles to receive a pintle 149. The pintle 149 has a slotted head at one end and a nut at the other.
Clearance notches 153 interrupt the rotating-bearing circles at two points. The yoke hinge 145 includes a yoke swivel bearing section 150, with a neck 154 and a swivel collar 155 defining a channel. At the lower end of the yoke swivel bearing section, which is circular in bottom plan, the inner surface of the swivel collar is rabbeted to provide a seat 156. Two diametrically disposed fingers 157 are spaced from the bottom of the seat, and project radially inwardly. The fingers 157 serve a double purpose, that of retaining a spring washer 158 in the bottom of the seat, and of locating an insulating disc 159, which is provided with notches in its perimeter to receive the two fingers. The insulating disc 159 carries on its outer face an outer contact ring 160 and a center contact plate, concentric with but spaced from the outer contact ring. The outer contact ring is electrically connected to an outer contact ring lead 162. The center contact plate 161 is electrically connected to a center contact plate lead 163. The two leads 162 and 163 project into the housing defined by the yoke hinge, and are electrically connected to electrical conductors 164 and 165 respectively. The conductors 164 and 165 are wrapped in opposite directions around the pintle bosses 148, which, being part of the yoke hinge, are made of electrically insulative plastic, as is the yoke fitting 140. The conductors 164 and 165 then enter and become part of a helically formed retractile cord 166, shown in FIGS. 6 and 10, wound in such a way as to provide ample allowance for the extension and retraction of the boom sections 120 and 125 with respect to one another. The other end of the cord 166 is brought out through the open inner end of the boom fitting 106, as shown particularly in FIG. 6, through the hollow shaft 79, through a hole in the end bell of the brake end casting 46, to a quick-connect plug 167 to which the conductors 164 and 165 are electrically connected.
A complementary plug fitting 168 is connected to conducting strips 171 and 172 of a flat tape conductor 170, best shown in FIGS. 1 and 3. The conducting strips 171 and 172 are spaced apart and lie beneath broad surfaces of an insulative strip 173, to form the tape conductor 170. One end of the flat tape conductor 170 is mounted in an insulation block 174, from which the plug 168 extends. The insulation block 174 is mounted on a bracket 175 carried by the wheel block on the outer, retard end casting 46, as shown in FIGS. 1, 4 and 6.
The other end of the flat tape conductor 170 is electrically connected to conductors at the wall end of the track and mount system contiguous the head ends of hospital beds as illustrated in FIG. 1 of Bobrick U.S. Pat. No. 3,354,301. Between its ends, the flat tape conductor is looped, as indicated in FIG. 1, the looped conductor being housed in a channel defined in part by the inner ledge 31 of each of the carriage tracks, as shown in FIG. 3. Through a short distance less than half of the total reach of the flat tape conductor 170, the conductor is held flat against an inner wall 36 by the conductor tabs 37. It will be noted that the conducting strips 171 and 172 are spaced inwardly from the top and bottom edges of the insulative strip, as shown in FIG. 3, so that the strip can be notched to traverse conductor tabs 37 at the desired distance.
The flat tape conductor 170 is completely flexible in the dimension shown in FIG. 1, so that the conductor can be flexed in the movement of the carriages 4 indefinitely. It is, of course, necessary that there be sufficient free space in the length of the chamber within which the flat tape conductor runs, to accommodate the tape as it "unrolls" as the carriage is moved away from the fixed, wall end of the tape.
Referring to FIGS. 10-16, at the outer end of the boom 5, the yoke assembly 6 includes a yoke 185 which serves not only pivotally to support a reading-examination light 7 but to carry conductors and connections for electrically connecting the conducting strips of the flat tape 170, hence a source of power, to a lamp inside the housing of the examination light. To that end, the yoke assembly 6 includes a yoke 185, made of electrically insulative material, with hollow arms 187 and 188 and a hollow cross bar 189, all with an open channel in an inside face, as shown in FIGS. 14, 15 and 16. A closure 190, also of electrically insulative material, removably mounted in the channel, serves totally to enclose an interior chamber 191, which serves as a wireway. In this embodiment, the closure 190 is U-shaped complementarily to the yoke 185. Legs of the closure are chamfered along their long edges, the chamfers 193 seating within complementary grooves in the channel defining edges of the arms 187 and 188, as indicated in FIGS. 15 and 26. A cross member of the closure has parallel edges, and fits directly into the channel in the yoke cross bar, as shown in FIG. 16. The closure is held in place by screws, as shown in FIG. 14. The two legs have at their lower ends semi-circular walls, as indicated in FIG. 14, and journals 184, fitting into a cut away portion of the side walls of the arms 187 an 188, as shown in FIG. 14. The legs of the closure are flexible, which facilitates assembly of the yoke and a light head.
On the outer face of the cross bar 189, and integral with it, is a swivel boss 192, which has a planar top surface 194, the plane of which lies at an angle to the lengthwise center line of the arms 187 and 188, as shown in FIGS. 14 and 16. The swivel boss 192 is formed with a cavity defined by outwardly convergent side walls and a bottom wall, to receive a swivel boss insert 195. The swivel boss insert, which is mounted by screws, permits the mounting of the yoke assembly 6 on the yoke fitting 140, but, in effect, merely completes the swivel boss. The swivel boss and insert together have a yoke bearing flange 196 complementary to the neck 154 of the yoke hinge 145, and a channel 197 shaped complementarily to the yoke swivel collar 155. The surfaces defining the inside faces of the yoke bearing flange 196 and channel 197 are perpendicular to the planar surface 194.
A circular opening through the swivel boss 192 and insert 195 is defined by a seat 178 with a step 179. The seat 178 has locating tabs 180 extending radially inwardly a short distance. A disc 181, of electrically insulative material, carries on its outer surface an outer contact ring 182 and a central contact plate 183, which when the yoke is mounted on the yoke swivel bearing section of the yoke hinge 145 correlate exactly with the contact ring and center contact respectively of the disc 159 in the yoke fitting. A spring washer 184, held in place axially by the stop tabs 180, is mounted between the step 179 and the inner side of the disc 181. The disc 181 has notches to receive the stop tabs 180 slidably.
At the outer ends of the yoke arms, the yoke arms have pivot sleeve passages 198 aligned with one another and extending transversely through the outside side wall of the yoke arm. The closure 190 also has a pivot sleeve passage 199 concentric with a part of the journal 184, as shown in FIGS. 14 and 25. An electrically conducting pivot sleeve 209 is journaled for rotation in the passages 198 and 199 of each arm. The pivot sleeve 209 extends through and is fixed in a thickened section of a side wall 204 of a reading-examinaton light head 200. The light head 200 includes a housing 201, with a top wall 202, a bottom wall 203 and side walls 204. A handle 205 is made integral with the light head housing 201 and projects from the bottom wall 203.
The light head housing also includes a radiation shield lip 206 which extends around the inside wall of the housing substantially inboard of the mouth of the housing, as shown in FIG. 16, and louver mounting pads 207 slightly inboard of the radiation shield lip 206, as shown in FIG. 15.
As can be seen in FIG. 16, the walls 202, 203 and 204 diverge in a direction away from the mouth of the housing, so that a rear open end is of greater area than the mouth. The inner surface of the housing at its rear end is rabbeted.
As has been indicated, the pivot sleeves 209 extend through the side walls of the housing. They project a short distance into the interior of the housing, and are provided near their inner end with an annular groove 210. The sleeves 209 project a longer distance outwardly from the housing, to accommodate a spacer 212 of electrically insulative material between the side wall 204 and the inside surface of the yoke arms 187 and 188, and to extend through the yoke arms. A yoke pin 211 of electrically insulative material has a stem 217 which extends through the pivot sleeve 209 into the interior of the housing 201, and a head 216 on its outside end. Spacer 218 is shown as mounted between the underside of the head 216 and the yoke arm 188.
Near its inner end, the stem 217 has an annular snap-ring groove 219 in which a snap-ring 220 is seated. A Heyco bushing 221 is mounted on the stem 217 between the snap-ring 220 and the pivot sleeve 209, as shown in FIG. 15.
A radiation shield 230, rectangular in end elevation, and made of reflective material, has its inner end postitioned between the radiation shield lip 206 and the inner surface of the walls 202, 203 and 204. The inner end of the radiation shield 230 is flared, as shown in FIGS. 15 and 16, and the space between the radiation shield 230 and the inside surface of the housing 201 is filled with thermally insulative material 231, such as glass wool.
A generally rectangular louver 232, with convergently inwardly directed bounding walls is provided with ears 233 corresponding in position to the louver mounting pads 207 on the housing, and the louver 232 is mounted to the pads by means of screws as shown in FIG. 14. The size and shape of the louver 232 is such as to leave a passage all the way around the louver, between the louver and the housing and the louver and the radiation shield 230, interrupted only by the small pads and cars by which the louver is mounted.
Inboard of the louver, and mounted within the confines of the radiation shield 230, is a heat sink 240. The heat sink 240 is a heavy extruded aluminum sleeve, with heat radiating fins 240 projecting outwardly from the outside surface of the heat sink, extending, in parallel ranks, fore and aft of the lamp housing, and spaced to provide passages between them for the free flow of air. The radiation shield 230 is made in two C-shaped parts, long side edges of which overlap. The corners of the parts are formed on a radius except through a length intermediate their ends slightly greater than the length of the heat sink, where the corners are embossed outwardly to provide a debossed inside seat of each corner to receive corner fins of the heat sink. The radiation shield and the heat sink 240 are mounted tightly together by rivets 235 which project through the overlapping edges of the radiation shield 230. The caging of the fins in the seats locates the heat sink accurately and precludes shifting of the heat sink. The arrangement also limits the contact between the heat sink and the radiation shield to line contact.
The radiation shield 230 has an opening in it, in which the Heyco bushing 221 is seated, as shown in FIG. 15. The stem 217 of the yoke pin 215 thus projects into a space between the radiation shield 230 and the wall of the heat sink 240, in a space between successive fins.
Mounted within the heat sink 240 is a reflector 250. The reflector 250 is made of semi-specular material, has an outwardly extending lip 251 with holes in it, and has a lamp receiving opening 252 in a curved rear wall.
A filter 255 is mounted in a U-shaped gasket 257 caged between the lip 251 of the reflector 250 overlying an end face of the heat sink 240 and an L-shaped filter frame 256, which has holes in its corners, aligned with the holes in the lip 251, to receive screws 257, extending into suitable openings in the heat sink 240. The corners of the filter 255 are cut off to permit the screws to clear, and the filter and the filter frame close the end of the heat sink 240.
An electrically conductive spring 213 is mounted in physical and electrical contact with the pivot sleeve 209 in the pivot sleeve groove 210. A short end 214 of the spring 213 bears on the inside surface of the wall 204 on one side of the pivot sleeve 209 and a long end 215 of the spring 213 bears on the inside surface of the wall 204 on the other side of the pivot sleeve near the rear opening of the housing 201. The spring 213 is elongated, and relatively wide as compared with the diameter of the conducting pivot sleeve 209, slopes inwardly of the housing in a direction from its ends toward the groove 210, and is biased tightly into engagement with the inner surface of the wall 204.
Near its outer end, the electrically conducting pivot sleeve 209 is in sliding electrical and mechanical engagement with a double hairpin-type spring contact 223 mounted in the end of the arm of the yoke concentrically with the passages 198 and 199. The hairpin contact 223 is electrically connected to one end of a conductor 224, which extends through the wireway defined by the yoke walls, to one of the contact ring or contact plate in the yoke swivel boss, by way of a lead from the ring or plate.
It will be understood that identical pivot sleeves, yoke pins, electrical contacts and conductors are provided on both sides of the yoke, as indicated in FIGS. 14 and 15.
Near the rear end of the housing 201, passages 258 through the side walls 204 are sized to receive the heads of socket head screws 259. The passages 258 are aligned with the center line of the springs 213, which in turn are parallel to the longitudinal center line of the side walls 204, and perpendicular to the plane defined by the outer edge of the rear end of the housing. Socket head screws 259, of plastic, have a threaded shank, which screws into a hole on the longitudinal center line of a lamp spring contact 260. The lamp spring contacts 260, one on either side, are electrically insulated from one another, and form parts of a lamp and switch assembly carried by a light head housing closure 265.
The light head housing closure 265 includes a stepped peripheral wall 266 which fits snugly within the rabbeted inside wall at the rear of the housing 201, an inverted cup-shaped hub 267, generally rectangular in plan, a spider 268 defining a multiplicity of passages, and an intermediate wall 269, which serves a strengthening, decorative and light-baffling function. On diametrically opposite sides, screw receiving bosses 270 at the junctures of legs of the spider 268 and the intermediate wall 269, receive screws 271, extending through holes in a cross piece 261 of the lamp spring contact 260. Screws 272, extending through holes in the cross piece 261 inboard of the screws 271, are threaded into screw receiving bosses 273 integral with the circumferential wall of the hub 267. The inboard end of the lamp spring contact 260 is bent parallel to the contact leg of the contact spring, to form a lead connecting tab 262. It will be seen from FIG. 15 that the contact leg of the contact spring 260 overlies and is in tight mechanical and electrical contact with the spring 213 at its end 215.
The screw 272, on each side of the hub 267 serves also to mount a stepped socket mounting plate bushing 274 of electrically insulative material, a socket mounting plate 275, through which a reduced shank of the bushing extends and a socket mounting plate insulator 276. The socket mounting plate insulator 276 rests against shoulders 277 provided by support bosses also integral with the circumferential wall of the hub, at the inner open end of the cup-shaped hub 267. The socket mounting plate insulator is made of thermally insulative material. The socket mounting plate is made of metal, and has two internally threaded openings to receive screws 279. The screws 279 mount socket mounting plate bushings 280 and a socket bracket 281, to which a socket 285 is fastened by means of a mounting bar 286 and screws 282. The open end of the socket 285 projects through an opening in the bottom of an open-topped socket box 291, made of specular material, which is mounted on two legs of the scoket bracket 281 as shown in FIG. 16. The specular surface of the box 291 reflects light and heat from the part of a lamp 290 which is not surrounded by the reflector 250.
In the embodiment shown, the socket 285 is adapted to receive a tungsten halogen lamp 290, specifically a 75-watt Sylvania single-ended Q/CL 28 V., but the use of the particular lamp is not a part of this invention. In this embodiment, the voltages supplied to the lamp are approximately 22 and 27 for reading and examination respectively.
As shown in FIG. 16, the lamp 290 projects through the lamp opening 252 and into the reflector 250.
The lamp socket 285 has electrical lead ears 287 projecting from diametrically opposite sides. A conductor 288 electrically connected to the tab 262 of one of the lamp spring contacts 260 is electrically connected directly to one of the lead ears 287 of the socket 285. An electrical conductor 289 connected to the other lead ear 287 extends through an insulating bushing in the socket mounting plate 275 and a hole in the socket mounting plate insulator 276 to a rotary switch 300 mounted in a central opening in the outer wall of the hub 267. Another conductor 292 extends from the switch 300 to the other of the lamp spring contact lead connecting tabs.
Except for a mounting nut 299, an end of a switen barrel 298 on which the nut 299 is threaded, and the electrical conductors 289 and 292, the space within the cup-shaped hub 267 is filled with insulating material such as fiberglass 283.
It will be seen that the lamp 290, its socket 285, switch 300 and the electrical connections necessary to supply current from the spring contacts 213 are all self-contained upon the light head housing closure 265. The light head housing closure 265 is held positively in place by the socket head screws 259, which serve the double function of retaining the light head housing closure positively and of ensuring that the lamp spring contacts 260 are held tightly against the spring contacts 213.
When the socket head screws 259 are removed and the light head housing closure pulled straight away, as for relamping, the withdrawing of the lamp spring contacts 260 with the light head housing closure breaks all electrical contact with the source of current, so that the lamp can be replaced safely. At the same time, the position of the ends 215 of the contact springs 213 well inboard of the rear end of the light head housing, and between the inner wall of the housing and the radiation shield 230 ensures that no one is likely to receive a shock by touching one of the spring 213. As has been described heretofore, insulation 231 fills the space between the radiation shield 230 and the inner wall of the light head housing 201. In order to provide for sure electrical contact, without the interruption of insulation between the contact springs 213 and 260, longitudinal ribs can be provided on either side of the contacts, integral with and projecting inwardly from the side walls 204, and a closure strip.
Merely by way of illustration, the yoke 185, the light head housing 201 and the light head housing closure 265 can be moulded of polycarbonate plastic. The retard-stop disc 90 can be made of polypropylene. The boom members can be made of extruded aluminum.
In assembling the components of the system, the track and mounting system is first installed. An opening at the reference wall end, for which a removable cover is provided, permits the insertion within the carriage tracks of far end wheel blocks 49 which are initially unmounted to the carriage but are connected to the insulation block 174 on the free end of the flat tape conductor 170 as shown in FIG. 1. The carriage and near end wheel block, which is mounted on the carriage, are then mounted in the carriage tracks 30, and the far wheel block mounted, in place, on the ends of the throughbolts 48. The connector plugs 167 and 168 can then be plugged together.
The boom 5 has preferably been mounted within the boom mount 70, but the yoke assembly and reading-examination light are not attached. To install the yoke and light assembly, it is only necesssary to remove two screws from the swivel boss insert 195, slide the swivel boss onto the end of the yoke swivel collar, and replace the swivel boss insert 395. The contact rings 182 and 160 mate, as do the contact plates 183 and 161. One of the contact rings and one of the contact plates may be made undulant, to ensure good contact.
It will be observed that in the system of this invention, all electrical contacts and connections are enclosed in such a way that the patients in the hospital beds and the nurses, doctors, attendants and maintenance people are protected against shock, and the opportunity for arcing or sparking is practically eliminated. It will be observed that the only sliding contacts are within the yoke fitting boss assembly, and within the yoke arms, at places entirely housed within electrically insulative material.
Numerous variations in the construction of elements of the system of this invention, within the scope of the appended claims, will be apparent to those skilled in the art in the light of the foregoing disclosure. For example, a two-way clutch can be provided with a throw-out mechanism at the vertical position, to eliminate the need for the retard-brake mechanism. The function of the present system involving the retard-stop disc 90 and rollpins 100 and 101 is to prevent free swinging of the examination lights and booms from a position past the vertical in a direction away from a hospital bed with a one-way clutch. It can be seen by referring to FIG. 2 that if the righthand light, for example, is pulled to the position shown by a broken line to the left of the vertical, the one-way clutch mechanism will offer no resistance to the swinging of the light boom to and past the vertical. The configuration of the grooves is such as to engage the rollpins through the travel of the boom through 35° to the "far" side of vertical, so that the light stays where it is put until it is returned to the vertical. The grooves and rollpins also serve as swing-limiting stops, permitting a swing of 55° in the direction of the beds and 35° away from the beds, from the vertical. A two-way clutch could be used for the same purpose, but it will be seen that a throw-out mechanism would be necessary to permit free-wheeling movement of the light in a direction toward the bed from the vertical.
In the embodiment shown, a three-position switch, mounted on a console on the reference wall, and provided with an indicator light which is turned on when the switch is at the high position, controls the voltage delivered to the lamp 290, the switch 300 serving as an on-off switch for the convenience of the patients. If the ribbon conductor were made with three conductive strips or if suitable internal circuitry were provided to regulate the voltage, the switch 300 could be made a three-position switch, in one of which the current supplied to the lamp produces sufficient illumination for reading, not for examination, while another position provides sufficient current for high-intensity illumination for examination purposes.
In the preferred embodiment shown, the yoke assembly and light are self-leveling in one plane by virtue of the spacer functon of the pintle bosses 148, the ends of which abut and which keep sufficient clearance between the radial surface outboard of the circles 147 and the flat outside radial surfaces of the ring 143 to ensure easy movement of the yoke hinge 145. This, too, can be modified by using a ball-type mounting or a fixed type, but the preferred embodiment has distinct advantages, the swiveling of the yoke on the yoke fitting 140 and the pivoting of the light on the yoke providing a universal adjustment from the reference level.
The fore and aft braked swinging mounting of the boom on the carriage can also be modified or eliminated, but it, too, has desirable advantages in permitting easy manipulation by the examining physician without having to move the carriage for each new position and positioning of the reading-examination light beyond the travel of the carriage at both ends of the track, stops on the track limiting that travel to protect the flat tape conductor. A sliding contact can be used, but its use would be difficult because of the rigid requirements of shielding against exposed arcing.
The provision of the diffusing insert in the fluorescent fixture or fixtures produces unique and highly desirable light distribution. With a conventional prism arrangement on the outboard side wall of the primary enclosure in which the inside, longitudinal prisms, 16 per inch, are at 45° on the lower side and 25° on the upper side from a plane perpendicular to the plane of the side wall, and the transverse outside prisms, 10 per inch, are equilateral, with an included angle of 105°, a plot of candlepower distribution in a plane transverse to the length of the fixture takes the form of an inverted butterfly, with a large lobe in the direction of the floor and wall beyond the bed, a somewhat smaller lobe in the direction of the ceiling and a much reduced area directly over the bed, by virtue of the diffuser. In the longitudinal plane, the plot is substantially circular, as would be expected from a planar translucent fixture, but the intensity is much reduced on account of the low transmisivity of the diffusing insert. This provides a bright wall wash as well as illumination of the ceiling, which makes the entire room attractive and well illuminated but at the same time a patient sees only a comfortable level of illumination whether lying down or sitting up. This permits the use of a ceiling mounted or recessed television set, for example. Other arrangements can be used, such for example as a primary enclosure with a linear bat-wing prism pattern on its lower wall, but no other arrangement has been found to give as desirable a lighting pattern as that of the preferred embodiment described. | An illumination system, particularly adapted to use in hospitals, has an elongated, low-profile fluorescent lighting fixture on the side of and parallel to a track, a reading-examination light mounted on one end of a telescoping boom, the other end of which is swingably connected to a boom mount rotatably carried by a carriage mounted to roll along the track. The lighting fixture includes means for providing low brightness down lighting and higher brightness side lighting. The reading-examination light is so constructed as to permit two levels of illumination from a single light source and color correction in a small, balanced, easily manipulated unit. The telescoping boom and its mounting are so constructed as to be light, strong and stable in any position within wide limits. The carriage is so constructed as to permit easy transport of the boom and light, and positive and continuous connection of electrical conductors within the boom to a source of current. | 8 |
BACKGROUND
[0001] The present invention relates generally to a method of making and recycling a golf ball.
[0002] The game of golf is an increasingly popular sport at both amateur and professional levels. A wide range of technologies related to the manufacture and design of golf balls are known in the art. Such technologies have resulted in golf balls with a variety of play characteristics. For example, some golf balls have a better flight performance than other golf balls. Some golf balls with a good flight performance do not have a good feel when hit with a golf club. While materials have advanced to increase the performance of golf balls, the materials are not always easy to recycle. Thus, to help manage costs and reduce damage to the environment, it would be advantageous to reuse a golf ball to make a new golf ball.
SUMMARY
[0003] Generally, the present disclosure presents a method of making and recycling a golf ball. The method may include processing a used golf ball to make the materials of the used golf ball reusable in a new golf ball. As a result, the disclosed method may decrease the waste of disposing of used golf balls and the costs associated with acquiring and/or processing new materials. The method of recycling a golf ball may generally include pulverizing a used golf ball into particles. The used golf ball may be made of materials having different densities. The particles may be placed in a liquid that causes the particles of different materials to float to different levels based on the densities of the materials. This phenomenon may facilitate separating the particles of different materials. The particles may be removed from the liquid while keeping like particles together and keeping different particles separate. Then, the particles may be dried and at least a portion of the particles may be reused in a new golf ball. The particles may be melted and injected into a sandwich mold to create a new golf ball.
[0004] In one aspect, the disclosure provides a method of making a golf ball. The method may include a step of injecting a first molten material into a mold chamber, thereby forming a cover layer. The method may include a step of injecting a second molten material into the mold chamber, thereby forming a mantle layer within the cover layer. The method may include a step of injecting a third molten material into the mold chamber, thereby forming a core layer within the mantle layer. The method may include a step delivering particles of a first material to a first heating chamber. The method may include a step of heating the particles of the first material, thereby melting the particles of the first material into the first molten material. The method may include a step of loading the particles of the first material into a first hopper. The method may include a step of delivering particles of a second material to a second heating chamber. The method may include a step of heating the particles of the second material, thereby melting the particles of the second material into the second molten material. The method may include a step of loading the particles of the second material into a second hopper. The method may include a step of delivering particles of a third material to a third heating chamber. The method may include a step of heating the particles of the third material, thereby melting the particles of the third material into the third molten material. The method may include a step of loading the particles of the third material into a third hopper.
[0005] In one aspect, the disclosure provides a method of making a golf ball. The method may include a step of pulverizing a golf ball into particles. The method may include a step of placing the particles into a liquid, thereby causing a first group of particles to settle at a first level and a second group of particles to settle at a second level that is different from the first level. The first group of particles may be of a material having a different density than the density of the material of the second group of particles. The method may include a step of using at least a portion of one of the first group of particles and the second group of particles to form a new golf ball. The method may include a step of removing the first group of particles while keeping the first group of particles separate from the first group of particles. The method may include a step of storing the first group of particles separately from the second group of particles. The method may include a step of removing the second group of particles while keeping the second group of particles separate from the first group of particles. The method may include a step of storing the second group of particles separately from the first group of particles. The method may include a step of agitating the liquid to aid in separating the particles of both the first group and the second group. The method may include a step of drying the first group of particles and a step of drying the second group of particles.
[0006] In one aspect, the disclosure provides a method of making a golf ball. The method may include a step of pulverizing a golf ball into particles. The method may include a step of placing the particles into a liquid, thereby causing a first group of particles to settle at a first level and a second group of particles to settle at a second level that is different from the first level. The first group of particles may be of a material having a different density than the density of the material of the second group of particles. The method may include a step of removing a first group of particles while keeping the first group of particles separate from the first group of particles. The method may include a step of removing a second group of particles while keeping the second group of particles separate from the second group of particles. The method may include a step of using at least a portion of one of the first group of particles and the second group of particles to form a new golf ball. The step of using at least a portion of one of the first group of particles and the second group of particles to form a new golf ball may include delivering particles of a first material to a first heating chamber and heating the particles of the first material, thereby melting the particles of the first material into a first molten material and injecting a first molten material into a mold chamber, thereby forming a cover layer. The step of using at least a portion of one of the first group of particles and the second group of particles to form a new golf ball may include delivering particles of a second material to a second heating chamber and heating the particles of the second material, thereby melting the particles of the second material into the second molten material and injecting a second molten material into a mold chamber, thereby forming a mantle layer within the cover layer.
[0007] The step of removing the first group of particles may include skimming the first group of particles from the liquid. The step of removing the first group of particles may include forcing the first group of particles from a vessel into a dryer. In some embodiments, a tube may connect the vessel to the dryer. The step of using at least a portion of one of the first group of particles and the second group of particles to form a new golf ball may include injecting a third molten material into the mold chamber, thereby forming a core layer within the mantle layer.
[0008] In one aspect, the disclosure provides a method of making a golf ball. The method may include a step of selling a golf ball having a trace element to a consumer. The method may include a step of collecting the golf ball and inputting the trace element data into a computer program. The method may include a step of calculating with the computer program an incentive award associated with the collected golf ball. The method may include a step of communicating the award to a user. The method may include a step of pulverizing a golf ball into particles. The method may include a step of separating the particles of the golf ball into a first group of particles and a second group of particles. The method may include a step of using at least a portion of one of the first group of particles and the second group of particles to form a new golf ball.
[0009] The step of separating the particles may include placing the particles into a liquid, thereby causing the first group of particles to settle at a first level and the second group of particles to settle at a second level that is different from the first level. The first group of particles may be of a material having a different density than the density of the material of the second group of particles. The method may include a step of removing a first group of particles while keeping the first group of particles separate from the first group of particles. The method may include a step of removing a second group of particles while keeping the second group of particles separate from the second group of particles.
[0010] Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
[0012] FIG. 1 is a golf ball according to an exemplary embodiment;
[0013] FIG. 2 is a flow chart showing a method of making a golf ball according to an exemplary embodiment;
[0014] FIG. 3 shows a cover layer of a golf ball being formed;
[0015] FIG. 4 shows a mantle layer of a golf ball being formed;
[0016] FIG. 5 shows a core layer of a golf ball being formed;
[0017] FIG. 6 shows particles of a pulverized golf ball being separated; and
[0018] FIG. 7 is a flow chart showing a method of recycling a golf ball according to an exemplary embodiment.
DETAILED DESCRIPTION
[0019] Generally, the present disclosure relates to a method of making and recycling a golf ball. In this disclosure, the terms “used golf ball” and “new golf ball” are used to distinguish between a golf ball that is to be recycled and a golf ball that is made from recycled materials. Accordingly, “used golf ball” means a golf ball that is to be recycled. The term “used golf ball” can include golf balls that have literally been used in a golf game and golf balls that have not literally been used. “New golf ball” refers to a golf ball made from materials recycled from the “used golf ball.”
[0020] FIG. 1 shows an exemplary embodiment of a golf ball 100 that may be made and recycled by the disclosed methods. Golf ball 100 may include a core layer 120 , a mantle layer 130 , and a cover layer 140 . While the exemplary embodiment of golf ball 100 has been described and illustrated as having three layers, other embodiments may include any number of layers. For example, in some embodiments, golf ball 100 may be a one-piece, two-piece, four-piece, or five-piece ball. In some embodiments, golf ball 100 may include more than five layers. The number of layers may be selected based on a variety of factors. For example, the number of layers may be selected based on the type of materials used to make the golf ball and/or the size of the golf ball.
[0021] The type of materials used to make the layers of the golf ball may be selected based on a variety of factors. For example, the type of materials used to make the layers of the golf ball may be selected based on the properties of the material and/or the processes used to form the layers. Exemplary materials are discussed below with respect to the individual layers of the exemplary embodiment. In some embodiments, one or more layers may be made from different materials. In some embodiments, one or more layers may be made from the same materials.
[0022] In some embodiments, the materials used to make the layers of the golf ball may be selected to aid in recycling the golf ball. In such embodiments, the materials may be selected to aid in separating and identifying the materials before reusing the materials. This way the materials may be stored separately before using and/or the proper proportions of the materials may be measured out for reusing. For example, in an embodiment in which a used golf ball is made of material A and material B, the used golf ball may be pulverized into particles so that the materials may be reused to make new golf balls and/or other items. Pulverizing the used golf ball may result in particles of material A and material B to become intermixed. If only material A, and not material B, is to be used in a layer of a new golf ball, it may be helpful to be able to separate material A from material B. Similarly, if material A and material B are to be used in a certain proportion in a layer of a new golf ball, it may be helpful to be able to distinguish between material A and material B. Separating and identifying materials may be helpful in recycling golf balls made of any number of materials and during any type of recycling process. For example, separating and identifying materials may be helpful in recycling golf balls made of four different types of materials.
[0023] In some embodiments, the density and/or specific gravity of the materials used to make golf ball 100 may be used to separate the materials during recycling. Specific gravity is the ratio of the density of a substance compared to the density of fresh water at 4° C. (39° F.). At this temperature the density of water is at its greatest value and equal 1 g/cm 3 . Since specific gravity is a ratio, specific gravity is dimensionless. An object will float in water if its density is less than the density of water and sink if its density is greater than the density of water. Thus, an object with a specific gravity less than 1 will float in water and an object with a specific gravity greater than one will sink in water. The same principle may be applied to other types of liquids. For example, if the ratio of the density of an object to the density of a liquid is less than 1, the object will float in that particular liquid. In some cases, the density of an object may cause the object to become suspended at a certain level within the liquid. The ratio of the density of the object to the density of the liquid may dictate the level to which the object is suspended in that particular liquid. These principles may be used to separate materials having different densities. For example, in some embodiments, golf ball 100 made from materials having different densities. For recycling, golf ball 100 may be pulverized into particles. Then, the particles may be added to a liquid having a certain known density. The liquid and/or the materials may be selected based on their densities. In other words, the materials and/or liquid may be selected based on the levels the particles will float to within the liquid. This way, the particles can be separated based on the level to which the particles float in the liquid. The method of recycling a golf ball is discussed in more detail below with reference to FIGS. 6-7 . A used golf ball made by any available method may be recycled by the disclosed method of recycling.
[0024] In some embodiments, core layer 120 , mantle layer 130 , and cover layer 140 may be each made from a single type of material or a composition including multiple materials. In some embodiments, each layer may be made from a thermoplastic such that the materials may be recycled by pulverizing the materials and then melting the materials during sandwich molding to make a new golf ball. For example, core layer 120 may be made from HPF 2000, which has a density of 0.96 g/cm 3 . Mantle layer 130 may be made from Neothane 6303D, which is the trade name of a thermoplastic polyurethane produced by Dongsung Highchem Co. LTD. Cover layer 140 may be made from PTMEG. “PTMEG” is polytetramethylene ether glycol, commercially available from Invista under the trade name of Terathane® 2000. The density of mantle layer 130 or cover layer 140 may range from about 1.1 g/cm 3 to about 1.35 g/cm 3 .
[0025] Pulverizing golf ball 100 of this embodiment into particles and putting the particles in water having a temperature of 4° C. (39° F.) may result in the materials of each layer floating to a different level in the water. The particles may be removed from the water level by level to keep like particles together. For example, particles of HPF 2000 may have the lowest density and may, therefore, float to the top of the water. These particles may be removed first to reveal the next level of particles, which may include the particles having the second lowest density. Then, the particles having the second lowest density may be removed to reveal the next level of particles. In this manner, the particles may be separated into levels and removed level by to level to keep like particles together.
[0026] In some embodiments, golf ball 100 may be made with a sandwich injection mold machine. For example, FIGS. 3-5 show components of a sandwich injection mold machine. FIG. 2 is a flowchart showing an exemplary method 200 of making a golf ball. Method 200 may be performed with the components shown in FIGS. 3-5 or components of any other sandwich injection mold machine. For example, method 200 may be performed by the components disclosed in Cavallaro et al., U.S. Pat. No. 6,676,541, entitled Co-Injection Molded Double Covered Golf Ball, issued on Jan. 13, 2004, the entirety of which is hereby incorporated by reference. In another example, method 200 may be performed by the components disclosed in Lammi, U.S. Pat. No. 5,783,293, entitled Golf Ball with a Multi-Layered Cover, issued on Jul. 21, 1998, the entirety of which is hereby incorporated by reference. In yet another example, method 200 may be performed by the components disclosed in Puniello et al., U.S. Pat. No. 7,862,760, entitled Co-Injection Nozzle, Method of its Use, and Resulting Golf Ball, issued on Jan. 4, 2011, the entirety of which is hereby incorporated by reference.
[0027] The components shown in FIG. 3 may include a vessel for collecting, storing, and/or dispensing particles of golf ball material. For example, the vessel may be a first hopper 300 . First hopper 300 may be connected to a first heating chamber 304 . First heating chamber 304 may include an auger 306 for moving material toward an opening of first heating chamber 304 . In some embodiments, first heating chamber 304 may include a pump and/or piston instead of or in addition to auger 306 . The opening may be aligned with an injection port 320 of a golf ball mold 310 having a mold chamber 312 such that molten material may flow from the opening into mold chamber 312 via injection port 320 . Golf ball mold 310 may include two mold cavities that mate together to form mold cavity 312 . Mold chamber 312 may include surfaces having the inverse of a substantially spherical shape.
[0028] The components shown in FIG. 4 may include a vessel for collecting, storing, and/or dispensing particles of golf ball material. For example, the vessel may be a second hopper 400 . Second hopper 400 may be connected to a second heating chamber 404 . Second heating chamber 404 may include an auger 406 for moving material toward an opening of second heating chamber 404 . In some embodiments, second heating chamber 404 may include a pump and/or piston instead of or in addition to auger 406 . The opening may be aligned with injection port 320 such that molten material may flow from the opening into mold chamber 312 via injection port 320 .
[0029] The components shown in FIG. 5 may include a vessel for collecting, storing, and/or dispensing particles of golf ball material. For example, the vessel may be a third hopper 500 . Third hopper 500 connected to a third heating chamber 504 . Third heating chamber 504 may include an auger 506 for moving material toward an opening of third heating chamber 504 . In some embodiments, third heating chamber 504 may include a pump and/or piston instead of or in addition to auger 506 . The opening may be aligned with injection port 320 such that molten material may flow from the opening into mold chamber 312 via injection port 320 .
[0030] Golf ball 100 may be made by method 200 . In some embodiments, method 200 may include a step 202 of loading particles of a first material 302 into first hopper 300 . The first material may include materials from which a cover layer may be made during method 200 . In some embodiments, particles of first material 302 may include ground material. In some embodiments, particles of first material 302 may include pellets. Method 200 may include a step 204 of delivering particles of first material 302 to a heating chamber. For example, step 204 may include delivering particles of first material 302 to first heating chamber 304 . Step 204 may be carried out in a variety of ways. For example, step 204 may be carried out by gravity acting on the particles. In such embodiments, a valve may open and close to let the particles fall into first heating chamber 304 . In another example, step 204 may be carried out by pumping materials from first hopper 300 into first heating chamber 304 .
[0031] In some embodiments, method 200 may include a step 206 of heating particles of first material 302 , thereby melting particles of first material 302 into a first molten material 308 . Step 206 may be carried out a variety of ways. For example, in some embodiments, step 206 may include raising the temperature of heating elements located within first heating chamber 304 to heat particles of first material 302 . In another example, step 206 may include raising the temperature of heating elements surrounding first heating chamber 304 .
[0032] In some embodiments, method 200 may include a step 208 of injecting first molten material 308 into mold chamber 312 . In some embodiments, step 208 may include forcing first molten material 308 toward the opening of first heating chamber 304 , through the opening, and through injection port 320 . For example, in some embodiments, step 208 may include twisting auger 306 to force first molten material 308 toward the opening of first heating chamber 304 . Twisting auger 306 may also force particles of first material 302 toward opening of first heating chamber 304 . The particles may be melting as they are being moved toward opening of first heating chamber 304 . In another example, a plunger and/or a pump may be used to force first molten material 308 toward the opening, through the opening, and through injection port 320 . In some embodiments, both step 206 and step 208 may be performed by twisting auger 306 . In such embodiments, the heat generated by the friction caused by twisting auger 306 may melt particles of first material 302 . This heat may be used instead of or in addition to any other heat generated within first heating chamber 304 to melt particles of first material 302 into first molten material 308 .
[0033] In some embodiments, method 200 may include a step 210 of loading particles of a second material 402 into a second hopper 400 . Step 210 may be performed in the same manner discussed above with reference to step 202 . The second material may include materials from which a mantle layer may be made during method 200 . In some embodiments, particles of second material 402 may include ground material. In some embodiments, particles of second material 402 may include pellets. In some embodiments, method 200 may include a step 212 of delivering particles of second material 402 to a heating chamber. For example, step 212 may include delivering particles of second material 402 to second heating chamber 404 . Step 212 may be performed in the same manner discussed above with reference to step 204 . Method 200 may include a step 214 of heating particles of second material 402 , thereby melting particles of second material 402 into a second molten material 408 . Step 214 may be performed in the same manner discussed above with reference to step 206 . Method 200 may include a step 216 of injecting second molten material 408 into mold chamber 312 . Step 216 may be performed in the same manner discussed above with reference to step 208 .
[0034] In some embodiments, method 200 may include step 218 of loading particles of a third material 502 into a third hopper 500 . Step 218 may be performed in the same manner discussed above with reference to step 202 . The third material may include materials from which a mantle layer may be made during method 200 . In some embodiments, particles of third material 502 may include ground material. In some embodiments, particles of third material 502 may include pellets. In some embodiments, method 200 may include a step 220 of delivering particles of third material 502 to a heating chamber. For example, step 220 may include delivering particles of third material 502 to third heating chamber 504 . Step 220 may be performed in the same manner discussed above with reference to step 204 . Method 200 may include a step 222 of heating particles of third material 502 , thereby melting particles of third material 502 into a third molten material 508 . Step 222 may be performed in the same manner discussed above with reference to step 206 . Method 200 may include a step 224 of injecting third molten material 508 into mold chamber 312 . Step 224 may be performed in the same manner discussed above with reference to step 208 .
[0035] In some embodiments, step 208 , step 216 and step 224 may be performed sequentially in any order. For example, step 208 may be performed about 1 μs to about 5 sec before step 216 is performed. In another example, step 208 may be performed about 1 sec to about 20 sec before step 216 is performed. In some embodiments, step 208 , step 216 and step 224 may be performed simultaneously and/or quickly successively. In some embodiments, step 208 , step 216 and step 224 may be performed simultaneously and/or quickly successively such that the performances of step 208 , step 216 , and step 224 overlap. In such embodiments, the components of the sandwich mold equipment may be configured to achieve simultaneous and/or quickly successively injections into mold chamber 312 . For example, concentric nozzles may be used to simultaneously injection multiple materials into mold chamber 312 . In another example, the components of the sandwich mold may include those disclosed in Cavallaro et al., U.S. Pat. No. 6,676,541, entitled Co-Injection Molded Double Covered Golf Ball, issued on Jan. 13, 2004, the entirety of which is incorporated by reference.
[0036] In some embodiments, step 208 , step 216 , and step 224 may be performed in an order such that molten first material 308 solidifies against the inner surface of mold chamber 312 to form cover layer 140 of golf ball 100 . Molten first material 308 may begin to solidify before, during, or after the other materials are injected into mold chamber 312 . In some embodiments, step 208 , step 216 , and step 224 may be performed such that molten second material 408 solidifies against cover layer 140 to form mantle layer 130 of golf ball 100 . Molten second material 408 may begin to solidify before, during, or after the other materials are injected into mold chamber 312 . In some embodiments, step 208 , step 216 , and step 224 may be performed such that molten third material 508 solidifies against mantle layer 130 and fills the space inside mantle layer 130 to form core layer 120 of golf ball 100 . Molten third material 508 may begin to solidify before, during, or after the other materials are injected into mold chamber 312 .
[0037] It is understood that any of the steps disclosed above may be performed in any order. For example, step 206 may be performed at the same time as step 208 . In another example, step 206 may be performed before step 208 .
[0038] FIG. 7 is a flowchart showing an exemplary method 700 of recycling a golf ball. The same golf ball made through method 200 may be recycled by method 700 . The following discussion describes performing the steps of method 700 to recycle a single golf ball. However, it is understood that the steps of method 700 may be performed to recycle multiple golf balls at one time. FIG. 6 shows equipment 600 that may be used to perform method 700 . Equipment 600 may include a vessel 602 , a propeller 610 , a first dryer 612 , and a second dryer 614 . Vessel 602 may include any type of vessel suitable for holding a liquid. For example, vessel 602 may be a tank. The type of vessel may be selected based on a variety of factors. For example, the type of vessel may be selected based on the amount of liquid to be held by the vessel and/or the environment in which the vessel is to be stored. Vessel 602 may be connected to first dryer 612 by a first tube 616 . First tube 616 and second tube 618 may be connected to outlets disposed within vessel 602 such that first tube 616 and second tube 618 are each in fluid communication with vessel 602 . First tube 616 may be connected to vessel 602 at a first level. Vessel 602 may be connected to second dryer 614 by a second tube 618 . Second tube 618 may be connected to vessel 602 at a second level. While the exemplary embodiment of FIG. 6 includes only two tubes and two dryers, it is understood that more tubes and dryers may be included. Propeller 610 may be spun to agitate liquid and particles within vessel 602 . While the exemplary embodiment of FIG. 6 may include a propeller, any other type mechanism may be provided to agitate the liquid inside vessel 602 . Similarly, more than one mechanism may be provided to agitate the liquid inside vessel 602 . The type of mechanism and the number of mechanisms may be selected based on a variety of factors. For example, the type of mechanism and the number of mechanisms may be selected based on the type of liquid used and/or the material of the particles. First dryer 612 and/or second dryer 614 may include any type of dryer suitable for drying particles of golf ball material. For example, CONAIR RESINWORKS Systems offer dehumidifying dryers for drying resin materials. The type of dryer may be selected based on a variety of factors. For example, the type of dryer may be selected based on the type of liquid used and/or the material of the particles.
[0039] In some embodiments, method 700 may include a step 702 of pulverizing a golf ball into particles, granules, and/or pellets. Step 702 may be performed by any type of equipment known to those skilled in the art. For example, a Cumberland A Series 1000X granulator may be used to pulverize a golf ball into particles, granules, and/or pellets. The type of equipment used to pulverize the golf ball may be selected based on a variety of factors. For example, the type of equipment may be selected based on the material of the layers of the golf ball. In some embodiments, cover layer 140 may be removed before performing step 702 . For example, cover layer 140 may be ground off of mantle layer 130 . In such embodiments, the remaining layers of the golf ball may be pulverized during step 702 . For example, mantle layer 130 and core layer 120 may be pulverized during step 702 . In other embodiments, step 702 may include pulverizing the entire golf ball without removing any layers first. In yet other embodiments, multiple layers of the golf ball may be removed before performing step 702 . For example, in some embodiments, a golf ball may have four or five layers and two outer layers may be removed before performing step 702 .
[0040] In some embodiments, method 700 may include a step 704 of placing the particles made during step 702 in a liquid 604 having a certain known density. Liquid 604 may be held in vessel 602 . The type of liquid and the amount of liquid may be selected based on a variety of factors. For example, liquid 604 may be selected based on the density of the liquid, the shape and size of the vessel, and/or the density of the pulverized particles of golf ball material. In other words, liquid 604 may be selected based on the levels the particles will float to within the liquid. This way, the particles can be separated based on the level to which the particles float in liquid 604 . Liquid 604 may include a combination of liquids. In some embodiments, the temperature of the liquid may be changed to alter the density of the liquid, thereby altering the level to which the particles float. Similarly, the type of liquid may be changed to alter the density of the liquid. For example, in some embodiments, salt may be added to water to change the density of the water.
[0041] FIG. 6 shows how the particles may settle in liquid 604 . In the embodiment shown in FIG. 6 , cover layer 140 may have been removed from golf ball 100 prior to performing step 702 . Thus, only particles of mantle layer material and particles of core layer material may be pulverized during step 702 and may be present in vessel 602 . The first level of particles 606 may include a first group of particles. The first group of particles may include the material having the lowest density, which may be more buoyant in the liquid. As shown in FIG. 6 , in some embodiments, the first level of particles 606 may float to the top of the liquid level. The second level of particles 608 may include a second group of particles. The second group of particles may include the material having the highest density, which may sink to the bottom of vessel 602 .
[0042] While the exemplary embodiment shows two levels of particles, it is understood that the number of levels may include as many levels as there are types of materials. For example, in some embodiments, a golf ball made of four materials each having different densities may be pulverized in step 702 and the pulverized particles may be placed in liquid in step 704 . The four materials may float to four different layers. In another example, in some embodiments, multiple golf balls each having different combinations of materials may be pulverized in step 702 and then placed in liquid in step 704 . In this example, a first set of golf balls may be made of materials A, B, C and D, each having a different density, and second set of golf balls may be made of materials A and E, each having a different density. Since the two sets of golf balls combined are made of materials A, B, C, D, and E, the particles may float to five different levels in the liquid.
[0043] In some embodiments, method 700 may include step 706 of agitating the liquid. Step 706 may help separate particles that may be stuck together, thereby aiding in separating the first group of particles from the second group of particles. For example, step 706 may include spinning propeller 610 to agitate the liquid and particles, thereby separating particles that may be stuck together. It is understood that step 706 may be performed by any equipment suitable for agitating the liquid and particles. For example, step 706 may be performed by stirring the liquid with a paddle.
[0044] In some embodiments, method 700 may include a step 708 of removing the first group of particles. Step 708 may include removing the first group of particles while keeping the first group of particles separate from the second group of particles. In some embodiments, step 708 may be performed by feeding the first group of particles into first tube 616 . For example, the first group of particles may be suctioned into first tube 616 . In some embodiments, the first group of particles may be skimmed from the top of liquid. For example, in some embodiments, vessel 602 may not be connected to tubes and the particles may be removed without using tubes.
[0045] In some embodiments, method 700 may include a step 710 of removing a second group of particles. Step 710 may include removing the second group of particles while keeping the second group of particles separate from the first group of particles. In some embodiments, step 710 may be performed by feeding the first group of particles into second tube 618 . For example, the second group of particles may be suctioned into second tube 618 . In some embodiments, step 708 may be performed before step 710 . Thus, the second group of particles may be the only particles remaining in the liquid before step 710 is performed. Step 710 may include skimming and/or straining the second group of particles from the liquid. For example, in some embodiments, vessel 602 may not be connected to tubes and the particles may be removed without using tubes. In some embodiments, liquid 604 may be poured over a sieve to strain out the second group of particles. In embodiments in which more than two materials are to be separated, step 710 may be repeated for each remaining material.
[0046] In some embodiments, method 700 may include a step 712 of drying the first group of particles. In some embodiments, step 712 may include using first tube 616 to transport the first group of particles to first dryer 612 . In some embodiments, step 712 may include using first dryer 612 to dry the first group of particles. In some embodiments, step 712 may be performed by twin screws disposed within a tube. In such embodiments, the twin screws may be twisted to move the first group of particles along inside the tube and to dry the particles through heat generated by friction caused by moving the twin screws against the particles. For example, step 712 may be performed by the twin screws described in ______, U.S. patent application Ser. No. ______ (client matter number 72-1452), entitled Method of Recycling a Golf Ball, filed on ______, the entirety of which is hereby incorporated by reference.
[0047] In some embodiments, method 700 may include a step 714 of drying the second group of particles. In some embodiments, step 714 may include using second tube 618 to transport the second group of particles to second dryer 614 . In some embodiments, step 714 may include using second dryer 614 to dry the first group of particles. In some embodiments, step 714 may be performed by twin screws disposed inside a tube. In such embodiments, the twin screws may be twisted to move the second group of particles along inside the tube and to dry the particles through heat generated by friction caused by moving the twin screws against the particles. For example, step 714 may be performed by the twin screws described in ______, U.S. patent application Ser. No. ______ (client matter number 72-1452), entitled Method of Recycling a Golf Ball, filed on ______, the entirety of which is hereby incorporated by reference.
[0048] Method 700 may include step 716 of using the first group of particles to make a new golf ball. For example, in some embodiments, the first group of particles may be mixed with new, unused particles of material. The combination of the first group of particles and the new, unused particles of material may be used in method 200 to form a layer of a new golf ball. In some embodiments, the new, unused particles of material mixed with the first group of particles may include the same type of material as the first group of particles. In some embodiments, the new, unused particles of material mixed with the first group of particles may include a different type of material from the first group of particles.
[0049] Method 700 may include step 718 of using the second group of particles to make a new golf ball. For example, in some embodiments, the second group of particles may be mixed with new, unused particles of material. The combination of the second group of particles and the new, unused particles of material may be used in method 200 to form a layer of a new golf ball. In some embodiments, the new, unused particles of material mixed with the second group of particles may include the same type of material as the second group of particles. In some embodiments, the new, unused particles of material mixed with the second group of particles may include a different type of material from the second group of particles.
[0050] It is understood that any of the steps of method 700 may be performed in any order. For example, step 712 may be performed at the same time as step 714 . In another example, step 712 may be performed before step 714 .
[0051] In some embodiments, method 700 may be performed with the components and/or in the manner disclosed in Molinari, U.S. patent application Ser. No. 13/483,718 (client matter number 72-1601), entitled Method Of Recycling A Ball And Ball For Use In Recycling Method, filed on May 30, 2012, the entirety of which is hereby incorporated by reference.
[0052] In some embodiments, golf ball 100 may be made to include a trace element, or unique identifier, as disclosed in Ishii et al., U.S. patent application Ser. No. 13/018,007 (client matter number 72-1160), entitled System and Method for Collecting, Recycling, and Tracking Products such as Golf Balls, filed on Jan. 31, 2011, the entirety of which is hereby incorporated by reference. For example, method 200 may include a step of attaching a trace element to golf ball 100 . In some embodiments, the method for incentivizing the collection and recycling of products disclosed in U.S. patent application Ser. No. 13/018,007 may be performed in addition to the methods disclosed herein. The method for incentivizing the collection and recycling of products may include a step of selling golf balls, including one or more golf balls identical to golf ball 100 . The method may further include a step of collecting one or more sold golf balls. If the collected golf ball(s) includes a trace element, the trace element may be scanned or read. This trace element data may then be input into a Recycling Incentive and Tracking Program (RIT), for data storage and further processing. An incentive award may be provided to a user based upon the information stored within the RIT program. The collected golf balls may be processed for recycling. This step may encompass many possible actions such as counting and sorting; separating by condition of product; separating by original manufacturer. Each of the sorting factors can be used to direct the collected products into designations such as routing for disassembly and recycling of materials and components for re-manufacture of products that are like or unlike the original collected products; or routing for re-use designations. In some embodiments, method 700 may be performed in place of or in addition to processing the collected golf balls for recycling. The method of incentivizing may include a step of determining the intended designation for recycled material from the golf ball(s), feeding data regarding the intended designation into the RIT program, and providing the intended designation to a user via a network.
[0053] While various embodiments of the invention have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims. | A method of making and recycling a golf ball is disclosed. The method may include processing a used golf ball to make the materials of the used golf ball reusable in a new golf ball. As a result, the disclosed method may decrease the waste of disposing of used golf balls and the costs associated with acquiring and/or processing new materials. The method of recycling a golf ball may generally include pulverizing used golf balls into particles. The used golf balls may be made of materials having different densities. The particles may be placed in a liquid that causes the particles of different materials to float to different levels based on the densities of the materials. At least a portion of the particles may be melted and injected into a sandwich mold to create a new golf ball. | 1 |
FIELD OF THE INVENTION
The present invention relates rotating trommels used to sort or size particulate matter in general and to an improved cleaner apparatus and drive system therefor used to clean the screens used in the trommel.
BACKGROUND OF THE PRESENT INVENTION
Rotating apparatus known as trommels have long been used to screen dirt, debris, and other undesirable material from desirable material as well as to sort or size particulate material, such as grains. In general, the trommels have a cylindrical configuration defined by a skeletal framework and one or more screen panels attached thereto. The screen panels each have a plurality of sorting (or sizing) holes or apertures therein that serve to pass particulate matter therethrough below a certain size range. The particulate matter is inserted into the trommel in one end thereof and, as the trommel rotates the undersized particles are passed through the holes into the appropriate collection apparatus disposed therebelow. In this manner, grain such as seed corn, oats, barley, etc. can be sorted according to size. Many times the materials are subjected to multiple sortings, sometimes within the same overall apparatus. In addition, there are several companies that place multiple trommels within a single unit, which will be referred to as a sizer hereafter.
As the material within the trommel rotates, particles slightly too large to pass through the apertures can become lodged therein. Within a very short time of beginning the sorting or sizing operation, the screen apertures can nearly all become completely obstructed, thereby preventing anymore material from passing therethrough and essentially ending the sorting operation as it begins. To prevent this from occurring, it is known in the art to use a variety of devices to clean the screen apertures as the screen is rotated. One such device uses a plurality of cylindrical rollers mounted on a shaft for free rotation relative thereto. The shaft is disposed above the trommel in such a manner that the rollers can rollingly engage the trommel. Friction between the trommel and the rollers causes the rollers to rotate as the trommel is rotated. The rollers are typically made of wooden or other suitable material. As the trommel rotates then, the rollers engage the portions of the particulate material extending through the sorting aperture and force the material out of the apertures and back into the interior of the trommel, thus opening the apertures so they can be used to sort material as intended. Another known type of screen cleaner utilizes an elongate cylindrical brush that cleans the screens by means of the brush bristles extending into the sorting apertures as the trommel rotates, forcing the material out of the apertures.
Still another form of trommel cleaner utilizes an elongate cleaner that includes a plurality, typically few in number, of flappers that extend outward from a central hub and into contact with the trommel. The flappers extend the length of the trommel and have a rectangular cross section. These units work well in cleaning the trommel screen, but are accompanied by several deficiencies. As the elongate flapper engages the trommel along its entire length, that is, as it slaps against the trommel, knocking the stuck material from the sizing holes, a torque spike is created that must be accommodated by the drive unit. Thus, a plurality of torque spikes equal to the number of flappers is created with each revolution of the trommel cleaner. These torque spikes necessitated the use of heavier elements than would otherwise be necessary in the drive system. In addition, the torque spikes most likely shortened the lifetime of all of the elements of the trommel system. Finally, this type of trommel cleaner requires a separate drive system to drive the cleaning unit. That is, they cannot be friction driven like the rollers and must have their own drive system comprising chains (or belts) and gears (or pulleys).
It would be desirable to have a trommel cleaner that provided the cleaning advantages of the flapper cleaners but that did not create the torque spikes found in such prior art cleaners.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide new and improved apparatus that is not subject to the foregoing disadvantages.
It is another object of the present invention to provide an improved trommel cleaner that provides the cleaning advantages of the flapper-type cleaner but that does not create the torque spikes that those types of cleaners do.
It is still another object of the present invention to provide an improved trommel cleaner that includes a plurality of flapper elements that together extend substantially the length of the trommel.
It is yet another object of the present invention to provide an improved trommel cleaner of the flapper type that can be driven by a friction drive rather than a separate chain or belt drive.
It is still yet another object of the present invention to provide an improved trommel cleaning apparatus comprising a plurality of individual, substantially identical, flapper elements mounted to a shaft for rotation thereabout.
The foregoing objects of the present invention are provided by a trommel cleaner apparatus in accord with the present invention, the trommel cleaner having a shaft having a non-circular outer surface. The shaft mounts a plurality of flapper elements thereon. Each flapper element has a hub having an inner and outer surface. A plurality of indexing lobes extend inwardly from the inner surface of the hub. The indexing lobes and the non-circular shaft cooperate to enable adjacent flapper elements to be mounted to the shaft with flappers of one flapper element angularly disposed relative to the flappers of the adjacent flapper elements. In the embodiment shown in the Figures, the flapper element has five flappers disposed symmetrically about the hub such that the flappers extend outwardly from their bases which are in turn disposed about 72° apart. With eight indexing lobes as shown and a square shaft as shown, the flappers can be disposed about 9° apart. Thus, the torque spike is reduced because flappers will be striking along one eighth of the trommel compared to the entire length as with the prior art flapper cleaner. The torque spike is thus reduced to one eighth of that found in the prior art, thereby enabling the drive system for the trommel to be made of "lighter" components, enabling the trommel cleaner to be driven by a friction wheel engaged with the trommel, and lengthening the life span of all of the component parts due to the reduced torque that the trommel, the trommel drive and the trommel cleaner apparatus must bear.
The foregoing objects of the invention will become apparent to those skilled in the art when the following detailed description of the invention is read in conjunction with the accompanying drawings and claims. Throughout the drawings, like numerals refer to similar or identical parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a sizer in accord with the present invention in a side elevation, partial phantom view.
FIG. 2 shows the sizer of FIG. 1 in an end elevation view and illustrates the feeders for the rotating trommels contained therein.
FIG. 3 depicts the sizer of FIG. 1 in an end elevation view from the other end and shows the drive mechanism for driving the rotating trommels.
FIG. 4 illustrates in a top plan view taken along viewing plane 4--4 of FIG. 3 the drive belt and pulley system used to drive the rotating trommels.
FIG. 5 is a cross sectional view taken along viewing plane 5--5 of FIG. 2.
FIG. 6 is a cross sectional view taken along viewing plane 6--6 of FIG. 5
FIG. 7 is a partial perspective view of a drive shaft and flapper element in accord with the present invention.
FIG. 8 is an end elevation, cross sectional and partial phantom view of a flapper unit in accord with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a sizer 10 in accord with the present invention is illustrated. Sizer 10 is used to sort undesirable from desirable particulate matter as well as to sort the particulate matter by size, such as the girth of a kernel of grain. As best seen in FIGS. 1-3, the sizer 10 illustrated includes four trommels arranged with two trommels side by side and directly over the other two. Sizers including one or more trommels are well known and the present invention is not limited to the present configuration shown herein.
As shown in the Figures, sizer 10 includes first and second, or lower and upper, modules 12 and 14. Modules 12 and 14 are attached to each other by fasteners 16, which may be nut/bolt combinations. Module 12 is in turn fastened to a base 18 by fasteners 20, which may also be nut/bolt combinations. Module 12 includes a pair of trommels 22 and 24 mounted side-by-side for rotation therein. Similarly, module 14 includes trommels 26 and 28 mounted in a side-by-side manner for rotation therein. Modules 12 and 14 have a substantially elongate, box-like configuration with the axis of rotation of the trommels defining the longitudinal direction. Transverse to the axis of rotation, the modules 12 and 14 each have a substantially rectangular configuration. Modules 12 and 14 each have an outer, four sided shell 30 and 32 respectively that mounts the trommels 22, 24 and 26, 28 therein, respectively. Shells 30 and 32 are typically manufactured from steel, though wood or other materials of suitable strength may appropriately be used.
Referring to FIGS. 1 and 2 particularly, now, it will be observed that sizer 10 includes a hopper 34 into which the particulate material 36 to be sorted is placed. Hopper 34 includes a plurality of branches therefrom that lead to the trommels within sizer 10. Thus, hopper 34 includes a branch 38 leading to trommel 22; a branch 40 leading to trommel 24; a branch 42 leading to trommel 26; and a branch 44 leading to trommel 28. It will be observed in FIG. 2 that hopper branches 38 and 40 are sub-branches of a larger main branch 46. The particulate matter 36 drops into hopper 34 and falls under the influence of gravity into branches 42, 44, and 46, and from branch 46 into branches 38 and 40. From the branches 38-44 the particulate matter flows into the trommels 22-28, respectively, in a known manner at the inlet ends thereof. Branches 38-46 may be formed of sheet steel or other appropriate materials.
Material passing through the trommel screens of trommels 22 and 24 is received by a receiving hopper 48. Hopper 48 has an elongate configuration with sloping side walls 50, 52 that converge near the bottom into an outlet channel 54, which in turn may empty into a conveyor (not shown). Similarly, material passing through the trommel screens of trommels 26 and 28 is received by an upper receiving hopper 56 that has sloping, converging side walls 58, 60 that empty into a channel 62. Channel 62 in turn empties the sorted material into lower receiving hopper 48. Material that does not pass through the screen openings in trommels 22-28 is carried through the trommels to the discharge ends thereof and discharged into a collection hopper 64, from which it flows into another conveyor (not shown). It will be understood that dependent upon the particulate matter 36 being screened or sized, that the material flowing into hopper 48 may be discarded or kept and that the same is true of the material flowing into hopper 64.
Referring now to FIGS. 1, 3, and 4, the drive mechanism for the trommels will be explained. Upper module 14 includes a support plate 66 attached thereto in any known manner that extends outwardly therefrom. Support plate 66 has a substantially triangular configuration as shown, though this is not critical to the present invention. A drive motor 68 is suspended therefrom though it could also be supported thereabove if desired) and drivingly connected to a pulley 72 rotationally mounted to support plate 66. A drive belt 70 drivingly connects pulley 72 with a pair of pulleys 74, 76 that are also rotationally mounted to the support plate 66. An appropriate shield 78 is attached to the support plate 66 to shield the moving pulleys and belt.
Each pulley 74, 76 is drivingly attached to a drive shaft 80, 82, that extend through the support plate 66 into gear boxes 84, 86, respectively that are mounted to the shell 32 by known means such as bolting. A driven shaft extends at substantially a right angle from each gear box 84, 86 through the end wall of the shell 32 and engage a drive shaft that drives a trommel. Thus, referring to FIG. 1 in particular, it will be seen that a driven shaft 88 extends inwardly inside shell 32 from gear box 84 and is attached to a trommel drive shaft 89 of trommel 28 by means of a collar 90. Trommel 28 is thus driven by motor 68 through pulleys 72, 74 shaft 80, gear box 84 and shaft 88. A similar drive arrangement drives trommel 26. Referring briefly to FIG. 5 it will be seen that a driven shaft 91 extends through shell 32 from gearbox 86 into an open ended collar 92 that also receives the trommel drive shaft 93 of trommel 26. Both shafts 91 and 93 may be held in place with set screws 94 as shown. A similar form of attachment may be used to drivingly connect drive shafts 88 and 89 to each other.
Gear boxes 84 and 86 each have another stub drive shaft extending outwardly and downwardly therefrom. Thus, referring to FIG. 1, a stub shaft 95 is driven by gear box 84. Shaft 95 is attached to an intermediate shaft 96 having universal joints 97 and 98 at each end thereof. Shaft 95 is attached to U-joint 98. U-joint 97 is attached to a driven stub shaft 100 that is attached to and part of a gear box 102, which is mounted in any known manner, such as by bolting, to shell 30 of module 12. A right angle driven shaft 104 extends inwardly into shell 30 and is attached to a trommel drive shaft 106 of trommel 24 by a collar 105. A similar, though not shown drive arrangement is used to drive trommel 22 from a gear box 108. The intermediate drive shaft 96 and the intermediate drive shaft used to drive gear box 108 are each covered with appropriate shielding members 110, 112, respectively.
A further protective shield is cover 114 that is bolted to the upper module 14.
Referring principally now to FIGS. 5-8 a trommel and an improved trommel cleaner will be described. Each trommel 22-28 has its own cleaner, all of which are substantially similar. Thus, only trommel 26 and the trommel cleaner 120 for trommel 26 will be described, it being understood that the trommels 22, 24, and 28 and the cleaners for trommels 22, 24, and 28 are substantially similar.
Trommel 26 comprises a pair of end support rings 122, 124. Typically, though not shown, trommel 26 has longitudinally extending ribbing that extends between end support rings 122, 124 and cross bracing that extends across the interior of the trommel. Trommel 26 supports one or more screen panels 126 that may be attached to the end rings 122, 124 and the supporting structure in any known manner. A spout 128, which is attached to hopper branch 42, empties into the interior 129 of trommel 26. Referring briefly to FIGS. 5 and 6, it will be seen that the intake or input side of trommel 26 includes a wheel 130 that runs on a pair of spaced apart idler wheels 132, 134 that are rotationally mounted to the end wall of shell 32 by means of shafts 136, 138 respectively, which in turn are fastened thereto by a nut/bolt combination as best seen in FIG. 5. Wheel 130 is attached to a larger diameter running wheel 140, which in turn is attached to end ring 122. As discussed earlier, trommel 26 is rotationally driven by trommel drive shaft 93, which is in turn attached to a spider 139, best seen in FIG. 6, that is attached by known means such as bolts to the end ring 124.
Trommel cleaner 120 comprises a shaft 160 having a non-circular outer configuration that is square as shown in the Figures. Cleaner shaft 160 mounts a plurality of individual flapper elements 162, which may be made of urethane or any other suitable material. Each flapper element 162 comprises a hub 164 having a plurality of flappers or beaters 166 extending outwardly therefrom that are substantially equally spaced therearound. As best seen in FIG. 8, the flappers 166 extend away from hub 164 substantially tangentially thereto. Each flapper element has five such flappers 166 and thus the flappers 166 extend outwardly from the hub 164 approximately seventy two degrees (7°) apart and at an angle of approximately thirty degrees (30°) relative to a radius of the hub 164, the latter angle being variable within a range of about plus or minus five degrees (±5 ). Hub 164 has an inner or central passage 168 that receives shaft 160. Central passage 168 is defined by the inner surface 170 of the hub 164 and includes a plurality of indexing lobes 172 extending inwardly from the inner surface 170 toward the center of the hub 164. Referring to FIG. 8, it will be observed that the corners, that is, the longitudinally extending edges, 174 of shaft 160 are received between two adjacent indexing lobes 172 and that two lobes 172 bear against each side 176 of shaft 160. The flapper element embodiment shown in the Figures includes eight such indexing lobes. This enables each flapper element 162 to be mounted to shaft 160 in eight different positions. Thus, adjacent flapper elements are mounted such that they are rotated approximately forty-five degrees (45°) relative to the adjacent flapper elements. Since each flapper element 162 has five flappers 166 as shown, the flappers 166 of adjacent flapper elements are rotated approximately nine degrees (9°) relative to each other. FIG. 8 illustrates a flapper element 162 in cross section as well as shows in phantom outline the positions of other flappers down the shaft 160 and illustrates that the flappers are displaced approximately nine degrees relative to each other such that the flappers extend outwardly from the shaft 160 in forty different positions according to the present embodiment.
Consequently, the flappers 166 of the plurality of flapper elements 162 mounted to shaft 160 engage the trommel 26 five times with each revolution of shaft 160 but they do not do so at the same time as is the case with prior art longitudinally continuous flapper designs. That is, prior art flapper or beater cleaners included five longitudinally continuous flappers mounted circumferentially to a shaft. With each revolution of the shaft, each flapper would strike the trommel once along the entire length of the trommel, thereby creating five separate but large torque spikes. With the present embodiment shown in the Figures, the flappers 166 are striking substantially continuously along the trommel, but because of the ability to index the flapper element 162 relative to the shaft 160, the torque spike is reduced by a factor equal to the inverse of the number of indexing positions, which in this embodiment would be 1/8; that is, only one eighth of the flappers are forcefully engaging the trommel at any point in time. It should be noted once again that to achieve this reduction the number of flappers must be odd if the number of indexing positions is even and odd if the number of indexing positions is even. Were the number of lobes and flappers both even the pattern would begin to repeat too quickly and the advantages of indexing, while still useful, would be less so.
Dimensionally, in one embodiment, each flapper element hub 164 has a longitudinal extent within the range of about 21/2 inches to about 31/2 inches, and preferably is about three inches. The flappers 166 have a width equal to that of the longitudinal extent of the hub and a length of about 2 inches to about 21/2 inches.
It will be noted that in the present embodiment as shown in the Figures that each flapper element has an odd number of flappers 166 and an even number of indexing lobes 172. Generally, the indexing and torque reduction provided by the present invention can be achieved by any combination of odd and even numbers of the lobes and flappers, though preferably the numbers of lobes and flappers would not be multiples of each other since that would reduce the benefits of the ability to index the flapper elements 162. That is, the number of flappers could be even and the number of indexing lobes could be odd and the torque reduction provided by the present invention will be achieved. Having both the number of lobes and the number of flappers be even, however, would provide for a rapid repetition of the positions of the flappers and therefore would not provide the dramatic torque reduction provided by the present invention. Similarly, where the number of flappers and lobes are multiples of each other, such as three and six or five and ten, the benefits of indexing will also be reduced.
The circumferential spacing of the flappers 166 about shaft 160 is shown in FIG. 8, thereby providing an indication of the reduction in the length of trommel being cleaned by the trommel cleaner at one time. Again, in the prior art, the entire longitudinal length of the trommel would be wiped by a flapper at one time. With the present invention, only one eighth of the trommel is being wiped at a time. The torque spike is therefore reduced by that same factor.
The reduction of the torque spike has consequences for the overall structure and configuration of the sizer 10. First is that the flapper trommel cleaner 120 can be driven by a friction wheel rather than requiring a separate chain, belt, or electric drive. Thus, as seen in FIGS. 5 and 6 the trommel cleaner 120 is mounted for rotation within the shell 32. More specifically, shaft 160 is rotationally mounted to a pair of arms 178, 180. Arms 178, 180 are in turn each mounted to a torsion block 182. Torsion block 182 is used to apply tension to the trommel cleaner 120 such that the flappers 166 forcefully engage the trommel. Torsion block 182 is attached to an inwardly extending flange 184, which is attached to the interior of the shell 32. Arms 178, 180 each engage a stop block 194 that is provided to limit the movement of the arms 178, 180 downwardly in the direction of the trommel 26.
More specifically yet, shaft 160 is mounted to a pair of friction wheels 186, 188, at each end thereof. Friction wheel 186 rotationally engages running wheel 140 formed at the end of trommel 26. Thus, as trommel 26 rotates counter-clockwise as indicated by arrow 190, trommel cleaner 120 will be rotated in a clockwise manner as indicated by arrow 192 through the frictional engagement of friction wheel 186 with running wheel 140. The flappers 166 of the flapper elements 162 will wipe across the trommel screens of trommel 26, dislodging particulate matter that may be lodged in the screen apertures.
As noted, in the embodiment shown, each flapper element 162 includes a plurality, here five, of lobes 172, that extend the entire longitudinal extent of the hub 164. The lobes 172 need not extend the entire length, though doing so helps strengthen the flapper element and spreads the stress felt by the lobes across a greater length. The lobes 172 have a substantially hemispherical cross section that transition into the inner surface area between the lobes with a somewhat wedge-shaped portion. Other cross sections may be used if desired. The inner surface 170 between the lobes 172 is substantially smooth and may be somewhat flat; that is, the surface 170 between the lobes 172 need not form a circular surface relative to the longitudinal axis of the hub 164.
The present invention having thus been described, other modifications, alterations, or substitutions may now suggest themselves to those skilled in the art, all of which are within the spirit and scope of the present invention. It is therefore intended that the present invention be limited only by the scope of the attached claims below. | A trommel cleaner apparatus having a non-circular rotatable shaft with a plurality of flapper elements mounted thereto for wiping and cleaning engagement with a trommel is provided herein. The flapper elements each have a hub having inner and outer surfaces, with the outer surface including a plurality of flappers extending therefrom so as to engage a trommel in cleaning operation and with the inner surface including a plurality of indexing lobes to variably position the flapper element relative to the shaft and adjacent flapper elements, thereby reducing the torque spikes applied to the trommel. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP200/059317 filed Sep. 6, 2007 and claims the benefit thereof. The International Application claims the benefits of German Patent Application No. 10 2006 048 627.7 DE filed Oct. 13, 2006, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a method for controlling traffic flows including hazardous material or abnormal load transportation units through safety-critical traffic zones, such as tunnels, bridges or locks for example.
[0003] The invention also relates to a traffic control system for controlling traffic flows including hazardous material or abnormal load transportation units through safety-critical traffic zones, such as tunnels, bridges or locks for example.
BACKGROUND OF INVENTION
[0004] Methods and traffic control systems for controlling traffic flows are known from the prior art, which measure lane conditions or traffic density for example and set traffic control signals, such as speed restrictions or general vehicle bans for example. Traffic control systems, which also take into account traffic density, are based here on contactless detection devices for vehicles, for example optical cameras.
SUMMARY OF INVENTION
[0005] Such systems are however not suitable for controlling traffic flows including hazardous material or abnormal load transportation units through safety-critical traffic zones such as tunnels, bridges or locks, as these require information about the presence and nature of hazardous materials for example. Automated requests for such information cannot be implemented using optical cameras alone. There is also the general problem of how to proceed when controlling traffic flows including hazardous material or abnormal load transportation units through safety-critical traffic zones. It is known that general speed restrictions can be provide in the region of tunnels, to reduce the general accident risk but such a measure sometimes also reduces the traffic flow.
[0006] An object of the invention is to use a method or traffic control system for controlling traffic flows including hazardous material or abnormal load transportation units through safety-critical traffic zones to minimize the safety risk associated with hazardous material or abnormal load transportation units selectively, without impeding the general traffic flow for all other vehicles unnecessarily in the process.
[0007] The object is achieved by a method and a system as claimed in the claims. Disclosed is a method for controlling traffic flows including hazardous material or abnormal load transportation units through safety-critical traffic zones, such as tunnels, bridges or locks for example. Provision is made for safety-relevant data to be read out with the aid of a signal transmitter disposed on the hazardous material or abnormal load transportation units as they pass read devices disposed in the safety-critical traffic zone and to be transmitted to a central computation unit, the central computation unit using the safety-relevant data of all the hazardous material or abnormal load transportation units present in the safety-critical traffic zone to determine a safety risk in the safety-critical traffic zone and to set traffic control signals, which reduce the accident risk for a hazardous material or abnormal load transportation unit in the safety-critical traffic zone to avoid an impermissible safety risk. The abnormal loads can also be buses or heavy vehicles of all types.
[0008] Intervention then only takes place in the traffic flow if hazardous material or abnormal load transportation units are actually present in the safety-critical traffic zone. To this end provision is made for specific signal transmitters, which are provided on the hazardous material or abnormal load transportation units, for example RFID transponders. But even when a hazardous material or abnormal load transportation unit is present in the safety-critical traffic zone, it is possible first to use the existing safety-relevant data for the relevant transportation unit to evaluate the safety risk that results in combination with another hazardous material or abnormal load transportation unit. If an impermissible safety risk is anticipated, traffic control signals are set, which reduce the accident risk for a hazardous material or abnormal load transportation unit in the safety-critical traffic zone.
[0009] In order not to impede the general traffic flow unnecessarily in this process, it is provided for the central computation unit to set traffic control signals which prevent an additional hazardous material or abnormal load transportation unit entering the safety-critical traffic zone, if there is already a hazardous material or abnormal load transportation unit present in the safety-critical traffic zone. No general speed limits or similar measures, which influence the general traffic flow, are therefore instituted; the additional hazardous material or abnormal load transportation units are simply prevented from entering the safety-critical traffic zone. To this end the traffic control signal can consist of a stop signal for a hazardous material or abnormal load transportation unit in the entry zone of a safety-critical traffic zone.
[0010] The claimed system a traffic control system for controlling traffic flows including hazardous material or abnormal load transportation units through safety-critical traffic zones, such as tunnels, bridges or locks for example. Provision is made here for the hazardous material or abnormal load transportation units to be equipped with a signal transmitter for safety-relevant data and for read devices for the signal transmitters to be disposed in the safety-critical traffic zone and for a central computation unit to be provided, which is connected on the one hand to the read devices for transmitting the safety-relevant data read out as a signal transmitter passes and on the other hand to a traffic control facility, which sets traffic control signals for a safety risk determined using the safety-relevant data of all the hazardous material or abnormal load transportation units present in the safety-critical traffic zone, to avoid an impermissible safety risk, said traffic control signals reducing the accident risk for a hazardous material or abnormal load transportation unit in the safety critical traffic zone.
[0011] The read devices are disposed in the entry and exit zones of the safety-critical traffic zone and the traffic control facility comprises a controllable stop signal in the entry and exit zones of the safety-critical traffic zone. This allows an additional hazardous material or abnormal load transportation unit to be prevented from entering the safety-critical traffic zone, if a hazardous material or abnormal load transportation unit is already present in the safety-critical traffic zone.
[0012] The signal transmitter is an RFID transponder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention is described in more detail below with reference to an exemplary embodiment and with the aid of the accompanying drawings, in which
[0014] FIG. 1 shows a schematic diagram of a safety-critical zone and the entry of a first hazardous material or abnormal load transportation unit into this zone,
[0015] FIG. 2 shows a schematic diagram according to FIG. 1 , in which an additional, second hazardous material or abnormal load transportation unit approaches the safety-critical zone,
[0016] FIG. 3 shows a schematic diagram according to FIG. 2 , in which the additional, second hazardous material or abnormal load transportation unit is stopped before the safety-critical zone and
[0017] FIG. 4 shows a schematic diagram according to FIG. 3 , in which the first hazardous material or abnormal load transportation unit has left the safety-critical zone and the additional, second hazardous material or abnormal load transportation unit is given permission to enter the safety-critical zone.
DETAILED DESCRIPTION OF INVENTION
[0018] FIGS. 1 to 4 show a possible embodiment of the method or traffic control system, in which a safety-critical traffic zone 1 , perhaps a tunnel, is to be accessible for just one hazardous material or abnormal load transportation unit 7 . FIGS. 1 to 4 here only show the hazardous material or abnormal load transportation unit 7 but the traffic flow consists of a plurality of other vehicles in addition to the hazardous material or abnormal load transportation unit 7 ; said other vehicles however do not represent an increased potential danger in the safety-critical traffic zone 1 and are not shown in FIGS. 1 to 4 . The safety-critical zone 1 can be an exposed section of road, a road tunnel, a rail tunnel, a maritime lock, a bridge, etc.
[0019] The hazardous material or abnormal load transportation unit 7 . 1 moves toward the safety-critical zone 1 in the marked arrow direction and is equipped with a signal transmitter 4 , perhaps an RFID (Radio Frequency Identification) transponder. The signal transmitter 4 contains safety-relevant data relating to the vehicle in question, such as nature of load, total volume of load, dimensions of vehicle or vehicle weight. The hazardous material or abnormal load transportation unit 7 . 1 can be any type of heavy vehicle or other vehicles with a greater need for protection, such as buses.
[0020] The safety-relevant data on the signal transmitter 4 is read out by read devices 5 , which are disposed in the entry and exit zones 2 of the safety critical zone 1 in the exemplary embodiment shown in FIG. 1 . Different embodiments of RFID transponders are known, which can be used in principle for the method or the traffic control system. What are known as “passive” RFID transponders are particularly advantageous as these do not require their own energy supply and can therefore be assembled easily and economically and also have a long service life. The read devices 5 then scan the data contained on the RFID transponders in the conventional manner. It is however also possible to use RFID transponders, which have their own energy supply, perhaps to extend the data exchange range. RFID transponders of this type are also known as “semi-active” or “active” transponders. The read devices 5 can then also be embodied as receive facilities for the data transmitted from the RFID transponder.
[0021] The read device 5 transmits the data with the aid of a cable connection or a radio connection based on UMTS or GPRS to the central computation unit 3 . The central computation unit 3 can be located in spatial proximity to the safety-critical traffic zone 1 , perhaps in the control center of a tunnel, or it can be spatially remote, perhaps in a central traffic control center monitoring a number of sections of road. The central computation unit 3 uses the safety-relevant data of all the hazardous material or abnormal load transportation units 7 .n present in the safety-critical traffic zone to determine a safety risk in the safety-critical zone 1 and sets traffic control signals, which reduce the accident risk for a hazardous material or abnormal load transportation unit 7 .n in the safety-critical traffic zone 1 , to avoid an impermissible safety risk.
[0022] In the exemplary embodiment shown according to FIG. 1 there is no further hazardous material or abnormal load transportation unit 7 .n in the safety critical traffic zone 1 , so there is no concern about the entry of the hazardous material or abnormal load transportation unit 7 . 1 . The traffic control facility 6 , perhaps a controllable stop signal, is therefore activated by the central computation unit 3 so that it permits the entry of the hazardous material or abnormal load transportation unit 7 . 1 .
[0023] As shown in FIG. 2 , as a further hazardous material or abnormal load transportation unit 7 . 2 approaches in the entry zone 2 of the safety-critical traffic zone 1 , the safety-relevant data relating to the hazardous material or abnormal load transportation unit 7 . 2 is again read by the corresponding read device 5 and sent to the central computation unit 3 . However the central computation unit 3 has been informed of the presence of the first hazardous material or abnormal load transportation unit 7 . 1 within the safety-critical traffic zone 1 and now takes a decision whether both hazardous material or abnormal load transportation units 7 . 1 and 7 . 2 can be allowed to be present in the safety-critical zone 1 at the same time. For example the sum of the loaded, combustible substances on two hazardous material transportation units 7 . 1 and 7 . 2 could overload the safety systems of a tunnel or buses might not be permitted to enter the tunnel for safety reasons when a hazardous material transportation unit 7 . 1 is passing through, etc. It is also possible for the permitted load for a bridge to be exceeded, if additional hazardous material or abnormal load transportation units 7 .n are allowed into the safety-critical zone 1 , in this instance a bridge. It is also possible for the decision concerning whether a hazardous material or abnormal load transportation unit 7 .n should be allowed into a safety-critical region 1 also to be made taking into account external parameters, such as wind speed in a particularly exposed valley crossing. In this instance it would be possible for a hazardous material or abnormal load transportation unit 7 .n to be refused permission to cross if its cross-sectional surface subject to wind loading were too large, with the corresponding dimensions likewise being among the transmitted safety-relevant data.
[0024] In the exemplary embodiment shown the passage of the hazardous material or abnormal load transportation unit 7 . 2 is to be temporarily prohibited, so the central computation unit 3 sends a stop signal for example to the corresponding traffic control facility 6 ( FIG. 3 ). It would however also be possible for a general speed restriction to be instituted temporarily as a traffic control signal, or another measure known to the person skilled in the art of traffic telematics to reduce the accident risk for a hazardous material or abnormal load transportation unit 7 .n in the safety-critical traffic zone 1 .
[0025] As it leaves the safety-critical traffic zone 1 the first hazardous material or abnormal load transportation unit 7 . 1 passes a read device 5 , which reads out the safety-relevant data of the hazardous material or abnormal load transportation unit 7 . 1 in question and transmits it to the central computation unit 3 . The central computation unit 3 is thus informed that the hazardous material or abnormal load transportation unit 7 . 1 has left the safety-critical traffic zone 1 . As there are no further hazardous material or abnormal load transportation units 7 .n in the safety-critical traffic zone 1 , the waiting hazardous material or abnormal load transportation unit 7 . 2 is allowed to pass ( FIG. 4 ).
[0026] The use of signal transmitters 4 , such as RFID transponders also has the advantage that the loading of hazardous material or abnormal load transportation units 7 .n is known at all times. It is thus possible to optimize rescue measures for example in the event of an accident. Also data relating to the dimensions of the relevant hazardous material or abnormal load transportation unit 7 .n can be compared with local conditions in the safety-critical region 1 , perhaps a subway, to be able to identify potential dangers in this manner.
[0027] The invention thus allows a method or traffic control system for controlling traffic flows including hazardous material or abnormal load transportation units 7 .n through safety-critical traffic regions 1 to be realized, which minimizes the safety risk associated with hazardous material or abnormal load transportation units 7 .n selectively, without impeding the general traffic flow for all other vehicles unnecessarily in the process. | Disclosed are a method and a traffic routing system for controlling traffic flows in which hazardous or special material is transported through safety-critical traffic zones such as tunnels, bridges or locks. In the method and traffic routing system, safety-relevant data is read with the help of a signal transmitter disposed on the transported hazardous or special material and is transmitted to a central computer unit when said vehicle passes reading devices located in the safety-critical traffic zone. The central computer unit determines a safety risk in the safety-critical traffic zone on the basis of the safety-relevant data of all transported hazardous or special material located in the safety-critical traffic zone and sets traffic routing signals. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present disclosure relates generally to the field of telemetry systems for transmitting information through a flowing fluid. More particularly, the disclosure relates to the field of signal detection in such a system.
[0002] Sensors may be positioned at the lower end of a well drilling string which, while drilling is in progress, continuously or intermittently monitor predetermined drilling parameters and formation data and transmit the information to a surface detector by some form of telemetry. Such techniques are termed “measurement while drilling” or MWD. MWD may result in a major savings in drilling time and improve the quality of the well compared, for example, to conventional logging techniques. The MWD system may employ a system of telemetry in which the data acquired by the sensors is transmitted to a receiver located on the surface. Fluid signal telemetry is one of the most widely used telemetry systems for MWD applications.
[0003] Fluid signal telemetry creates pressure signals in the drilling fluid that is circulated under pressure through the drill string during drilling operations. The information that is acquired by the downhole sensors is transmitted by suitably timing the formation of pressure signals in the fluid stream. The pressure signals are commonly detected by a pressure transducer tapped into a high pressure flow line at the surface. Access to, and penetration of, the high pressure flow line may be restricted due to operational and/or safety issues.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] A better understanding of the present invention can be obtained when the following detailed description of example embodiments are considered in conjunction with the following drawings, in which:
[0005] FIG. 1 shows schematic example of a drilling system;
[0006] FIG. 2 shows an example block diagram of the acquisition of downhole data and the telemetry of such data to the surface in an example drilling operation;
[0007] FIGS. 3A-3D show examples of pressure signal transmitter assemblies suitable for use in a fluid telemetry system;
[0008] FIG. 4 shows an example embodiment of an optical interferometer system used to detect downhole transmitted pressure signals;
[0009] FIG. 5 shows an example of a measurement section fiber adhered to a pliant substrate;
[0010] FIG. 6 is a block diagram showing an example of the processing of a received optical signal; and
[0011] FIG. 7 is a chart of laboratory test data showing raw interferometer data and integrated interferometer data compared to conventional pressure sensor data for pressure signal detection.
[0012] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION
[0013] Referring to FIG. 1 , a typical drilling installation is illustrated which includes a drilling derrick 10 , constructed at the surface 12 of the well, supporting a drill string 14 . The drill string 14 extends through a rotary table 16 and into a borehole 18 that is being drilled through earth formations 20 . The drill string 14 may include a kelly 22 at its upper end, drill pipe 24 coupled to the kelly 22 , and a bottom hole assembly 26 (BHA) coupled to the lower end of the drill pipe 24 . The BHA 26 may include drill collars 28 , an MWD tool 30 , and a drill bit 32 for penetrating through earth formations to create the borehole 18 . In operation, the kelly 22 , the drill pipe 24 and the BHA 26 may be rotated by the rotary table 16 . Alternatively, or in addition to the rotation of the drill pipe 24 by the rotary table 16 , the BHA 26 may also be rotated, as will be understood by one skilled in the art, by a downhole motor (not shown). The drill collars add weight to the drill bit 32 and stiffen the BHA 26 , thereby enabling the BHA 26 to transmit weight to the drill bit 32 without buckling. The weight applied through the drill collars to the bit 32 permits the drill bit to crush the underground formations.
[0014] As shown in FIG. 1 , BHA 26 may include an MWD tool 30 , which may be part of the drill collar section 28 . As the drill bit 32 operates, drilling fluid (commonly referred to as “drilling mud”) may be pumped from a mud pit 34 at the surface by pump 15 through standpipe 11 and kelly hose 37 , through drill string 14 , indicated by arrow 5 , to the drill bit 32 . The drilling mud is discharged from the drill bit 32 and functions to cool and lubricate the drill bit, and to carry away earth cuttings made by the bit. After flowing through the drill bit 32 , the drilling fluid flows back to the surface through the annular area between the drill string 14 and the borehole wall 19 , indicated by arrow 6 , where it is collected and returned to the mud pit 34 for filtering. The circulating column of drilling mud flowing through the drill string may also function as a medium for transmitting pressure signals 21 carrying information from the MWD tool 30 to the surface. In one embodiment, a downhole data signaling unit 35 is provided as part of MWD tool 30 . Data signaling unit 35 may include a pressure signal transmitter 100 for generating the pressure signals transmitted to the surface.
[0015] MWD tool 30 may include sensors 39 and 41 , which may be coupled to appropriate data encoding circuitry, such as an encoder 38 , which sequentially produces encoded digital data electrical signals representative of the measurements obtained by sensors 39 and 41 . While two sensors are shown, one skilled in the art will understand that a smaller or larger number of sensors may be used without departing from the principles of the present invention. The sensors 39 and 41 may be selected to measure downhole parameters including, but not limited to, environmental parameters, directional drilling parameters, and formation evaluation parameters. Such parameters may comprise downhole pressure, downhole temperature, the resistivity or conductivity of the drilling mud and earth formations, the density and porosity of the earth formations, as well as the orientation of the wellbore.
[0016] The MWD tool 30 may be located proximate to the bit 32 . Data representing sensor measurements of the parameters discussed may be generated and stored in the MWD tool 30 . Some or all of the data may be transmitted in the form of pressure signals by data signaling unit 35 , through the drilling fluid in drill string 14 . A pressure signal travelling in the column of drilling fluid may be detected at the surface by a signal detector unit 36 employing optical fiber loop 230 . The detected signal may be decoded in controller 33 . The pressure signals may be encoded binary representations of measurement data indicative of the downhole drilling parameters and formation characteristics measured by sensors 39 and 41 . Controller 33 may be located proximate the rig floor. Alternatively, controller 33 may be located away from the rig floor. In one embodiment, controller 33 may be incorporated as part of a logging unit.
[0017] FIG. 2 shows a block diagram of the acquisition of downhole data and the telemetry of such data to the surface in an example drilling operation. Sensors 39 and 41 acquire measurements related to the surrounding formation and/or downhole conditions and transmit them to encoder 38 . Encoder 38 may have circuits 202 comprising analog circuits and analog to digital converters (A/D). Encoder 38 may also comprise a processor 204 in data communication with a memory 206 . Processor 204 acts according to programmed instructions to encode the data into digital signals according to a preprogrammed encoding technique. One skilled in the art will appreciate that there are a number of encoding schemes that may be used for downhole telemetry. The chosen telemetry technique may depend upon the type of pressure signal transmitter 100 used. Encoder 38 outputs encoded data 208 to data signaling unit 35 . Data signaling unit 35 generates encoded pressure signals 21 that propagate through the drilling fluid in drill string 14 to the surface. Pressure signals 21 are detected at the surface by signal detector 36 and are transmitted to controller 33 for decoding. In one example embodiment, signal detector 36 may be a fiber optic signal detector, described below. Controller 33 may comprise interface circuitry 65 and a processor 66 for decoding pressure signals 21 into data 216 . Data 216 may be output to a user interface 218 and/or an information handling system such as logging unit 220 . Alternatively, in one embodiment, the controller circuitry and processor may be an integral part of the logging unit 220 .
[0018] FIGS. 3A-3D show example embodiments of pressure signal transmitter 100 . FIG. 3A shows a pressure signal transmitter 100 a disposed in data signaling unit 35 a . Pressure signal transmitter 100 a has drilling fluid 5 flowing therethrough and comprises an actuator 105 that moves a gate 110 back and forth against seat 115 allowing a portion of fluid 5 to intermittently pass through opening 102 thereby generating a negative pressure signal 116 that propagates to the surface through drilling fluid 5 .
[0019] FIG. 3B shows a pressure signal transmitter 100 b disposed in data signaling unit 35 b . Pressure signal transmitter 100 b has drilling fluid 5 flowing therethrough and comprises an actuator 122 that moves a poppet 120 back and forth toward orifice 121 partially obstructing the flow of drilling fluid 5 thereby generating a positive pressure signal 126 that propagates to the surface through drilling fluid 5 .
[0020] FIG. 3C shows a pressure signal transmitter 100 c disposed in data signaling unit 35 c . Pressure signal transmitter 100 c has drilling fluid 5 flowing therethrough and comprises an actuator 132 that continuously rotates a rotor 130 in one direction relative to stator 131 . Stator 131 has flow passages 133 allowing fluid 5 to pass therethrough. Rotor 130 has flow passages 134 and the movement of flow passages 134 past flow passages 133 of stator 131 generates a continuous wave pressure signal 136 that propagates to the surface through drilling fluid 5 . Modulation of the continuous wave pressure signal may be used to encode data therein. Modulation schemes may comprise frequency modulation and phase shift modulation.
[0021] FIG. 3D shows a pressure signal transmitter 100 d disposed in data signaling unit 35 d . Pressure signal transmitter 100 d has drilling fluid 5 flowing there through and comprises an actuator 142 that rotates a rotor 140 back and forth relative to stator 141 . Stator 141 has flow passages 143 allowing fluid 5 to pass therethrough. Rotor 140 has flow passages 144 and the alternating movement of flow passages 144 past the flow passages 143 of stator 141 generates a continuous wave pressure signal 146 that propagates to the surface through drilling fluid 5 . Modulation of the continuous wave pressure signal may be used to encode data therein. Modulation schemes may comprise frequency modulation and phase shift modulation.
[0022] FIG. 4 shows an example of signal detector 36 configured as an optical interferometer 200 for detecting pressure signals in conduit 211 . Interferometer 200 comprises a light source 202 , an optical fiber loop 230 , an optical coupler/splitter 215 , and an optical detector 210 . Light source 200 may be a laser diode, a laser, or a light emitting diode that emits light into optical coupler/splitter 215 where the light is split into two beams 231 and 232 . Beam 231 travels clockwise (CW) through loop 230 , and beam 232 travels counter-clockwise (CCW) through loop 230 .
[0023] Loop 230 has a length, L, and comprises measurement section 220 and delay section 225 . In one embodiment, measurement section 220 may be 2-10 meters in length. In this example, measurement section 220 is wrapped at least partially around conduit 211 , which may be standpipe 11 of FIG. 1 . Alternatively, measurement section 220 may be wrapped around any section of flow conduit that has pressure signals travelling therein. The length of measurement section 220 is designated by X in FIG. 4 , and represents the length of fiber that reacts to hoop strains in standpipe 11 caused by the pressure signals therein. The optical fibers of measurement section 220 may be physically adhered to conduit 211 . Alternatively, see FIG. 5 , measurement section 220 may comprise a length, X, of optical fiber 302 adhered in a folded pattern to a pliant substrate 300 that is attachable to a conduit. In one embodiment, pliant substrate 300 may be a biaxially-oriented polyethylene terephthalate material, for example a Mylar® material manufactured by E.I. Dupont de Nemours & Co. Pliant substrate 300 may be adhesively attached, for example, to standpipe 11 of FIG. 1 using any suitable adhesive, for example an epoxy material or a cyanoacrylate material.
[0024] Delay section 225 may be on the order of 500-3000 meters in length. The small diameter of optical fibers contemplated (on the order of 250 μm) allows such a length to be wound on a relatively small spool. As shown in FIG. 4 , delay section 225 comprises a length identified as L−X. It will be seen that L is a factor in the sensitivity of the sensor.
[0025] Counter-propagating beams 231 , 232 traverse loop 230 and recombine through coupler/splitter 215 , and detected by photo-detector 210 . Under uniform (constant in time) conditions, beams 231 , 232 will recombine in phase at the detector 210 because they have both traveled equal distances around loop 230 . Consider counter-propagating beams 231 , 232 and a time varying pressure P(t) in standpipe 11 . Beams 231 , 232 will be in phase after they have traveled the distance X in their two paths, and they will be in phase after they have continued through the distance L−X as well. Now, let the pressure within the pipe be changing at a rate of dP/dt during the time Δt while beams 231 , 232 travel the distance L−X, then
[0000] Δ t= ( L−X ) n/c,
[0026] where c is the speed of light, and n is the refractive index of the optical fiber. During this time interval, the pressure within the pipe changes by an amount ΔP, which acts to radially expand standpipe 11 . This expansion results in a change ΔX in the length, X, of the measurement section 220 of optical fiber 230 wrapped around conduit 211 . Although at the end of the interval Δt the two beams are in phase, they will go out of phase for the last portion of the circuit before they recombine, because the length of measurement section 220 has changed during the previous interval Δt. For the final leg of the trip around the loop, the counter-clockwise beam 232 will travel a distance that is different by an amount ΔX from the clockwise rotating beam 231 . When the beams combine at detector 210 , they will be out of phase by a phase difference, Δφ, where
[0000] Δφ=2π(Δ X )/ nλ,
[0027] where λ is the wavelength of the light emitted by source 202 . As beams 231 , 232 are combined, it can be shown that a factor in the signal will be cos(Δφ/2). Thus, counter propagating beams 231 , 232 will be out of phase when ΔX=λ.
[0028] The change of the pressure in the pipe during the interval Δt is given by
[0000] Δ P =( dP/dt )Δ t =( dP/dt )( L−X )( n/c ).
[0000] Let K be the sensitivity of the pipe to internal pressure; that is, the change in circumference of the pipe ΔC due to a change in pressure ΔP given by,
[0000] Δ C=K (Δ P )
[0000] K can be computed from dimensions and material properties of the pipe materials. For example, for a thin-walled pipe, where D pipe >10*pipe thickness, t, it can be shown that
[0000] K=πD pipe 2 /2 Et
[0029] where E is the modulus of elasticity of the pipe material.
[0000] For a thick walled pipe, where D pipe ≦10*pipe thickness, t, it can be shown that
[0000] K= 2 πD o D i 2 /E ( D o 2 −D i 2 )
[0030] where D o and D i are the outer and inner pipe diameters, respectively.
[0000] If N coil is the number of turns of fiber around the pipe, then
[0000] Δ X=N (Δ C )= N coil K ( dP/dt )( L−X )( n/c ).
[0000] Thus, the change in length indicated by the interferometer is a function of the time derivative of the pressure signal, the number of turns N coil of fiber on the pipe, and the length L of the delay portion of the fiber.
[0031] FIG. 6 is a block diagram showing an example of the processing of a received optical signal using interferometer 200 . Counter propagating beams 231 , 232 travel through optical fiber 230 comprising measurement section 220 and delay section 225 . In this example, delay section 225 comprises multiple loops of optical fiber around a spool. Pressure signal 21 causes a lengthening of measurement section 220 which produces a phase shift in the recombined beams at detector 210 , as described previously. Detector 210 outputs a phase shift signal that is conditioned by signal conditioner 312 and outputs as an analog signal proportional to the time derivative of pressure dp/dt at 314 . The signal 314 is transmitted to A/D in block 316 where the dp/dt signal is digitized. The digitized dp/dt signal is integrated in block 318 to produce a digital signal similar to the original pressure signal P(t). The P(t) signal is then decoded in block 320 to produce data 216 . Data 216 may be used in log modules 324 to produce logs 326 . In one embodiment, optical source 202 , optical detector 210 , and signal conditioner 312 may be physically located close to conduit 211 in signal detector 36 . Alternatively, some of these items may be located away from conduit 211 , for example in controller 33 . The functional modules 316 , 318 , 320 , 324 , and 326 may comprise hardware and software and may be located in controller 33 . In one embodiment, controller 33 may be a stand alone unit located in a separate location, for example a logging unit. Alternatively, controller 33 may be an integral part of a logging unit using shared hardware and software resources. While described above with reference to a single optical signal detector on a conduit, it is intended that the present disclosure cover any number of such detectors space out along such a conduit.
[0032] FIG. 7 is a chart of laboratory test data showing raw interferometer data and integrated interferometer data compared to conventional pressure sensor data for pressure signal detection. Pressure signals are generated in a flowing fluid in a flow loop. A pressure signal transmitter generates pressure signals into the flowing fluid. An interferometer similar to interferometer 200 is installed on a section of conduit. A conventional strain gauge pressure sensor is mounted within 2 m of the interferometer. FIG. 7 shows the raw interferometer data proportional to dp/dt in curve 700 . The raw data is processed as described above to produce an integrated interferometer curve 710 . Curve 705 is the reading from the conventional pressure transducer. As shown in FIG. 7 , integrated interferometer curve 710 is substantially similar to conventional pressure transducer curve 705 .
[0033] Numerous variations and modifications will become apparent to those skilled in the art. It is intended that the following claims be interpreted to embrace all such variations and modifications. | An apparatus for detecting data in a fluid pressure signal in a conduit comprises an optical fiber loop comprises a measurement section and a delay section wherein the measurement section is disposed substantially circumferentially around at least a portion of the conduit, and wherein the measurement section changes length in response to the fluid pressure signal in the conduit. A light source injects a first optical signal in a first direction into the measurement section and a second optical signal in a second direction opposite the first direction into the delay section. An optical detector senses an interference phase shift between the first optical signal and the second optical signal and outputs a first signal related thereto. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. §119(e)(1) of U.S. provisional application No. 60/242,044, entitled METHOD OF FABRICATION OF INTEGRATED OPTICAL STRUCTURES HAVING PLURAL WAVEGUIDE STRUCTURES by inventors Petrov et al., filed on Oct. 20, 2000. The aforementioned application is incorporated herein by reference.
GOVERNMENT RIGHTS
This invention was made with Government support under contract no. NAS-00090 awarded by the National Aeronautics and Space Administration. The Government has certain rights in the invention.
BACKGROUND
1. Field of the Invention
The present invention relates generally to methods for fabricating optical waveguides, and more specifically to methods for fabricating plural waveguide sections in a single substrate.
2. Description of the Prior Art
Formation of waveguides in lithium niobate (LN) and similar optical materials is typically accomplished by one of two well-known processes: titanium indiffusion and annealed proton exchange (APE). The APE process is increasingly favored over titanium indiffusion for commercial manufacturing applications due in part to the high temperatures required to achieve waveguide formation by the titanium indiffusion process.
APE traditionally involves a first step of exposing selected regions of an LN substrate to an acidic medium (deemed the proton exchange step), followed by a second step of maintaining the LN substrate at an elevated temperature for a specified time period (deemed the annealing step).
The physical and operational characteristics of waveguides fabricated by the APE process may be optimized for a particular application by tuning the process parameters. For conventional APE, the process parameters consist of the following:
Channel width (w)
Channel duty cycle (η)
Proton exchange time (t e )
Proton exchange temperature (T e )
Exchange agent
Anneal time (t a )
Anneal temperature (T a )
It is noted that not all of the foregoing process parameters are independent, and that some of the parameters may not be easily varied. For example, the exchange agent (the acidic medium selected to effect proton exchange), which controls overall proton exchange rate at a given temperature, is generally considered to be a fixed parameter, due to the limited availability of acidic media which do not produce etching of the LN substrate.
It is further noted that the proton exchange time and temperature parameters t e and T e are mutually dependent, i.e., one can control exchange depth by adjusting either process time or temperature. Similarly, the anneal time and temperature t a and T a are mutually dependent. Because of these dependencies, the process temperatures T e and T a are generally considered to be fixed, and only the process times are varied.
The limitations and dependencies discussed above effectively reduces the total number of independent APE process parameters to four: w, η, t e , and t a (it is recognized that there exists a weak interdependence between w and η; however, this weak interdependence may be ignored for the purpose of this discussion). The designer of the waveguide-containing device may thus select appropriate values of channel width and duty cycle (which are controlled by adjusting the shape and dimensions of the mask defining the regions exposed to the acidic medium) and exchange and anneal times in order to produce a waveguide having desired physical and operational characteristics.
A problem arises in cases where an integrated optical component designer wishes to fabricate two or more waveguide structures having differing physical or operational characteristics in the LN substrate. In conventional APE waveguide fabrication, all waveguide structures are simultaneously formed in the LN substrate, i.e., a single APE process is employed. Due to the relatively limited number of independent process parameters that may be adjusted, it may be difficult or impossible to select a single set of process parameters that produce the desired physical and operational characteristics in all of the waveguide structures. In other words, a single-stage APE process does not offer a sufficient number of degrees of freedom to optimize fabrication of plural waveguide structures having disparate properties.
For example, a three-section coupler for use in a difference-frequency mixing application may include an input waveguide structure, having a relatively narrow channel width, coupled via an adiabatic taper structure to a multimode mixing waveguide structure having a relatively broad channel width. If the coupler is formed by conventional APE, the anneal time t a is set by the requirements of the multimode mixing (wide-channel) waveguide structure, and is consequently very long. This long t a results in excessive proton diffusion in the narrow-channel input waveguide structure, causing the mode size propagating therein to be relatively large. This condition is undesirable, as it prevents matching of the input waveguide mode to a standard optical fiber mode and thereby complicates the task of launching light into the three-section coupler.
U.S. Pat. No. 5,982,964 to Marx et al. describes one approach for creating additional degrees of process freedom to enable separate optimization of the characteristics of different waveguide structures formed in a common substrate. Marx et al. discloses fabricating a first waveguide structure by the titanium indiffusion process, which, as alluded to above, requires high-temperature conditions (approximately 1000° C.) to enable titanium diffusion into the substrate to occur at an industrially practical rate. The titanium-indiffusion process is followed by fabrication of a second waveguide section by APE, which is performed at a relatively low exchange and anneal temperatures T e and T a (typically 275° C. and 400° C., respectively). Because the titanium atoms possess very low mobility at the exchange and anneal temperatures, the first waveguide structure remains substantially unchanged during the APE process. In this manner, the parameters of the titanium-indiffusion and APE processes may be independently tuned to optimize desired characteristics in the first and second waveguide structures. It is noted, however, that the Marx et al. approach increases the complexity (and potentially the cost) of manufacture of integrated optical devices by requiring use of two different waveguide fabrication processes operating at different temperature ranges.
SUMMARY
Roughly described, the invention provides a method for forming plural waveguide structures having separately optimized physical and optical characteristics in a common optical substrate. The method comprises a first APE stage, including a first proton exchange step and a first annealing step, wherein protons are diffused into a first region of the optical substrate corresponding to at least a first waveguide structure, and a second APE stage, including a second proton exchange step and a second annealing step, wherein protons are diffused into a second region of the substrate different from the first region and corresponding to at least a second waveguide structure. The first and second regions of the substrate may be defined by openings in first and second masks, which are deposited on the substrate and patterned using conventional techniques. A set of process parameters (e.g., time/temperature conditions, mask channel width, duty cycle, and exchange agent) is selected for each APE stage so as to obtain targeted optical and physical properties in the associated waveguide structure. In effect, the method expands the number of degrees of process freedom relative to a conventional single-stage APE process to thereby enable each waveguide structure to be independently optimized.
The multi-stage APE method of the present invention may be advantageously utilized to fabricate any number of high-performance, compact integrated optics devices, including without limitation sub-Rayleigh range couplers and surface step couplers.
BRIEF DESCRIPTION OF THE FIGURES
In the accompanying drawings:
FIG. 1 is a flowchart depicting the steps of a two-stage APE method in accordance with an embodiment of the invention;
FIGS. 2 ( a )-( c ) are symbolic perspective views depicting the formation of a first waveguide structure in an optical substrate at various points of the multi-stage APE method;
FIGS. 3 ( a )-( c ) are symbolic perspective views depicting the formation of a second waveguide structure in the optical substrate at various points of the multi-stage APE method;
FIG. 4 is a longitudinal cross-sectional view taken through line A—A of FIG. 3 ( c ), showing in particular the spatial relationship of the first and second waveguide structures;
FIG. 5 depicts plots showing typical profiles of mode intensity versus depth within the first and second waveguide structures of FIG. 4;
FIG. 6 is a longitudinal cross-sectional view of a step-coupler device comprising first and second waveguide structures formed in an optical substrate by the FIG. 1 method;
FIG. 7 depicts plots showing typical profiles of mode intensity versus depth within the first and second waveguide structures of FIG. 6;
FIG. 8 is a symbolic fragmentary top plan view of a coupler device formed by the FIG. 1 method; and
FIG. 9 is a symbolic fragmentary plan view of a compact optical difference frequency generator device, a portion of which is formed by the FIG. 1 method.
DETAILED DESCRIPTION
The invention will now be described in terms of various embodiments and implementations thereof, which are intended to illustrate rather than limit the invention. FIG. 1 is a flowchart depicting the steps of a two-stage APE method for constructing plural integrated waveguide structures in accordance with one embodiment of the invention. The method of FIG. 1 may best be understood in connection with its application to an exemplary optical device shown in various stages of its fabrication in FIGS. 2 ( a )-( c ) and 3 ( a )-( c ).
Reference is initially directed to FIG. 1 a , which shows a substrate in the form of a wafer 200 of lithium niobate (LN) material. As used herein, the term “lithium niobate” is intended to include both pure lithium niobate in its different compositional variations such as congruent and stoichiometric material, as well as lithium niobate doped with magnesium oxide, zinc oxide or other dopants that may be added for various purposes. Wafer 200 may alternatively comprise another suitable optically transparent material in which index-altered waveguide regions may be formed by a proton exchange process. It is noted that wafer 200 may be a representative portion of a larger wafer on which numerous optical devices may be formed.
In a first step 102 of the method, a first masking layer 202 is deposited to a suitable thickness on the upper major surface of wafer 200 . First masking layer 202 may also be applied to the edge and lower major surfaces of wafer 200 . First masking layer 202 will comprise a material such as silicon dioxide (SiO 2 ) capable of blocking contact between the exchange agent and the underlying portions of wafer 200 , and may be applied by any one of a number of techniques known in the art, including without limitation physical or chemical vapor deposition and sputtering.
In a second step 104 , an opening 204 of width 206 in a shape and position corresponding to a first optical waveguide structure is formed in first masking layer 202 . Opening 204 may be formed by any suitable technique known in the art, such as a photolithographic/etching based method or laser ablation. In the example depicted in FIG. 2 ( a ), which shows the substrate and masking layer following completion of step 104 , the width 206 of opening 204 is chosen to be suitable for a wide-channel optical waveguide structure, such as one designed to be single mode at a long wavelength, or multi-mode at a short wavelength. Opening 204 is shown to be closed at one end 208 , where the wide-channel optical waveguide structure will terminate, but may extend farther in the opposite direction as desired for different applications. Opening 204 is further shown to be straight and of substantially constant width 206 , but may alternatively be curved, tapered and/or segmented, again as desirable for different applications.
In the third step 106 , a proton exchange agent is applied to wafer 200 to form a protonated layer 210 in regions of wafer 200 underlying opening 204 . The proton exchange step 106 is typically conducted by contacting at least the upper major surface of wafer 200 (having masked layer 202 applied thereto) with a first proton exchange agent bath held at a first exchange temperature T 1e for a first exchange time t 1e . The first exchange agent will typically take the form of a weak or moderate strength organic acid, such as benzoic acid. The first proton exchange step conditions, including first exchange time, temperature T 1e (noting the dependency of the two parameters), and exchange agent are selected to produce a desired degree of protonation of layer 210 . In a typical implementation of the present method, T 1e is around 160° C., and t 1e is approximately 25 hours. Following completion of the first proton exchange step 106 , wafer 200 is removed from the exchange agent bath, and first masking layer 202 is stripped from the wafer 200 , step 108 . Stripping of first masking layer 202 may be achieved using a suitable etch solution or similar expedient known in the art.
FIG. 2 ( b ) depicts wafer 200 after completion of the first proton exchange and mask removal steps 106 and 108 . Protonated layer 210 has a width 213 substantially equal to width 206 of mask opening 204 , and a relatively small depth 212 extending downwardly into wafer 200 .
In the fourth step 110 , wafer 200 is annealed to form a deeper (relative to protonated layer 210 ) protonated channel 214 . Annealing of wafer 200 is typically performed by uniformly heating wafer 200 to a first anneal temperature and maintaining it at T 1a for a first anneal time t 1a . As will be discussed in further detail below, the first anneal conditions, including first anneal time t 1a and temperature T 1a , are chosen in view of the desired optical and physical properties of the associated resultant first waveguide structure, including waveguide depth and width, refractive index profile, and mode confinement. Typical anneal conditions for first anneal step 110 set T 1a to about 340° C. and t 1a , to approximately 75 hours. FIG. 2 ( c ), which depicts wafer 200 following completion of the first anneal step 110 , shows protonated channel 214 as having a significantly greater depth 216 and somewhat larger width 218 relative to depth 212 and width 213 of protonated layer 210 . As is known in the art, the depth 216 and width 218 of protonated channel 214 are controlled primarily by adjusting the first anneal time t 1a and/or temperature T 1a , wherein higher anneal temperatures and/or longer anneal times will produce a greater depth 216 and width 218 .
Next, a second masking layer 302 is deposited on at least the upper major surface of wafer 200 , step 112 . Second masking layer 302 will again typically comprise a material, such as SiO 2 , capable of blocking contact between the exchange agent and the underlying portions of wafer 200 , and may be applied by any one of a number of techniques known in the art, including without limitation physical or chemical vapor deposition and sputtering.
In step 114 , an opening 304 in a shape and position corresponding to a second optical waveguide structure is formed in second masking layer 302 , as depicted by FIG. 3 ( a ). Formation of opening 304 may be accomplished in substantially the same manner as described above in connection with FIG. 2 ( a ). It is noted that in the implementation depicted herein, opening 304 has a width 306 significantly narrower than width 206 of opening 204 in first masking layer 202 . As will be discussed below in further detail, the first or initial stage(s) of the multi-stage APE process will generally be employed to form waveguide structures having relatively large transverse dimensions, whereas the second or subsequent stages are employed to form waveguide structures having relatively small transverse dimensions. Opening 304 may be precisely positioned with respect to the previously formed protonated channel 214 using fiducial marks or similar alignment techniques.
Opening 304 is shown to be closed at one end 308 at the termination of the corresponding narrow-channel (second) waveguide structure, but may extend farther in the opposite direction as desired for particular applications. Opening 304 is shown to be straight and of substantially constant width 306 but may alternatively be curved, tapered and/or segmented, as desirable for different applications.
In the next step 116 , a proton exchange agent (which is typically, but not necessarily, the same exchange agent used for the first proton exchange step 106 ) is applied to wafer 200 to form a protonated layer 310 in regions of wafer 200 immediately underlying opening 304 . The second proton exchange step 116 may be performed by contacting at least the upper major surface of wafer 200 (with masked layer 302 fixed thereto) with a second exchange agent held at a second exchange temperature T 2e for a second exchange time t 2e . The second exchange agent will again typically take the form of a weak or moderate strength organic acid, such as benzoic acid. The second proton exchange step conditions, including second exchange time t 2e , temperature T 2e , and exchange agent are selected to produce a desired degree of protonation of layer 310 . In a typical implementation of the present method, T 2e is around 160° C., and tie is approximately one hour. Following completion of the second proton exchange step 116 , wafer 200 is removed from the exchange agent bath, and second masking layer 302 is stripped from the wafer 200 , step 118 . Stripping of second masking layer 302 may be achieved using a suitable etch solution or similar expedient known in the art.
FIG. 3 ( b ) depicts wafer 200 after completion of the proton exchange and mask removal steps 116 and 118 . It is noted that protonated layer 310 , which abuts at one end thereof protonated channel 214 , has a width substantially equal to width 306 of mask opening 304 , and a relatively small depth extending downwardly into wafer 200 .
In the final step 120 , wafer 200 is subjected to a second annealing step to form a deeper protonated channel 312 . The second annealing step 120 involves uniformly heating wafer 200 to a second anneal temperature T 2a (which will typically, but not necessarily, be substantially equal to first anneal temperature T 1a ) and maintaining it at T 2a for a second anneal time t 2a . The parameters of second anneal time t 2a and/or temperature are selected to effect a targeted amount of diffusion of protons initially contained within protonated layer 214 and thereby cause the second waveguide structure to possess the desired set of physical and operational characteristics. Because of the relatively smaller dimensions of the second waveguide structure (defined by the dimensions of protonated channel 312 ), the second anneal time required for sufficient proton diffusion will generally be significantly shorter than the first anneal time t 1a (assuming that the anneal temperatures T 1a and T 2a are constant). Typical second anneal conditions have T 2a equal to approximately 340° C. and t 2a equal to around 10 hours.
FIG. 3 ( c ) depicts wafer 200 following completion of second anneal step 120 . Because the entire wafer is brought to an elevated temperature during the second anneal step, proton diffusion will also occur within protonated channel 214 (which, together with the surrounding portions of substrate 200 , defines first waveguide structure 314 ) resulting in some deepening and widening of the channel. The device designer will therefore adjust the anneal conditions for the first anneal step 110 to account for additional diffusion effected during the subsequent anneal steps (which, in the present example, consists of second anneal step 120 ). For example, the designer may set the first anneal time t 1a such that the total anneal time (t 1a +t 2a ) yields the desired physical/operational qualities of first waveguide structure. It will be recognized that second waveguide structure 316 (defined by protonated channel 312 and surrounding portions of the substrate 200 ) is subjected only to a single anneal step 120 and so its operational and physical characteristics do not depend on the conditions under which first anneal step 110 is performed.
In essence, the above-described waveguide fabrication method, which provides two proton exchange/annealing stages, expands the number of degrees of process freedom and enables the designer to select a separate set of process parameters (including mask width, proton exchange time/temperature conditions, annealing time/temperature conditions, and duty cycle) for each stage. The availability of these additional degrees of process freedom thereby enables independent optimization of the characteristics of the two resultant waveguide structures 314 and 316 .
It will be apparent to one skilled in the art that the method described above can be extended to any number of exchange/anneal stages, and to other geometrical shapes of refractive index-modified regions besides optical waveguides, wherein a plurality of progressively smaller-featured integrated optical structures are fabricated in succession.
The method of the invention enables, inter alia, fabrication of improved integrated optical devices employing narrow-channel and wide-channel optical waveguides on the same substrate. Referring again to FIG. 3 ( c ), optical waveguide structures 314 and 316 are shown to be aligned along a common optical axis 318 with their facing ends immediately adjacent to each other at a plane 320 that is perpendicular to both the wafer surface and optical axis 318 . This arrangement represents a short, sub-Rayleigh range narrow-channel to wide-channel waveguide junction, which has desirable qualities of mode matching and consequent high coupling efficiency at the coupling plane indicated at 320 . It should be apparent to those familiar with the art that a suitable number of tunable process parameters are provided in this method to optimize such a structure, both in terms of optical mode overlap at 320 and low-loss waveguides on either side of plane 320 , whereas the conventional one-step annealed ion-exchange waveguide fabrication method (and other known methods using different processes) do not provide the degrees of freedom or capabilities required for optimization to the same degree.
The optical mode overlap of the sub-Rayleigh range waveguide junction may be further explained with reference to FIG. 4 and 5. FIG. 4 is a cross-sectional view taken along the line A—A identified in FIG. 3 ( c ). The narrow-channel (second) waveguide structure 316 and wide-channel (first) waveguide structure 314 are shown in heavy shading, and their junction is shown disposed at plane 320 . FIG. 5 depicts exemplary profiles of local light intensity I in the two waveguide structures 314 and 316 (measured at longitudinal positions 404 and 406 ) plotted as a function of depth y (measured from the wafer surface in the Y-direction), for light at a wavelength that is propagating as a weakly confined single mode in second waveguide structure 316 and as the (more confined) fundamental mode of multiple propagation modes in first waveguide structure 314 . The intensity profiles within waveguide structures 314 and 316 are respectively shown as solid and dotted lines. It may be discerned that the mode profiles within the two waveguide structures 314 and 316 exhibit substantial overlap, suggesting high coupling efficiency at the junction of the waveguide structures. It should be understood that the specific optical waveguide properties shown here such as the particular mode properties, profiles and degree of confinement of light are presented for illustrative purposes and that other mode properties and shapes can be employed in different applications while conforming to the principles described.
Another integrated optical device enabled by the method of this invention is a surface step device (referred to hereinbelow as a “step coupler”), which provides efficient selective coupling of light from a single mode optical waveguide structure to a higher mode of a multi-mode optical waveguide structure. FIG. 6 is a fragmentary cross-sectional view of a portion of an exemplary step coupler 600 . Step coupler 600 is closely similar in its construction to the sub-Rayleigh range junction device depicted in FIGS. 2-4 and described above, with the principal difference being the inclusion of a surface step 602 . Surface step 602 causes wafer surface 604 overlying narrow-channel waveguide structure 606 to be lower, in the Y-direction, than surface 608 overlying wide-channel waveguide structure 610 . Step 602 may be in the form of a trench containing, and slightly wider than, the narrow-channel waveguide structure, or extending over a wider region of the wafer surface as appropriate for different applications. The trench may be fabricated by a known method such as etching, ion milling, or laser ablation. The height difference Y step of the surface step can be appropriately chosen as explained below.
FIG. 7 depicts exemplary profiles of local light intensity I in the two waveguide structures 606 and 610 (measured at longitudinal positions 620 and 622 ) plotted as a function of depth y (measured from the wafer surface in the Y-direction), for light at a wavelength that is propagating as a weakly confined single mode in narrow-channel waveguide structure 606 and as a “One-Zero” (1,0) higher-order mode in wide-channel waveguide structure 610 . The intensity profiles within waveguide structures 610 and 606 are respectively shown as dotted and solid lines. The mode profile of the “One-Zero” mode in the wide-channel waveguide (dotted line) has two peaks corresponding to two lobes as known in the art. The step height y step is selected to provide good mode overlap and efficient coupling from the narrow-channel (single-mode waveguide) into a selected higher-order mode of the wide-channel (multimode) waveguide structure, which in this case is the “One-Zero” mode.
Alternatively by appropriate choice of waveguide width, depth, refractive index profile, and step height, a step coupler may provide efficient coupling into other higher-order modes.
Other improved integrated optical devices enabled by the method of this invention are depicted in FIGS. 8 and 9. FIG. 8 shows a portion of an optical substrate 800 adapted with a narrow-channel optical waveguide structure 802 and a wide-channel optical waveguide 804 . Waveguides structures 802 and 804 are preferably fabricated by the two-stage APE method described above in connection with FIG. 1 . Waveguide 802 has a bend of radius r. It is known in the art that such bends cannot have curvature of small radius (measured in units of channel width) without incurring significant radiative loss of light propagating in the waveguide, and thus the minimum area required on the wafer surface for a low-loss bend scales approximately with the square of the waveguide channel width. Waveguide 802 has a small channel width, and consequently can have a small bend radius r. It can therefore take up a small region of the substrate 800 area, which is desirable to provide higher integration density on a chip. With the fabrication method of this invention, optimum parameters, such as confinement of light, can be realized in both waveguide structures 802 and 804 . In alternative embodiments, a different type of large, high-refractive index optical structure may be substituted for wide-channel optical waveguide structure 804 as suitable other applications.
Referring to FIG. 9, there is shown a compact integrated optical difference frequency generator device 900 formed on an optical substrate 902 . Device 900 comprises narrow-channel waveguide structures 904 having short-wavelength input ports 906 and 908 , a wide-channel waveguide structure 910 with output port 912 , a waveguide directional coupler 914 utilizing small-radius waveguide bends formed according to an embodiment of this invention, a sub-Rayleigh range waveguide junction 916 again formed in accordance with an embodiment of the invention, and a periodically poled nonlinear optical region 918 . In a particular implementation of device 900 designed for input light wavelengths of 1,083 nm and 834 nm, with a nonlinear region 918 that is approximately 1.5 cm long, has been observed to generate light at an output wavelength of, 3,630 nm with an efficiency of 0.58%/W per cm 2 (of nonlinear region length). The smaller size of the waveguide bends, directional coupler, and narrow-to-wide channel waveguide junction, compared to known art, is desirable for higher optical integration density and consequent reduced cost of such devices.
It should be appreciated that the two-stage waveguide fabrication method may be utilized in connection with ionic transfer processes other than proton exchange, and with optical substrate materials other than lithium niobate. For example, the two-stage fabrication method may also be applied to waveguide fabrication in glasses (such as zinc-borosilicate 0211 glass available from Corning Incorporated of Corning, N.Y.) using silver-sodium ion exchange. Other suitable alternative ionic transfer processes that may be employed in connection with the invention include reverse proton exchange and field-assisted ion exchange.
It should be further appreciated by those skilled in the art that, while the invention has been described above in terms of preferred embodiments, it is not limited thereto. Various features and aspects of the above-described invention may be used individually or jointly. Further, although the invention has been described in the context of its implementation in a particular environment and for particular applications, those skilled in the art will recognize that its usefulness is not limited thereto and that the present invention can be beneficially utilized in any number of environments and implementations. | A method for forming plural waveguide structures in an optical substrate, such as lithium niobate, employs multiple stages of annealed proton exchange. In each stage, the substrate is masked to define a region corresponding to at least one waveguide structure. The mask-defined region is exposed to a proton exchange agent for a predetermined time and at a predetermined temperature, and the substrate is then annealed at predetermined time/temperature conditions. By selecting appropriate process parameters for each APE stage, each of the resultant waveguide structures may be optimized for desired physical and optical characteristics. The method may be utilized, for example, to fabricate sub-Rayleigh range couplers having high coupling efficiencies. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Application No. 61/580,035, filed on Dec. 23, 2011, which is incorporated herein by reference in its entirety.
FIELD
[0002] The present disclosure relates to fluidic devices that can facilitate preparation of samples. Moreover, it relates to sample preparation devices and systems.
BACKGROUND
[0003] A variety of methods are available to prepare fluidic samples for performing scientific experiments. However, some devices used for preparing samples can be expensive, bulky, and can have large dead volume space. Low cost, portable, reliable, and easy to use devices can be desirable to overcome such problems. With improved sample preparation devices, scientific analysis such as PCR, ELISA, or fluorescence/absorbance analysis can be perform more easily and accurately.
SUMMARY
[0004] According to a first aspect, a device for performing fluidic operations is described, the device comprising: a fluidic chamber having a plurality of pairs of ports, a first port of each pair being located on a first side of the fluidic chamber and a second port of each pair being located on a second side of the fluidic chamber, each second port being opposite a respective first port; a plurality of reservoirs adapted to be fluidly connected with the fluidic chamber at each of the plurality of pairs of ports, the plurality of reservoirs configured to flow fluid from a reservoir on the first side of the fluidic chamber to a reservoir on the second side of the fluidic chamber, or vice versa; and a structure slidably moveable within the fluidic chamber, the structure having one or more openings adapted to be aligned through sliding of the structure with at least one pair of ports to allow fluidic connection between one or more reservoirs on the first side and respective one or more reservoirs on the second side, the one or more openings being alignable with a desired pair of ports through said sliding.
[0005] According to a second aspect, a device for performing fluidic operations is described, the device comprising: an adapter comprising at least one pair of ports; a plurality of reservoirs fluidly connectable with the at least one pair of ports, the plurality of reservoirs configured to flow fluid from at least a first reservoir to at least a second reservoir; and a first structure associated with the adapter and displaceable with respect to the adapter, the first structure comprising a first channel arrangement configured to fluidly connect the at least first reservoir with the at least second reservoir, the first channel arrangement being alignable with a desired pair of ports through displacement of the first structure.
[0006] According to a third aspect, a device for performing fluidic operations is described, the device comprising: a first fixed structure and a second fixed structure having a plurality ports; a plurality of reservoirs adapted to be fluidly connected with the plurality of ports, the plurality of reservoirs configured to flow fluid from a reservoir associated with the port on the first fixed structure to a reservoir associated with the port on the second fixed structure, or vice versa; and a structure slidably moveable between the first fixed structure and the second fixed structure, the structure having one or more openings adapted to be aligned through sliding of the structure with at least one port of the first fixed structure and at least one port of the second fixed structure to allow fluidic connection between one or more reservoirs associated with the first fixed structure and respective one or more reservoirs associated with the second fixed structure, the one or more openings being alignable with a desired pair of ports through said sliding.
[0007] According to a fourth aspect, a method of performing fluidic operations using the device according to claim 2 is described, the method comprising: a) slidably moving the structure to align the at least one opening with a first pair of ports; b) transferring the fluid from the reservoir on the first side of the fluidic chamber to the reservoir on the second side of the fluidic chamber by flowing the fluid through the functional element in the opening; and c) repeating a)-b) a desired number of times.
BRIEF DESCRIPTION OF DRAWINGS
[0008] The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more embodiments of the present disclosure and, together with the description of example embodiments, serve to explain the principles and implementations of the disclosure.
[0009] FIGS. 1-7 show cross-sectional views of exemplary fluidic devices with a structure being slidably moveable in an axial direction.
[0010] FIGS. 8-9 show cross-sectional views of exemplary fluidic devices with a structure being slidably moveable in a radial direction.
[0011] FIGS. 10 , 12 A- 12 E show cross-sectional and perspective views of fluidic devices with a displaceable structure.
[0012] FIG. 13 shows the displaceable structure with a fluidic channel and a functional element.
[0013] FIG. 14 shows a second displaceable structure located above another displaceable structure.
[0014] FIG. 15 shows a perspective view of the displaceable structure associated with an adapter.
[0015] FIG. 16 shows a close-up cross-sectional view of the displaceable structure associated with the adapter.
[0016] FIG. 17 shows a cross-sectional view of a possible configuration of two fluidic channels in the displaceable structure.
[0017] FIGS. 18A-18D show cross-sectional and perspective views of fluidic devices with a structure being slidably moveable in an axial direction.
DETAILED DESCRIPTION
[0018] Some embodiments of the present disclosure describe devices, systems and methods for performing fluidic operations and fluidic routing. Samples can be prepared for various diagnostic and analytical tests, fluid routing, complex manifold replacement as well as other operations. Some embodiments can allow for manual and/or automated operation. The invention allows rapid and reliable operation. It is low cost and obviates many problems possessed by present design and systems.
[0019] In some embodiments, complex fluid routing and operations can be performed without (or with fewer number of) valves and channels. Furthermore, dead volume space can be very low (or zero) for fluid movement between fluids located at relatively long distances. The invention allows a universal way to perform very complex fluidic operations with a much simpler design. A sequence of operation can be established on-the-fly depending on type of sample thus allowing universal sample processing units. It also allows mix and match and on the fly reconfiguration and design, thus being a truly modular and customizable. It allows flexibility in sequence of operations depending on sample type. It allows parallel operations in some cases allowing multiple operations to run at the same time. The invention is useful for cartridge, lab on chip and other design approaches. The invention allows scalable design and the devices on these concepts can be made of a large range of dimensions. It also allows universal sample type input capability. Although we describe sample preparation for examples, the invention is also useful for wide variety of applications including fluid manipulation, chemical and biological analysis, food safety, drug testing, fluid metering and many others.
[0020] FIG. 1 shows an exemplary device 100 for performing fluidic operations. In some embodiments, the device 100 can comprise a fluidic chamber 102 having a plurality of ports 104 a/b - 110 a/b. The ports can be configured in pairs such that a respective port for a particular port is located on an opposite side of the fluidic chamber 102 , as shown, for example, port 104 a and a respective port 104 b, and so on.
[0021] In some embodiments, a plurality of reservoirs can be fluidly connected (e.g., luer connection) with the fluidic chamber 102 at one or more of the ports. Such configuration allows for flowing fluid from the reservoir to or through the fluidic chamber 100 to another reservoir connected with an opposite side of the fluidic chamber 102 at another port. By way of example and not of limitation, reservoirs can be syringes, custom shaped syringes, tubes with or without pinching mechanisms, planar reservoirs and channels with a chip, pouches, collapsible pouches, reagent storage, or cartridges. However, those skilled in the art would understand that other types of reservoirs can also be utilized.
[0022] In some embodiments, a slidably moveable structure 114 can be located within the fluidic chamber 102 . Such moveable structure 114 can have an opening 116 such that when the opening 116 is aligned with one or more ports (e.g., ports 106 a and 106 b ), fluid is able to flow from one reservoir to another reservoir, through the opening.
[0023] In some embodiments, the opening 116 in the moveable structure 114 can comprise a functional element 118 . A functional element 118 can be defined as a something that performs a particular function when the fluid flows through the opening 116 . By way of example and not of limitation, functional elements 118 can be one or more of a DNA binding matrix, lysis structure, plasma filter, cell filter, mixing filter, binding filter, washing element, mixing element, bacteria filter, virus filter, cytometry, analysis element, de-bubbler, di-electrophoresis, impedance spectroscopy, fluorescence/absorbance measuring elements, clear channel, capillary filling, and/or droplet generation. Therefore, when the fluid flows through the opening 116 , the fluid can have an interaction with the functional element 118 . In the case of the DNA binding matrix, when a fluid containing DNA flows through the DNA binding matrix, the DNA binds to the matrix, thus capturing the DNA.
[0024] In some embodiments, a fluidic pressuring mechanism 120 can be configured to facilitate movement of the fluid from the associated reservoir to the fluidic chamber 102 . Such fluidic pressuring mechanism 120 can be, by way of example and not of limitation, pistons, actuators, pumps, or valves. Pistons can have various sizes and shapes, for example, to function with a syringe. Actuators can be internal to the reservoir or external to the reservoir. Pumps can also be internal or external to the reservoir, and can be electrochemical pumps, parasitic pumps, electro-osmotic pumps or vacuum pumps. Electro-osmotic pumps can be used to pump elute buffer with DNA in the cartridge. In some embodiments, a membrane can be used to press down in the reservoir, thus forcing the fluid to flow. The fluidic pressure obtained from such fluidic pressuring mechanism can comprise positive or negative pressure. For example, the fluid can be pushed from the source of the fluid, or pulled from the destination of the fluid. However, those skilled in the art would understand that other types of pressuring mechanisms are possible to facilitate the movement of the fluid.
[0025] FIGS. 2A-2D shows an exemplary fluidic procedure for obtaining DNA. By way of example and not of limitation, a first reservoir 200 a on a first side 210 of the fluidic chamber 208 can contain a fluidic sample such as a lysate mixture. The fluidic pressuring mechanism 214 can push the lysate mixture from the first reservoir 200 a on the first side 210 of the fluidic chamber 208 to a first reservoir 200 b on a second side 212 of the fluidic chamber 208 , through the opening 216 in the moveable structure 220 . As the fluid flow through the opening 216 , the functional element 218 (e.g., DNA binding matrix) can capture the DNA and the fluid can continue to flow through/past the functional element 218 , to the second reservoir 200 b. Once the DNA is captured in the functional element 218 , the moveable structure 220 can be moved to a second position as shown in FIG. 2B . In the configuration shown in FIG. 2B , the moveable structure 220 is slid to the right such that the opening 216 is now aligned with a pair of second reservoirs 202 a/b. The second reservoir 202 b on the first side 210 of the fluidic chamber 208 can comprise a solution, by way of example and not of limitation, water to wash the DNA that is captured in the functional element 218 (e.g., DNA binding matrix). The fluidic pressuring mechanism 214 can be used again to push the water from the second reservoir 202 a on the first side 210 of the fluidic chamber 208 to the second reservoir 202 b on the second side 212 of the fluidic chamber 208 . A process can be repeated as many times as desired as shown in FIG. 2C according to the fluidic operation being performed, which can be determined by those having ordinary skill in the art. Finally, in the exemplary embodiment shown in FIG. 2D , a fourth reservoir 206 can comprise an elution buffer to elute the DNA from the functional element 218 (e.g., DNA binding matrix). A cartridge or a pouch can be connected with the second side 212 of the fluidic chamber 208 to collect the DNA as a result of the elution. An external ultrasonic or vibration device can be coupled with the reservoir (internally or externally) to mix the fluid in the reservoir.
[0026] In some embodiments, the moveable structure 300 shown in FIG. 3 can comprise more than one openings 302 - 305 . Each of the openings can comprise the same or different functional elements 306 - 308 according to the desired fluidic operation to be performed. In some embodiments, the opening 305 does not necessarily comprise a functional element. Alternatively, the opening 305 can comprise a channel for routing the fluid from one reservoir to another reservoir. In some embodiments, the fluidic chamber can comprise more than one moveable structures, one on top of another. Such moveable structures can slides in an axial direction as shown or along a curved path. Therefore, more than one application or operation can be performed simultaneously. The temperature of the fluidic device can be controlled to optimize functionality (e.g. bonding condition) of the functional element.
[0027] FIGS. 4A-4D show alternative configurations of the fluidic chamber and reservoirs. By way of example and not of limitation, FIG. 4A shows cartridges 400 - 403 as reservoirs in addition to those shown in FIGS. 1-3 . Accordingly, the moveable structure 114 can be moved along an axial direction of the device to perform the fluidic operation and ultimately fill the cartridges 400 - 403 with, for example, DNA from the functional element 118 . Additionally, as shown in FIGS. 4C-4D , the pair or ports 404 a/b - 406 a/b are not necessarily located directly opposite to its respective port. Alternatively, the cartridges can be replaced with tubes or well plate. Examples of applications using the method shows in FIGS. 4A-4D can include, for example, but not be limited to separating serum and plasma for ELISA or other immunoassay operations. Results can be read using, for example, fluorescence or other methods known by those skilled in the art.
[0028] FIG. 5 shows an exemplary configuration of the fluidic device 500 when used to perform, for example, sample preparation for Polymerase Chain Reaction (PCR). The fluidic chamber 512 can comprise a plurality of ports 513 and have a moveable structure 501 configured to slide within the fluidic chamber 512 . The moveable structure 501 can have a first opening 502 with a functional element (e.g., DNA binding matrix) and a second opening 505 without a functional element. The plurality of reservoirs 504 (e.g., syringes) and the moveable structure 501 can be used to wash and elute the sample in a sequence as described in previous paragraphs. Cartridges 510 , 511 can also be connected with the ports 513 and the cartridges can be further connected with other devices such as a hybridization chamber 506 or capillary electrophoresis 507 . The syringes used can be low cost syringes and the syringe can be direction applied to the fluidic chamber 512 . As a consequence of the moveable structure 501 , the fluidic chamber 512 can be valveless and channels having dead volume can be minimized in the fluidic chamber 512 . The amount of dead volume space is unaffected by varying the size and/or relative distances of the reservoir 504 and the moveable structure 501 since when the moveable structure 501 is aligned with the ports 513 , the entire opening 502 is part of the flow path of the fluid. When the moveable structure 501 is moved to a new position, the same opening can be used at the flow path, thereby almost completely eliminating any dead volume space.
[0029] In some embodiments, the syringes and the moveable structure 501 can be operated manually by a user or the entire operation can be automated by, for example, motors configured to move the moveable structure 501 , operate the syringes, and/or the hybridization chamber 506 . In some embodiments, a motor with a screw can be used to drive the moveable structure. For rotary design moveable structures, a stepper motor can be used. A single fluidic device can comprise both manual and automated operation so that in cases where power is unavailable (e.g., dead battery, emergency), manual operation can be used. The entire fluidic device can be a closed system thus avoiding contamination issues.
[0030] In some embodiments, multiple lysis operations can be integrated in the reservoir and the moveable structure. For example, tough bacteria or gram positive bacteria can have beads. In such case, the sample can be placed in a lysis reservoir. Alternatively, there can be beads inside the moveable structure or the reservoir for bead beating. In some embodiments, cells greater than certain sizes can be retained to perform lysis, which can be helpful in the case of Malaria. In some embodiments, different DNA and/or RNA can be obtained through different sequences from the same sample from a person. Some embodiments allows for on-the-fly or field mix-and-match of modules for sample processing.
[0031] FIGS. 6-7 show alternative configurations of the fluidic device. For example, the reservoirs 601 in FIG. 6 is shown with springs 602 to cause movement of the fluid from the reservoir. FIG. 7 is shown with a flexible pouch 701 as reservoirs.
[0032] FIG. 8 shows an exemplary embodiment of a fluidic device 800 having a moveable structure 802 that can be configured to slide in a radial direction of the device as shown with arrow 804 . Similarly to the configuration of the fluidic devices shown in FIGS. 1-7 , the fluidic device 800 in FIG. 8 has a plurality of ports 805 a/b - 806 a/b and reservoirs 803 . The moveable structure 802 can comprise one or more openings 807 , which can be aligned with the plurality of ports such that when the opening is aligned, by way of rotating the moveable structure 802 , the fluid can flow from the reservoir on a first side of the reservoir to a second side of the reservoir. Accordingly, the opening 807 can comprise a functional element 808 such as a DNA binding matrix.
[0033] FIGS. 9A-9D show a fluidic process that can be equivalent to the exemplary fluidic procedure for obtaining DNA as shown in FIGS. 2A-2D using a moveable structure 802 that can rotate radially.
[0034] FIGS. 10-11 show another exemplary fluidic device 1000 for performing fluidic operations, similarly to the device described for FIGS. 1-9 . The device 1000 can comprise an adapter 1001 having at least one pair of ports 1002 a/b, and a plurality of reservoirs 1007 , 1008 that can be connectable with the ports. The device 1000 can also comprise a structure 1003 that can be displaceable with respect to the adapter 1001 . By way of example and not of limitation, the structure 1003 can rotate in radial direction as shown with an arrow 1004 . The structure can comprise a fluidic channel arrangement 1005 adapted to allow fluid to flow. The channel arrangement 1005 can be a single channel or a plurality of channels making up the channel arrangement 1005 . The channel arrangement 1005 can comprise a functional element 1006 within the fluidic path of the channel arrangement 1005 .
[0035] In some embodiments, the plurality of channels can be adapted to allow flow cytometry using fluorescence, absorbance, impedance or other detection mechanism. Hydrodynamic focusing can be achieved with a 3D design of the plurality of channels in the displaceable structure. High pressure can be applied by using a piston to speed up the operation of the fluidic device. To perform fluorescence, absorbance, impedance analysis, the reservoirs can be replaced with light guides, fibers or other optical devices to optically connect light sources, filters and detectors to the fluidic sample.
[0036] FIGS. 12A-12E show a fluidic process that can be equivalent to the exemplary fluidic procedure for obtaining DNA as show in FIGS. 2A-2D and FIGS. 9A-9D . By way of example and not of limitation, FIG. 12B shows when a fluid such as a lysate is flowed from a first reservoir 1007 to a second reservoir 1008 through the channel arrangement 1005 containing the functional element 1006 (e.g., DNA binding matrix), the DNA is captured in the functional element 1006 . Then, FIG. 12E shows the structure 1003 rotated such that the channel arrangement 1005 is now aligned with reservoirs 1009 , 1010 and the fluid can be flowed from a third reservoir 1009 to a fourth reservoir 1010 . Such process can be repeated according to the number of steps desired to perform the fluidic operation (e.g. DNA binding).
[0037] In some embodiments, a fluidic pressuring mechanism 1011 can be associated with the reservoirs 1007 - 1010 to facilitate movement of the fluid. By way of example and not of limitation, the fluidic pressuring mechanism 1011 can be pistons, actuators, pumps, or valves. Pistons can have various sizes and shapes, for example, to function with a syringe. Actuators can be internal to the reservoir or external to the reservoir. Pumps can also be internal or external to the reservoir, and can be electrochemical pumps, parasitic pumps, electro-osmotic pumps or vacuum pumps. In some embodiments, a membrane can be used to press down in the reservoir, thus forcing the fluid to flow. The fluidic pressure obtained from such fluidic pressuring mechanism can comprise positive or negative pressure. For example, the fluid can be pushed from the source of the fluid, or pulled from the destination of the fluid. However, those skilled in the art would understand that other types of pressuring mechanisms are possible to facilitate the movement of the fluid.
[0038] In some embodiments, the first reservoir 1007 can comprise elute buffer, while the second reservoir 1008 can comprise water. DNA can be eluted into the water and mixing can be performed by pushing the fluidic sample through the functional element 1006 (e.g., membrane) in the channel arrangement 1005 . A reservoir of the final stage can be, for example, a microwell or a cartridge comprising a dry reagent, and the DNA can be deposited. In some embodiments, the reservoir can comprise a PCR buffer such that the PCR ready solution can be available without any dry reagents in a reaction structure. In some embodiments, the plurality of reservoirs can comprise wash buffers to wash the functional element, channels, or structure a desired number of times.
[0039] In some embodiments, a reservoir can comprise a lysate. The fluidic device can be configured such that the lysate flows through the functional element of the channel to lyse the desired cells. By way of example, the functional element can be an orifice for lysing particular cells, which is known by those skilled in the art. Alternatively, an electrical field can be applied to the channel. Another functional element can comprise a bead beating element to lyse desired cells. Consequently, a plurality of lysis operation can be performed and DNA can be extract using a single fluidic device having various functional elements.
[0040] FIG. 13 shows a close up view of the displaceable structure 1003 having a channel arrangement 1005 with a functional element 1006 . The exemplary displaceable structure 1003 is shown as a substantially disk shaped planar shape. However, the displaceable structure can have other shapes and sizes, for example, substantially sphereical. Additionally, the structure 1003 can have a via 1012 , as also shown in FIG. 14 with a second structure 1013 layered on the first structure 1003 and adapted to operate dependently or independently with the first structure 1003 . In some embodiments, when two structures 1003 , 1013 are layered upon one another, the structures can be aligned such that the via 1012 of the first structure 1003 can be aligned with the channel arrangement 1014 of the second structure 1013 . Therefore, a reservoir can be connected with the via 1012 of the first structure 1003 and the fluid can flow through the channel arrangement 1014 of the second structure 1013 , while maintaining minimal dead volume space. Vias facilitate the fluid to flow from one structure to another structure. Alternatively, tubing or integrated pathways can be utilized (similar to wires or jumpers in a PCB) to fluidly connect two or more channels.
[0041] FIG. 15 shows a perspective view of an exemplary adapter 1001 with the displaceable structure 1003 associated with the adapter 1001 . The locations of the ports 1002 a, 1002 b can be shown on the structure 1003 , with slots 1501 , 1502 in the adapter 1001 such that reservoirs (e.g., syringes) can be connected with the structure 1003 through the ports 1002 a, 1002 b.
[0042] FIG. 16 shows a close-up view of the displaceable structure 1003 with the adapter 1001 and an exemplary reservoir 1007 such as a syringe connected with the structure 1003 . In some embodiments, the channel arrangement 1005 can be wide enough such that the fluid pressuring mechanism (e.g., a piston) can be configured to enter the channel arrangement 1005 , thus requiring less pressure to move the fluid. The problem with the fluid material sticking to channel walls can be minimized since the piston can remove any material that may be stuck on the channel walls. Conveniently, wider channels can be easier to fabricate. A functional element 1006 is also shown in the fluidic path of the channel arrangement 1005 .
[0043] FIG. 17 shows a schematic drawing of an alternative channel arrangement in the displaceable structure 1003 where there are two separate channel arrangements 1701 , 1702 for two distinct fluidic flow paths.
[0044] FIGS. 18A-18D show an alternative device 1800 for performing fluidic operations. In some embodiments, the slidably moveable structure 1801 can be a square or a substantially rectangular rod between two fixed structures 1807 , 1808 . The fixed structures 1807 , 1808 can have ports for flowing fluids from one port 1804 on one of the fixed structures 1807 to a second port 1805 on the other fixed structure 1808 , through the slidable moveable structure 1801 . The slidable moveable structure 1801 can have more than one distinct fluidic paths. For example, a first fluidic path can be a substantially vertical fluidic path 1802 , and a second fluidic path can be a substantially inclined fluidic path 1803 . The slanted fluidic path can be used to flow fluid from the first port 1804 on one of the fixed structures 1807 to a second port 1806 on the other fixed structure 1808 , thus fluidly connecting the two ports, wherein the two ports 1804 , 1806 are not located directly across from one another.
[0045] In some embodiments, the ports can be a luer connection to connect the ports with, by way of example and not of limitation, syringes. In some embodiments, the ports can be a vertical hole to connect the ports with, by way of example and not of limitation, plungers. In some embodiments, the fixed structures 1807 , 1808 can have guiding structures 1809 to facilitate guiding and sliding of the slidable moveable structure 1801 in alignment with the ports. The slidable moveable structure 1801 can be made of materials such as TEFLON®, plastic with a low friction coating, or other hydrophobic coating material. Hydrophobic coating material can minimize the changes of the fluid leaking out of the fluidic device 1800 .
[0046] In some embodiments, the fixed structures 1807 , 1808 can have sliding regions 1810 in which the slidable moveable rod 1801 can be configured to slide against. Therefore, the slidable moveable rod 1801 makes minimal contact with the fixed structures, thus minimizing the surface area and friction between the slidable moveable rod 1801 and the fixed structures.
[0047] In some embodiments, the slidable moveable rod 1801 can be larger than the vertical distance between the sliding regions thereby allowing the slidable moveable rod 1801 be compressed and fit snugly to create a seal. The slidable moveable rod 1801 can be adapted to expand in a horizontal direction to accommodate such compression in the vertical direction. Therefore, the guiding structures 1809 can be located on the fixed structures with consideration for expansion of the slidable moveable rod 1801 .
[0048] Various devices according to the embodiments of the present disclosure can be used to perform plasma base pathogen detection (e.g., hepatitis). For example, a syringe containing blood can be connected with the luer connection port. A filter can be placed in the hole 1803 , 1802 of the slidable moveable rod 1803 to capture cells yet allow plasma to pass through the filter. The lysate (e.g., blood) can be forced from the syringe, through the filter to a reservoir or another syringe on the other side of the filter. Next, a DNA binding matrix can be placed in the hole of the slidable moveable rod 1803 and the lysate can be forced from one reservoir to another, through the DNA binding matrix. By way of example and not of limitation, the separated cells can be used independently for various applications such as detecting malaria or HIV. A capillary effect can also be used for sample collection such as for finger pricks.
[0049] In some embodiments, can be desirable to have air in the fluidic devices described in various embodiments of the present disclosure. The air can be used to dry the channels and/or the functional elements, or push out any remaining fluid in the channels.
[0050] In some embodiments, dielectrophoresis can be performed in addition to filtering a sample concentration by way of evaporation. For example, a channel can be expanded and heated to control the flow of fluid from the channels. The shape of the channel can also be optimized to form a film of fluid in the channel to accelerate evaporation.
[0051] In some embodiments, the functional element can be a filteration element configured to allow dead cell components to pass through the filter. Accordingly, cells larger than a selected side based on the filter will be captured by the filter and smaller cell will pass through the filter.
[0052] In some embodiments, DNA extraction quality analysis can be performed by way of absorbance measurements. Thus, quality of the DNA can be determined before performing PCR reaction.
[0053] In some embodiments, a sample can be homogenized in the reservoir. By way of example and not of limitation, a rotational grinder can be installed in a syringe to homogenize the sample. Then the fluidic sample can be withdrawn or pulled by other reservoir (e.g., syringe) by pulling the plunger of the other syringe, thus creating a vacuum. Alternatively, the reservoir comprising the grinder can also be configured to push out the fluidic sample. Homogenization can be performed on samples such as food, tissue, feces and/or soil.
[0054] In some embodiments, various samples can be mixed in the reservoirs. For example, a first reservoir can comprise a first sample. Then, the first sample can be pushed to the second reservoir comprising a second sample. The second reservoir can comprise a 3D spiral shape to achieve thorough mixing. In some embodiments, if the texture of the reservoir does not facilitate ease of pushing out the sample, the sample can be pulled out by creating a vacuum as described previously.
[0055] In some embodiments, comprehensive tests can be performed using the fluidic device according to the present disclosure. Such test can measure protein concentration, bio markers, nucleic acids (both pathogenic and genomic) and analytes using analysis methods known by those skilled in the art. Cytometry can be performed to conduct cell based analysis. By way of example and not of limitation, after cell filtration, flow cytometry can be performed on one portion of the sample while the other undergoes sample preparation for ELISA, PCR, real-time PCR and/or qPCR. In some embodiments separate ELISA or ELISA with PCR tests can be performed by using the fluidic device according to the present disclosure, thus reducing health related problems.
[0056] In some embodiments, the fluidic device of the present disclosure can be used to separate blood serum, plasma and cells. Different filters can be implemented as the functional element in the moveable structure to achieve desired separation and analysis. In some embodiments, the functional element can be a bubble removal element (e.g., de-bubbler). In some embodiments, impedance spectroscopy can be performed.
[0057] In some embodiments, droplet generation of the fluid (e.g., sample) can be performed by precisely moving the moveable structure. By way of example and not of limitation, two reservoirs can perform droplets of oil emulsion, which can then be used for digital PCR. An array can be integrated into the system instead of cartridges to hold the droplets. A low cost system can be made using the device described in U.S. Patent Publication No. 20100321696 published on Dec. 23, 2010 and U.S. Patent Publication No. 20110207137 published on Aug. 25, 2011, for qPCR for digital PCR applications, both of which are incorporated by reference in their entirety. Such system can be robust, low cost and portable.
[0058] Examples of samples that can be processed using the fluidic device according to the present disclosure can include, but not be limited to swabs, whole blood, food parts (homogenized), stool, urine, other bodily fluids, soil, and/or forensic evidence.
[0059] In some embodiments, the fluidic device according to the present disclosure can be fabricated using plain plastic, polymer, and/or metal sheets and drawing holes in such material by drilling, laser cutting, using a water jet, EDM, etching and among other methods known by those skilled in the art. Injection molding methods can also be used. Other fabrication methods such as laser fabrication, xerography, and other semiconductor manufacturing processes. Low friction coatings and lubrication can be used to reduce friction of the moveable structure.
[0060] The examples set forth above are provided to give those of ordinary skill in the art a complete disclosure and description of how to make and use the embodiments of the present disclosure, and are not intended to limit the scope of what the inventors regard as their disclosure. Modifications of the above-described modes for carrying out the disclosure may be used by persons of skill in the art, and are intended to be within the scope of the following claims. All patents and publications mentioned in the specification may be indicative of the levels of skill of those skilled in the art to which the disclosure pertains. All references cited in this disclosure are incorporated by reference to the same extent as if each reference had been incorporated by reference in its entirety individually.
[0061] It is to be understood that the disclosure is not limited to particular methods or systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the content clearly dictates otherwise. The term “plurality” includes two or more referents unless the content clearly dictates otherwise. 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 the disclosure pertains.
[0062] A number of embodiments of the disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the present disclosure. Accordingly, other embodiments are within the scope of the following claims. | Devices and system for preparing samples are described. Such devices can comprise fluidic chambers, reservoirs, and movable structures for controlling the movement of samples. The device can also comprise functional elements for performing specific operations. | 8 |
This application is a continuation application of PCT/CH00/00179 filed on Mar. 27, 2000.
FIELD OF THE INVENTION
The present invention concerns a watch movement, in particular a watch movement with a microgenerator. The present invention also concerns a method for testing such watch movements.
RELATED ART
Watch movements with a microgenerator have been described notably in the patent documents CH597636 (Ebauches SA) and EP0851322 (Ronda SA). In such a watch movement, the balance known from mechanical watch movements is replaced by a generator 10 - 22 (FIG. 2) and an electronic regulating circuit 81 with a quartz oscillator 85 . The generator is driven by a spring (not represented) over a part of the gear train 50 , 60 , 70 (FIG. 1 ). The generator feeds the electronics that in turn regulate the rotational speed of the generator and thus the running of the watch movement. Such watch movements therefore combine the advantages of a mechanical clock with the precision of a quartz watch.
The forces, moments and rotational speeds that are effective in such a watch movement correspond roughly to those in a mechanical clock. Thus, it is to be expected that the wear would be more or less the same.
The present invention is based on the observation that is surprisingly not the case. In such watches, strong signs of wear appear after a short time.
It has been observed, for example, that the oil in the jewel bearings deteriorates within a short time period. Furthermore, strong signs of wear have been noticed at the addendums of the teeth.
Wear has also been noticed in places where the teeth never touch, for example precisely at the teeth cusps. A lot of abrasion has also been found in the oil on the jewel bearings. The faster the wheel rotates, the stronger the destruction of the oil at the bearings of the corresponding wheel.
It is one aim of the invention to build a watch movement with a microgenerator that does not show these problems.
It is another aim of the invention to construct a watch movement with a microgenerator that is at least as durable as a conventional mechanical watch movement.
It is another aim of the invention to build a cheap and, in addition, reliable watch movement that is controlled with a generator and in which these wear problems do not occur.
BRIEF SUMMARY OF THE INVENTION
According to the invention, these aims are achieved by means of a microgenerator having the characteristics of the characterizing part of claim 1, preferred embodiments being further indicated in the dependent claims.
These aims are achieved specifically by understanding the phenomenon that causes the rapid wear.
The aforementioned problem was solved in particular by discovering a totally unexpected effect in such watch movements and by inventing solutions to prevent this effect.
Empirical Background and Solutions Proposed
The essential difference between a mechanical watch movement and a generator watch movement lies in the electric grounding of the components. In a conventional mechanical clock, the balance is electrically grounded directly over the spring coil. In a watch movement with a microgenerator, the rotor 10 of the generator should also be grounded electrically over the train 50 , 51 , 60 , 61 , 70 , 71 . But, as measurements have shown, this is surprisingly not the case: the rotor is insulated from the plate of the watch movement.
The explanation found in the framework of this invention for this surprising fact is the following: as the driving torque at the generator is very small and the magnets 12 of the rotor stray fields, the axis 50 of the wheel 51 driving the rotor may not be magnetic. Otherwise, the rotor receives a positioning torque substantially greater than the driving torque available to the generator, which causes the generator to stop. To prevent this, the axis in question is made of copper-beryllium (CuBe). This solution has already been described in the above-mentioned application EP0851322. Copper-beryllium however has the tendency to develop layers of oxide. If this oxide layer is thick enough and the surface pressure in the gearing is small, the rotor 10 as well as the wheel 51 and the pinion 50 (Inter2) driving the rotor can be electrically insulated from the rest of the watch movement.
On the other hand, if the generator 10 , the pinion 50 and the wheel 51 are electrically insulated from the other parts of the watch movement, they can be charged electrically through frictional electricity and/or through the rotor's stray fields that induce a voltage in the wheel 50 - 51 . As soon as the voltage has reached a certain value, there can be a discharge of sparks, as described below, which can lead to a more rapid wear of the gear train and a rapid deterioration of the lubrication.
The insulated wheels and the rotor can be charged especially through frictional electricity. If two surfaces are in contact and then separate, electrons will be torn from one of the surfaces, with the result that one body has a negative and the other a positive charge. If the bodies are not electrically insulated from one another, the charges will simply be exchanged again at the next contact.
If on the other hand the bodies are insulated from each other, for example by a layer of oxide, these charges cannot be exchanged, so that the bodies will be charged.
Charges with the same polarization repel mutually, leading to the charges being at maximum distance from each other. Because the separation of the charge occurs on the little pinion, the charges have the possibility of spreading onto the big wheel, so that the pinion is no longer charged and can be recharged at the next separation. The well-known Van den Graaf generator works according to this principle. In this manner, a charging pump results that deposits the charges on the rotor 10 . If it is assumed that the engagement between the rotor 10 and wheel 51 yields about 7,000,000 meshings and between the pinion 50 and the wheel 61 about 1,000,000 meshings per day, it is evident that in this way considerable voltages build up.
As soon as the voltage developed in this fashion is bigger than the breakdown voltage of the insulation layer, there is an exchange of charge. Depending on the voltage, a spark discharge may occur.
If then the rotor 10 is electrically insulated from the rest of the watch movement, as demonstrated by measurements of the electric resistance between the plate 30 and the rotor 10 , it is charged, either through air friction, through charge separation as described further above or through the voltage induced in the wheel 50 - 51 by the magnetic stray fields of the rotor 10 .
If the voltage built up through friction electricity and/or through the rotor's stray fields is too big for the electric insulation, there are discharges. This can be spark discharges in the meshing or there can be other discharges, for example directly between the rotor 10 and the plate 30 . These discharges cause the following damage in the watch movement:
There is a lot of abrasion at the teeth cusps of the wheel 61 (Inter 1), the teeth cusps are heavily damaged, though these teeth cusps are never in contact with teeth of the other wheel.
On the pinion 50 (Inter 2), quite a thick layer of oxide develops. Here, too, the teeth cusps are partially destroyed. Furthermore, there are traces of abrasion on the teeth flanks.
The oil of Inter ( 60 - 61 ), Inter 2 ( 50 - 51 ) and generator 10 is deteriorated, on the one hand by the formation of ozone, on the other hand by the high electric voltage and the spark discharge.
In the bearings 41 , there are traces of abrasion and the oil is full of small particles.
The teeth of the wheel are soiled with abrasion particles.
The pegs are heavily worn out because of the particles in the oil.
The different chemical substances in the oil attack the pegs chemically.
The electronics 81 may possibly be disturbed by the discharges.
These problems occur only after a certain time, but if they do, the watch movement stops after a short time. Once there are spark discharges, the layer of oxide grows, as does the tendency to charge the wheels through frictional electricity, and the damages continue with ever growing intensity. After a short time, the friction caused by the deteriorated oil and the dirt in the jewel bearings is so great, that the driving force available at the generator is smaller that the needed driving force, so that the regulation does not function any more.
These experiments according to the invention were carried out under a scanning electron microscope in order to check whether the wheels in the train can be charged. In this process, an electron beam is focused on the rotor 10 . If the rotor can be charged, it means that it is not grounded over the train 50 , 51 , 60 , 61 , 70 , 71 of the plate 30 , i.e. it is not insulated from the plate.
Spark discharges could be observed in the scanning electron microscope, which demonstrates that the rotor 10 is electrically insulated. The damage visible on the wheels in the train looks very similar to the damage that happens in watches after a wear test of several months.
In order to solve the problem of the watch movements with a microgenerator according to the state of the art, the gearing is grounded, in a first embodiment of the invention. Thus, an electric charging of the rotor and of the gearing is avoided. It is for example possible to ground the gearing over the meshing or over the axes, for example in the bearings or by means of brush contacts on the axes.
In a second embodiment of the invention, which may be combined with the first embodiment, charge separation is prevented. The occurrence of charge separation can for example be avoided by using materials that have approximately the same electrochemical potential and/or the same dielectric constant. If the materials that are in contact with each other possess approximately the same surface characteristics, the tendency of electrons being torn away when there is a separation of the materials is not very high. Therefore, materials or surfaces with good tribological characteristics and a hardness greater than 200DH can for example be used.
In a third embodiment of the invention, which may be combined with the first and/or second embodiment, oil that is resistant to ozone is used. This allows for the lubrication to be kept intact, if within the watch movement ozone is regularly produced by spark discharges.
In a fourth embodiment of the invention, which may be combined with the first and/or second and/or third embodiment, jewel bearings are used that protect the oil as much as possible against oxidation. This is achieved by keeping the jewel bearings as closed as possible, on the one hand in order to keep the oil in the bearings by capillary effect and, on the other, in order that the oil is thus not exposed to oxygen and the possible ozone it contains.
DESCRIPTION OF THE DRAWINGS
The invention will be better understood with reference to the description of an embodiment illustrated by the attached drawings containing the figures, in which:
FIG. 1 shows a cross section of a part of the gearing and of the microgenerator of a watch movement.
FIG. 2 shows a top view of a module fitted with a microgenerator and the associated electronics.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a side cut of a microgenerator fitted in a watch movement according to the invention, with only the parts of the watch movement necessary for understanding the invention being shown. The watch movement contains a mechanical energy storage in the form of a (not represented) spring. The spring is wound by a (not represented) winding device or preferably by a mass that is put into oscillation by the movements of the watch wearer's arm. The spring drives the various hands and displays of the watch, especially the seconds hand that is fastened on the seconds axis 70 over a (not represented) conventional gearing.
The seconds wheel 71 fitted on the seconds axis 70 drives a first intermediate pinion 60 (Inter 1) that in turn over the first intermediate wheel 61 drives a second intermediate pinion 50 (Inter 2). The first intermediate pinion 60 as well as its axis consist for example of steel or another suitable metal; the second intermediate pinion 50 and its axis, in contrast, consist of a non-magnetizable material, preferably a copper-beryllium alloy, to avoid a positioning torque to be exerted on the generator because of the force of the magnet s on the intermediate wheel.
The second pinion 50 , in turn, drives the axis 10 of the generator's rotor over the second intermediate wheel 51 and the pinion 15 . The axis 10 is held rotating between two synthetic shock-absorbent bearings 31 and 41 . The first shock-absorbent bearing 31 is connected to the plate 30 of the watch movement, whereas the second shock-absorbent bearing 41 is connected with a bridge 40 .
The rotor consists of an upper disk 11 and a lower disk 13 that are connected firmly with the axis 10 . The lower surface of the upper disk 11 in this example contains six single magnets 12 that are arranged at regular intervals close to the periphery of the disk. The upper surface of the lower disk 13 is fitted in the same manner with six single magnets 14 that are arranged symmetrically to the six magnets of the upper disk.
The stator contains three induction coils 20 , 21 , 22 , that are mounted between the disks 11 and 13 . The generator is mounted between the plate 30 of the watch movement and a bridge 40 , which allows for the complete generator inclusive of the coils to be concealed.
FIG. 2 shows a top view of the module 80 fitted with a microgenerator. The three coils 20 , 21 , 22 of the microgenerator's stator are mounted on the module 80 and linked serially between the points 800 and 803 of the electronic module 80 . An integrated circuit 81 is mounted on the module 80 . The purpose of this integrated circuit is to monitor the rotation speed of the microgenerator and to regulate this speed by changing the value of a variable load resistance which can be exerted on the microgenerator.
As explained above, a layer of oxide can develop on the wheel 51 and the pinion 50 from the copper-beryllium which insulates these wheels electrically from the other wheels 61 , 71 and from the plate 30 . This problem occurs especially with watch movements with a microgenerator, because the forces between the wheels and hence the surface pressure in the meshing is very small so that there is no good electric contact between the wheels. Although the forces in a mechanical watch are of a similar magnitude, in this case the balance, regulating the rotational speed, is electrically connected over the spiral coil with the plate so that it can not charge.
Through the mechanism as explained above, charges accumulate in the wheels and pinions and in the rotor 10 , which can cause spark discharges. These spark discharges wear down the wheels and the oil in the watch movement deteriorates because of the ozone that is generated by the spark discharges. Furthermore, the spark discharges interfere with the regulating circuit 81 so that the watch movement is no longer correctly regulated.
To avoid these problems, according to a first embodiment of the invention at least a part of the wheels 51 , 61 , 71 , and pinions 50 , 60 , 70 are grounded. For the wheels one uses preferably materials or layers with very good electric contact characteristics so that no strong surface pressure is necessary to secure a good electric contact.
According to a second embodiment of the invention, the occurrence of charge separation is avoided by using in the gearing materials which posses approximately the same electrochemical potential and/or the same dielectric constant. If the materials that are in contact with each other possess approximately the same surface characteristics, the tendency of electrons being torn away when there is a separation of the materials is not very high.
Preferably, then, a material or at least a surface is used for the wheels and pinions 50 , 51 , 60 , 61 , 70 and/or 71 that avoids charge separation and at the same time also allows between the wheels an electronic contact at a weak surface pressure.
Preferably, a material is used which has good electric characteristics, on which no layers of oxide develop and which furthermore possesses good tribological characteristics. For example, wheels and pinions of cheaper material can be used, for example plastic, CuBe, aluminum, brass or steel (for wheels and pinions that are not influenced by the magnetic field of the rotor), which can then be covered with a carefully chosen material. The thickness of the layer is preferably less than 1 μm, the hardness greater than 200DH, the coating material may not be magnetic and has to adhere well onto the basic material. Furthermore, a combination of materials has to be used in which the basic material of the wheels is not diffused into the coating. The coating can consist for example of gold, a gold alloy or electrically conductive oxides. One can, however, also use wheels and pinions made completely of gold, silver, of an electrically conductive material, of ceramicor, of an electrically conductive plastic material or any similarly well conductive material.
In order to have a good electric contact, the meshing of the wheels and pinions may not be epilamized, because epilam acts as an insulator.
According to the invention, the gearing can also be grounded through the axes. Normally, rubies, which are good electric insulators, are used for the bearing of axes in the watch industry. In an embodiment of the invention, a material 41 is used for the bearing which has good tribological characteristics but is also electrically conductive. Thus, the gearing can also be grounded over the bearing.
In a preferred embodiment of the invention, a lubricat is used in the bearings, for example in the form of an electrically conductive grease or oil to make it possible to ground the gearing over the bearings.
According to the invention, the oil used is furthermore ozone resistant, so that the lubrication stays unaltered for longer, even in the case of spark discharges. A dry-film lubrication can also be used, or a mixture of oil and dry-film lubrication.
In a preferred embodiment of the invention, jewels or rubies are used that protect the oil as well as possible against oxidation by oxygen or ozone. This is achieved by keeping the jewel bearings as closed as possible, on the one hand in order to keep the oil in the bearings by capillary effect and, on the other, in order that the oil is thus not exposed to oxygen and the possible ozone it contains.
If a normal horologic oil is to be used, there is still the possibility of using for the bearings special jewel bearings that are constructed in such a way as to protect as much as possible the oil against oxidation from all sides. Such bearing elements can be used among others for the generator, the Inter 2 and the Inter 1. Tests have been conducted for example with the Duofix, Duobil and Duokif jewel bearings of the company KIF Parechoc AG that contain cap jewels which keep the oil in a nearly closed space. Compared to the jewel bearings usually used, such bearings, thanks to the capillary effect, have the advantage that the oil stays better in the bearings and has fewer tendencies to spread.
Thus, oils having a not too great surface tension may be used, such as for example perfluorinated oils like Fomblin Z 25.
The present invention also concerns a test method that can check whether the wheels in a watch movement are grounded. With this test method, various materials and coatings can be tested. The working watch movement to be tested is bombarded with electrons in a scanning electron microscope. The parts that are not grounded will then be charged. If certain parts, for example the rotor and the pinions/wheels 50 / 51 are electrically insulated from the plate or other components, these parts will be charged until the voltage at any place in the train is high enough to cause a spark discharge. At this place, a slight damage will occur. In this way, it can be determined whether the wheels are grounded. If the watch movement works perfectly well for a certain time in the scanning electron microscope and no damage can be found at the wheels after this test, it means that the wheels are electrically connected with each other.
In another embodiment of the test method, an electric charge is deposited without contact on the rotor. During this, a high tension source is connected to the watch movement by connecting one pole to the plate 30 and the other pole as closely as possible to the rotor 10 , 11 , 13 . If then a spark discharge occurs on the rotor, the rotor will be electrically charged. If the rotor and the train are electrically grounded, the charges are spread out in the watch movement and there is no reason for a spark discharge between the meshed wheels. Therefore, there should be no damage visible on the wheels. However, should the dented wheels not be electrically well connected with each other, a spark discharge can take place in the meshing. In this case, the wheels will be damaged.
In another embodiment of the method, the resistance between the rotor and the plate is measured. To do this, the spring must be wound so that the wheels are meshed and the surface pressure in the meshing corresponds more or less to the surface pressure necessary for normal operation. The rotor may not however be subjected to strong mechanical force to avoid anti-shock elements being ejected and the rotor's axis being electrically connected to the plate. It is best to use a thin wire to contact the rotor for the measurement. To do this, the rotor has to be brought to a standstill by contact with the wire.
The present invention also concerns watches that were tested with this method. | Watch movement in which the rotor of a generator ( 10, 11, 13 ) is driven by a spring over a plurality of wheels ( 51, 61, 71 ) and pinions ( 50, 60, 70 ), the operation of the generator being regulated by an electronic regulating circuit ( 81 ).
Said wheels and pinions are all electrically grounded to avoid spark discharges which can be produced by the charging of voltages through frictional electricity. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to filters, and more particularly to apparatus for preventing foreign materials from entering furnaces.
2. Description of the Prior Art
Modern high-efficiency furnaces are well known and are in widespread use. Their economical and reliable operation contributes to their popularity.
Intake air for a high-efficiency furnace is usually drawn directly from out-of-doors. The inlet air flows through an inlet tube that passes through a building wall and connects to the furnace. Similarly, exhaust gasses from the furnace flow through an outlet tube that terminates out-of-doors, usually close to the inlet end of the inlet tube. The outdoor ends of the inlet and outlet tubes are normally located within a few feet of ground level outside the building. The tubes vary in size, with two inch diameter tubes being satisfactory for most residences, and a three inch tube usually being required for commercial and industrial applications.
Despite their general acceptance, high-efficiency furnaces have a drawback that occasionally causes rather serious problems: the inlet and outlet tubes are susceptible to plugging. Common reasons for the tubes becoming plugged include leaves or other debris blowing into them. Birds are another a problem; birds have been known to fly into furnace tubes and getting killed upon reaching the furnace. Another source of plugging is children tossing stones or other items into the tubes.
When a tube becomes plugged, sensors on the furnace automatically shut it off. It is then necessary to service the furnace. The only practical way to unplug a tube is to cut it in order to reach the plugged section. Then the cut tube must be patched or replaced. The inconvenience and expense caused by a plugged tube are highly aggravating.
In an attempt to prevent furnace tubes from plugging, it is known to install strip-like strainers at their outdoor ends. However, the prior strainers are not entirely satisfactory. A disadvantage of the prior strainers is that they are recessed into the tube ends. The space between a tube end and a strainer can become filled with leaves and the like and thereby plug the tube. Although the leaves or other material can be removed fairly easily, the task of doing so, plus restarting the furnace, is nevertheless an annoyance. Another disadvantage of the prior strainers is that they reduce the area for the flowing gasses. Consequently, there is an increased likelihood that even a partially plugged strainer will cause the furnace to shut down.
Thus, a need exists for improvements in filters for modern furnaces.
SUMMARY OF THE INVENTION
In accordance with the present invention, a simple and economical furnace breathing filter is provided that solves the problems associated with providing air to and removing exhaust gasses from a high-efficiency furnace. This is accomplished by apparatus that includes high capacity filters placed on the outdoor ends of the furnace air inlet and exhaust gas outlet tubes.
The furnace breathing filter is comprised of two sections: a filter section and a hub. The filter section is designed with a gas flow capacity that suits the largest furnace that is anticipated to employ the invention. In the preferred embodiment, the filter section is generally tubular in shape, and the circumferential wall is formed as a grid. An end wall of the filter section is also formed as a grid.
The hub is integrally joined to a second end wall of the filter section. The hub is designed to fit one size of furnace tube. For that purpose, the hub has a collar with an outer diameter that is assembled to the furnace tube by fitting snugly inside a fitting at the outdoor end of a furnace tube. Alternately, the hub collar may be designed to fit on the outside of the end fitting of the furnace tube. Furnace tubes of different sizes require furnace breathing filters with different diameter collars.
The filter section and hub of the invention are designed to allow inlet air or exhaust gases to flow through them without restriction. At the same time, a furnace tube becomes almost impossible to plug with a furnace breathing filter in place.
In a modified embodiment of the present invention, the filter section and hub are fabricated as two individual components. In that design, a single filter section is used with interchangeable hubs. The filter section has a circumferential grid and one end wall that is also a grid. Each hub has a flange and a collar. The flange is assemblable to a second end of the filter section so as to form an annular second wall. The collars of different hubs have different diameters to suit different size furnace tubes. The collars may fit on either the inside or the outside of the furnace tube end fittings.
The apparatus and method of the invention, using filters located on the outdoor ends of furnace air inlet and exhaust gas tubes, thus prevents the tubes from plugging. The possibility of a furnace shutdown due to a plugged tube is remote even if a portion of the filter section should become covered with debris.
Other advantages, benefits, and features of the present invention will become apparent to those skilled in the art upon reading the detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified view of a typical furnace installation that advantageously includes the present invention.
FIG. 2 is a front view of the furnace breathing filter of the present invention.
FIG. 3 is a view taken along line 3--3 of FIG. 2.
FIG. 4 is a view taken along line 4--4 of FIG. 2.
FIG. 5 is a partially broken front view of the furnace breathing filter installed in a furnace tube.
FIG. 6 is a view similar to FIG. 5, but showing an alternate construction for the hub of the furnace breathing filter.
FIG. 7 is an exploded and partially broken front view of a modified embodiment of the present invention.
FIG. 8 is a view taken along line 8--8 of FIG. 7.
FIG. 9 is a partially broken front view of the furnace breathing filter of FIG. 7 in its assembled condition.
FIG. 10 is a cross sectional view taken along line 10--10 of FIG. 9.
FIG. 11 is a view similar to FIG. 9, but showing a furnace breathing filter with a hub that fits on the outside of a furnace tube fitting.
DETAILED DESCRIPTION OF THE INVENTION
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention, which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto.
FIG. 1 shows in simplified form a modern high-efficient furnace installation 1 that includes the present invention. The installation 1 typically includes a gas or oil burning furnace 3 located inside a building wall 5. An air inlet tube 7 supplies the furnace 3 with fresh air from the atmosphere 9 outside the building wall 7. An exhaust tube 11 vents exhaust gases from the furnace to the atmosphere 9.
The inlet tube 7 and exhaust tube 11 are typically made from a polyvinylchloride plastic material, as is known in the art. Individual pieces of tubing 12 are cut and joined by various fittings 13 to suit the particular installation 1 and building wall 5. The inlet and exhaust tubes invariably terminate at their outdoor ends in known fittings such as couplings or elbows 15.
In accordance with the present invention, a breathing filter 17 for the furnace 3 is installed on the outdoor ends of the inlet tube 7 and the exhaust tube 11. Looking also at FIGS. 2-5, the furnace breathing filter 17 is comprised of a filter section 19 and an integral hub 21 that together define an axial centerline 25. In the preferred embodiment, the filter section 19 is generally tubular in shape, having an end wall 23 and a circumferential wall 27. Both the end wall 23 and the circumferential wall 27 define any of a number of patterns of grid openings 28 and 29, respectively, therein. Opposite the end wall 23 of the filter section 19 is an annular second wall 31. The annular second wall 31 may be solid, or it may define a grid of openings 32 therethrough.
The hub 21 of the furnace breathing filter 17 is made as a short collar 30 having one end that joins the annular wall 31 of the filter section 19 and a free end 33. The collar 30 has an outer diameter 26 that fits snugly into the end fitting 15 of a furnace tube 7 or 11. To suit different diameter tubes, the furnace breathing filter is manufactured with collars of different outer diameters 26. For example, for a two inch nominal size tube 7 or 11, the outer diameter of the hub collar is approximately 2.38 inches. For a three inch nominal size tube 7 or 11, the outer diameter of the collar 30 is approximately 3.50 inches. Other dimensions for the furnace breathing filter include a diameter of approximately 5.00 inches and a length of approximately 2.75 inches for the filter section 19.
The grid openings 28 of the end wall 23 may be formed by 16 radially extending ribs 36 joined to several circular ribs 38. The ribs 36 and 38 may be approximately 0.25 inches wide and 0.09 inches thick. The grid openings 29 are defined by a number of axially extending circumferentially spaced ribs 34. I have found that 32 ribs 34, each having a width of approximately 0.25 inches and a thickness of approximately 0.09 inches, works very well. The grid 32 of the annular wall 31 has partial radial ribs 40 and a circular rib 42 that are substantially similar to the corresponding portions of the radial and circular ribs 36 and 38, respectively, of the grid 28 of the end wall 23. A satisfactory length for the hub is approximately 0.75 inches, as is a wall thickness of approximately 0.19 inches.
In use, a furnace breathing filter 17 is chosen that has a hub 21 that suits the size of the furnace tube 7 or 11 with which it is to be used. The furnace breathing filter is assembled to a tube by inserting the hub collar 30 into the open end of a furnace tube end fitting 15. Although the hub may be cemented into the tube end section, I prefer that the furnace breathing filter be retained in place with one or two screws 35.
With the furnace breathing filters 17 in place on the tubes 7 and 11, inlet air and exhaust gasses are free to flow through the filter sections 19 without restriction and in sufficient quantities to satisfy the furnace 3. At the same time, the furnace breathing filters prevent the tubes 7 and 11 from plugging, whether due to natural or intentional causes.
FIG. 6 shows a furnace breathing filter 54 that has an alternate design for the hub 56. The furnace breathing filter 54 has a filter section 19' that is substantially similar to the filter section 19 described previously in connection with FIGS. 1-5. The filter section 19' includes an annular wall 31'. The inner diameter 8 of the annular wall 31' is approximately the same size as the inner diameter of the end fitting 15 of the furnace tube 12. The annular wall 31' may be solid, or it may have a grid of openings therethrough. The hub 56 is made as a short collar that is integral with the annular wall 31'. The hub collar has an inner diameter that fits over the outer diameter of the end fitting 15. An inner diameter of approximately 2.75 inches for the hub collar works very well for two-inch nominal size furnace tubes 7, 11 (FIG. 1). The portion of the annular wall 31' between its inner diameter 58 and the inner diameter of the hub collar forms a shoulder 62. The shoulder 62 assures proper location of the furnace breathing filter 54 on the end fitting 15. The furnace breathing filter 54 is retained to the end fitting 15 with screws 35'.
Now turning to FIGS. 7-10, a furnace breathing filter 37 is shown that is made of two separate components, a filter section 39 and a mounting hub 41. The filter section 39 is tubular in shape, having one end 43 that is completely open. The opposite wall 45 is fabricated as a grid that may be similar to the grid 28 of the filter section 19 of the furnace breathing filter 17 described previously. The filter section 39 of the two-piece furnace breathing filter 37 also has a circumferential wall 47 having a grid 52 that may be substantially similar to the circumferential grid 29 of the furnace breathing filter 17. As illustrated, the circumferential wall 47 is partially defined by annular rings 42, 44, and 46, each having an inner diameter 50. Circumferentially spaced, axially extending ribs 53 connect the rings 42, 44, and 46. The ribs 53 do not extend all the way to the filter section end 43; there is a space 55 between the ends 57 of the ribs and the filter section end 43. A nominal diameter of 5 inches and a nominal axial length of 2.75 inches for the filter section are satisfactory.
The mounting hub 41 of the furnace breathing filter 37 is comprised of a collar 48 and an outturned flange 49 at one end of the collar. The outer diameter 51 of the flange 49 is slightly less than the inner diameter 50 of the filter section ring 46. Circumferentially spaced around the flange 49 of the hub 41 are several tabs 59. The tabs 59 radiate from the centerline 60 and overhang the flange outer diameter 51. Each tab has a notch 61 at its outer end.
The mounting hub 41 is manufactured in different sizes to suit different tubes 7 and 11 of the furnace installation 1, FIG. 1. Specifically, the collar 48 is made with an outer diameter 63 that fits into the end fittings 15 of the furnace tubes 7 and 11. For example, the outer diameter 63 of the collar is approximately 2.38 inches for two inch furnace tubes, and approximately 3.50 inches for three inch furnace tubes. On the other hand, the outer diameter 51 of the flange 49 and the tabs 59 are the same for all hubs 41. Similarly, a length of approximately 0.75 inches and a wall thickness of approximately 0.19 inches for the collar 48 is satisfactory for all hubs. The mounting hub 41 shown in FIGS. 7-10 has relative dimensions suitable for use with two-inch furnace tubes. In that situation, the flange may be fabricated with grid openings that are similar to the grid openings 32 of the filter 17, FIG. 4. For hubs used with three-inch furnace tubes, the flange 49 is solid.
The filter section 39 and the mounting hub 41 of the furnace breathing filter 37 are preferably manufactured from a relatively soft polyethylene plastic material. The filter section is designed to be flexible enough to enable the hub tabs 59 to slide past the ring 46 of the filter section such that the notches 61 of the tabs 59 lock over the ring 46. In that manner, a single filter section can be used interchangeably with different hubs that suit the tubes 7 and 11. Mounting of the two piece furnace breathing filter 37 to the tubes 7 and 11 may be the same as for the single piece furnace breathing filter 17 described previously in connection with FIGS. 1-5.
In FIG. 11, a furnace breathing filter 65 has a filter section 39' that is substantially similar to the filter section 39 described above and a hub 67. The hub 67 has a flange 49' and a collar 69. The collar 69 of the hub 67 has an inner diameter 70 that fits over the furnace tube end fitting 15. The flange 49' has an inner diameter 71 that is approximately the same size as the inner diameter of the fitting 15 such that there is a shoulder 73 between the flange inner diameter 71 and the collar inner diameter 70. The furnace breathing filter 65 is assembled and used in the same manner as the furnace breathing filter 37 described above in connection with FIGS. 7-10.
In summary, the results and advantages of modern high-efficiency furnaces 3 can now be more fully realized. The furnace breathing filters 17, 37, 54, and 65 of the present invention provide both adequate flow for inlet air and exhaust gasses while protecting against plugging of the furnace tubes 7 and 11. This desirable result comes from using the combined functions of a filter section 19, 19' or 39, 39' and a hub 21, 41, 56, or 67. The filter section and hub can be one integral part, in which case the hub is manufactured with different outer diameters to suit different furnace installations. Alternately, the filter section and hub can be separate pieces to enable a single filter section to be interchangeably assembled with different hubs that are sized to suit different furnace installations 1. The hubs may be designed to fit either into or over the end fittings of the furnace tubes.
It will also be recognized that in addition to the superior performance of the furnace breathing filters 17 and 37, their construction is such as to be of minimal cost. Accordingly, they represent a value that is far greater than their cost relative to the cost of a complete furnace installation 1. Also, the furnace breathing filters are made of rugged designs and materials, so the need for maintenance is practically non-existent.
Thus, it is apparent that there has been provided, in accordance with the invention, a furnace breathing filter that fully satisfies the aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. | A furnace breathing filter protects the air inlet and exhaust gas outlet tubes of high-efficiency furnaces from plugging while enabling adequate gas flow. The furnace breathing filter comprises a filter section and a hub. The hub is designed to be inserted into and secured to a fitting on the outdoor end of the furnace tube. The filter section has a grid of openings that are sufficiently large to enable adequate gas passage but small enough to block entry of foreign materials into the furnace tube. The hub may be joined integrally with the filter section, or it maybe a separate piece that is removably assembled to the filter section. The hubs are made with different outer diameters to suit different sized furnace tubes. In an alternate design, the hub fits over the furnace tube fitting. | 5 |
This is a continuation-in-part application of U.S. Ser. No. 07/947,613, filed Sep. 21, 1992, now U.S. Pat. No. 5,263,319, issued Nov. 23, 1993.
TECHNICAL FIELD
This invention relates to a three element fluid torque converter for use between an engine and a transmission. More particularly, this invention relates to a torque converter having a variable pitch stator.
BACKGROUND OF THE INVENTION
Torque converters having variable pitch stators are desirable for reducing the tendency of the vehicle to creep when the vehicle is idling and the transmission is in a drive gear range. Reduction of creep torque offers several benefits. Fuel economy can be increased. The engine load at idle can be decreased, thereby reducing engine vibration perceived by the driver. And further, for vehicles requiring elevated idle speeds to satisfy high electrical power requirements at idle, idle speed can be increased while maintaining the same creep power.
Variable pitch stators are well known in the art of torque converter design. In most such stators, each stator blade is mounted for rotation about a blade axis passing through the blade. These blade axes typically intersect the torque converter axis.
Both active and passive means are used to provide blade rotation. U.S. Pat. No. 3,398,532, issued to Egbert et al. on Aug. 27, 1968, shows an example of active rotation with the blades being rotated to one of three positions by axial motion of a fluid driven piston. U.S. Pat. No. 2,015,300, issued to C. Dell et al. on Sep. 24, 1935, shows a passive system, wherein the blades rotate in response to fluid force against the blades.
The angle of the stator blades with respect to the torque converter axis changes as the blades are rotated about their respective blade axes. Generally, when the stator blades are rotated to a high inlet angle or closed position, the torque converter capacity for multiplying input torque at a given engine speed is substantially reduced. The blades are typically in the closed position when the vehicle engine is idling. This has the effect of reducing the torque transmitted to the vehicle wheels, thereby substantially reducing the tendency of the vehicle to creep.
However, the disruption of the fluid flow within the torque converter caused by the blades being in the closed position results in vibrations being generated within the torque converter. These vibrations are transmitted through the vehicle to the driver as audible noise and unpleasant vibrations. This condition typically occurs at idle. Also, variable pitch stators have been contributors to harshness of torque converter clutch engaging and disengaging.
SUMMARY OF THE INVENTION
It has been found that providing a variable pitch stator with a moderately open stator flow path when the blades are in the closed position will reduce creep torque by over 50% while inducing little of the vibrations, noise and harshness commonly associated with torque converters having variable pitch stators.
The present invention offers the advantage of creep torque reduction at idle with a minimum increase in noise over a fixed blade stator. This advantage is attained by using variable pitch stator blades with high inlet blade angles and by limiting the portion of the flow area blocked by the blades. This combination of providing the high positive inlet angle and limiting the reduction in flow area reduces the noise and harshness.
A spring load biases the blades to a closed position when the engine is at idle speed. As engine speed increases, the velocity of the fluid leaving the turbine and impinging against the stator blades increases, thus overcoming the spring load to rotate the stator blades to the open position.
As the vehicle begins to accelerate, the relative speed between the turbine and the impeller decreases, thereby shifting the direction of fluid impingement against the stator. This change in direction does not change the position of the stator blades. The blades continue to be held in the open position by the fluid.
The present invention both reduces noise and vibration at idle and reduces harshness of converter clutch engagement and disengagement.
The present invention, when both fixed and rotatable blades are employed, provides a stator with both the advantages of rotatable blades and much of the structural rigidity of a stator having all blades fixed.
It is an object of this invention to provide an improved torque converter having a stator with variable pitch blades, wherein the blades in a closed position provide an open area approximately 15% of the flow area of the stator, and further wherein the blades have a closed position inlet angle between 30 degrees and 70 degrees depending upon the number of stator blades, the torque converter thereby being capable of reducing creep torque at idle by approximately 50% without inducing vibrations.
It is also an object of this invention to provide a three element fluid torque converter having a bladed impeller rotatively fixed to the engine, a bladed turbine rotatively fixed to a transmission input element, and a bladed stator rotatively fixed to a stationary shaft when subjected to torque in a first direction, yet rotating freely about the shaft when subjected to torque in a second direction, this stator comprising a stator shell, a stator core, and a plurality of stator blades distributed around the torque converter axis between the core and the shell, the blades being rotatable between an open position and a closed position, the blades blocking approximately 75% to 90% of an annular area between the shell and the core when in the closed position, an inlet angle of the blades being between approximately 30 degrees and 70 degrees in the closed position, with this angle varying inversely with the number of stator blades, with the closed position inlet angle and the area blocked being sufficient to diminish a flow of fluid from the turbine to the impeller so as to reduce torque converter torque transmitting capacity in the closed position by approximately 50% of the torque transmitting capacity of the torque converter with the stator blades in the open position.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top half of a section of a torque converter in an open position.
FIG. 2 shows a stator having rotatable blades with the rotatable blades in the open position from the direction of Arrows 2 of FIG. 1.
FIG. 3 shows a stator having rotatable blades with the rotatable blades in the open position from the direction of Arrows 3 of FIG. 1.
FIG. 4 shows a stator having rotatable blades with the rotatable blades in the closed position from the direction of Arrows 2 of FIG. 1.
FIG. 5 shows a stator having rotatable blades with the rotatable blades in the closed position from the direction of Arrows 3 of FIG. 1.
FIG. 6 shows a plot of creep torque as a function of engine speed.
FIG. 7 shows a stator having alternate fixed and rotatable blades with the rotatable blades in the open position from the direction of Arrows 2 of FIG. 1.
FIG. 8 shows a stator having alternate fixed and rotatable blades with the rotatable blades in the open position from the direction of Arrows 3 of FIG. 1.
FIG. 9 shows a stator having alternate fixed and rotatable blades with the rotatable blades in the closed position from the direction of Arrows 2 of FIG. 1.
FIG. 10 shows a stator having alternate fixed and rotatable blades with the rotatable blades in the closed position from the direction of Arrows 3 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A three element fluid torque converter 10 has a bladed impeller or pump 12, a bladed turbine 14 and a bladed stator 16. The impeller 12 is rotatively fixed to the engine crankshaft (not shown) through a flex plate 17 in a conventional manner. The turbine 14 is rotatively fixed to a transmission input element 18. The stator 16 is rotatively fixed to a stationary shaft 20, when subjected to torque in a first direction, but rotates freely about the stationary shaft 20, when subjected to torque in a second direction.
The stator 16 is disposed in a flow path from the turbine 14 to the impeller 12. The stator 16 has a stator core 22 with a core surface 24 having a center 26 disposed on a torque converter axis 28. FIGS. 1-5 show the core surface 24 having a concave spherical shape. The stator 16 also has a stator shell 30 with a shell surface 32 disposed radially inward of the core surface 24 with the center thereof being disposed in common with the center 26 of the core surface 24. FIGS. 1-5 show the shell surface 32 having a convex spherical shape.
The stator 16 has fourteen stator blades 34 distributed around the torque converter axis 28 between the core surface 24 and the shell surface 32. The blades 34 each have a first edge surface 36 and a second edge surface 38 proximate to and complementary to the shell surface 32 and the core surface 24 respectively. Each blade 34 also has an axis of rotation 40 passing through the center 26 of the stator shell 30 and core 22. The blades 34 are rotatable between an open position, shown in FIG. 2 and FIG. 3, and a closed position, shown in FIG. 4 and FIG. 5.
In the closed position, the blades 34 block approximately 75% to 90% of an annular flow area 42 between the core 22 and the shell 30. The blades 34 also have a closed position inlet angle A, shown in FIG. 4, between the torque converter axis 28 and a line 43 from the axis of rotation 40 of the blades 34 through the tip of the blade 34. In the preferred embodiment, the angle A equals 64 degrees. The closed position inlet angle A is sufficiently large to diminish the flow of fluid from the turbine 14 to the impeller 12, thereby reducing torque converter transmitting capacity with the blades 34 in the closed position approximately 50% when compared with the torque transmitting capacity of the torque converter 10 when the stator blades 34 are in the open position. The difference in the torque transmitting capacity is shown in the plots in FIG. 6.
An open position inlet angle B of the blades 34, corresponding to the closed position inlet angle A, is shown in FIG. 2.
The torque transmitting capacity reduction results in low creep torque. The combination of using the inlet angle A and blocking of the flow area between the core 22 and the shell 30 being limited to 75% to 90%, results in appreciably less driveline noise and vibration when compared with a conventional variable pitch stator.
The rotation of the stator blades 34 is controlled by a rotary control assembly 44 which establishes the angular disposition of the stator blades 34 between the open and the closed positions. The rotary control assembly 44 includes an annular piston cylinder 46 integral with the stator core 22, an annular piston 48 axially aligned with the piston cylinder 46, a plurality of stator pivots 50--one for each stator blade 34, and a plurality of piston springs 58 disposed between the piston cylinder 46 and the piston 48. The rotary control assembly 44 biases the blades 34 toward the closed position. Fluid impinging on the stator blades 34 must overcome the bias to rotate the blades 34 to the open position.
The rotary control assembly 44 is largely disposed in a core void 52. The core void 52 is bounded by an impeller core 54, a turbine core 56 and the stator core 22. The piston cylinder 46 is principally disposed in the core void 52 as is the annular piston 48. The stator pivots 50 are rotatively fixed to the corresponding blades 34. The pivots 50 have a cam portion 60 and a shaft portion 62 which passes through the stator core 22, the blades 34 and the stator shell 30. The stator pivots 50 are rotatively supported by the stator core 22 and the stator shell 30. The cam portion 60 is disposed in the core void 52 contiguous with the annular piston 48.
The piston springs 58 between the piston cylinder 46 and the piston 48 press the piston 48 into contact with the pivot cam portions 60. The blades 34 are thus biased to the closed position. The stator blades 34 are rotated to the open position by fluid flow past the blades 34. The piston 48 is displaced by the cam portions 60 of the stator pivots 50 toward the piston cylinder 46.
A pair of double labyrinth seals or restrictions 64 impede fluid from moving into and out of the core void 52. One double labyrinth seal 64 is located between the turbine core 56 and the stator core 22. The other double labyrinth seal 64 is located between the stator core 22 and the impeller core 54. The double labyrinth seals 64 minimize fluid flow through the core void 52 to reduce fluid drag in the core void 52.
A torque converter clutch 66 rotatively couples and uncouples the impeller 12 and the turbine 14.
An alternative configuration of the variable pitch stator 16 has eighteen stator blades 34 with the closed position inlet angle A equaling 30 degrees. Other stator configurations with the number of blades 34 being between fourteen and eighteen are possible. The closed position inlet angle A for a particular stator will vary inversely with the number of stator blades 34, from approximately 30 degrees to 70 degrees.
In a second alternative configuration, shown in FIGS. 7-10, a stator 16 has seven rotatable blades 34 and seven fixed blades 68. The fixed blades 68 are located alternately with the rotatable blades 34. The closed position inlet angle A of the rotatable blades 34 is approximately 64 degrees. The fixed blades 68 are integral with both the stator shell 30 and the stator core 22. An inlet angle C of the fixed blades 68 is approximately equal to the inlet angle B of the rotatable blades in the open position.
The fixed blades 68 have a chord length W longer than a chord length X of the rotatable blades 34. The chord length is a distance from the tip to a tail of the blade. This longer chord length W enables the blades 34 and 68 to block 75% to 90% of the flow area 42 with the rotatable blades 34 in the closed position. The chord length X of the rotatable blades 34 is longer than it appears in FIGS. 7 and 9 because the axes of rotation 40 of the rotatable blades 34 are not parallel to the fixed blade 68 shown.
The fixed blades 68 increase the structural rigidity of the stator 16, thereby improving the durability of the stator 16. However, there seems to be an increase in difficulty in obtaining the 50% reduction in torque transmitting capacity as the number of fixed blades 68 relative to the number of rotatable blades 34 is increased.
As few as three fixed blades 68 provide an appreciable increase in stator stiffness. For such a stator, the fixed blades 68 would be distributed generally uniformly among a remainder of rotatable blades 34.
The stator shell surface 32 and stator core surface 24 are shown as having core flats 70 and shell flats 72 for interfacing with the blades 34 and 68, as opposed to the spherical surfaces shown in FIGS. 1 through 5.
As the engine speed is increased from idle, the force of the fluid impinging on the stator blades 34 also increases. The force on the blades 34 is transferred to the cam portions 60 through the shaft portions 62. The cam portions 60 press against the piston 48, displacing the piston 48 into the piston cylinder 46, thereby compressing the springs 58. As the piston 48 moves further into the cylinder 46, the blades 34 are able to rotate further toward the open position.
The effect on creep torque of the transition in blade position from closed to open is illustrated in FIG. 6. Torque is shown as a function of the rotative speed of the engine crankshaft to which the impeller 12 is rotatively locked. The turbine 14 is stalled. The torque level with the stator blades 34 locked in the closed position is less than half the torque levels with the stator blades 34 locked in the open position. The stator blades 34, when not locked, make the transition from the closed to the open position between 800 and 1200 rpm.
As with a conventional fixed blade stator, the variable pitch stator 16 is rotatively fixed to the stationary shaft 20 when the rotative speed of the impeller 12 is significantly greater than that of the turbine 14. This is the case when the turbine 14 is stalled. Fluid exiting the turbine 14 impinges on the stator blades 34 at an angle resulting in a rotative force being applied to the stator 16 in the first direction opposite the direction of rotation of the impeller 12, thereby rotatively fixing the stator 16 to the stationary shaft 20. When the turbine 14 is allowed to rotate, its rotative speed approaches that of the impeller 12. The direction of fluid exiting the turbine 14 is shifted to produce a rotative force on the stator 16 in the second direction, the direction of rotation of the impeller 12 and turbine 14, thereby rotating the stator 16 relative to the stationary shaft 20 in the second direction.
An increased harshness of clutch 66 coupling and uncoupling has been perceived with previous variable pitch stators. The present invention is effective at minimizing any such harshness.
Obviously, many modifications and variations of the present invention are possible in light of the above teaching. It is therefore to be understood, that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | A three element fluid torque converter has a variable pitch stator. The stator blades have two principal orientations, closed and open. The blades are biased toward the closed position by a spring loaded annular piston. In the closed position, the blades block approximately 75% to 90% of the annular area between a stator core and a stator shell. An inlet angle for the stator blades is between 30 degrees and 70 degrees in the closed position. This combination reduces creep torque without any significant increase in driveline noise and vibration when the engine is idling. As engine speed and torque are increased, the blades overcome the spring bias to rotate to the open position thereby increasing the torque transmitted to effectively propel the vehicle. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to the mechanic arts, and particularly to the field of building demolition. It often happens that the site of an urban renewal or other building project is already occupied by structures which are not suited for the new use, or are in ill repair, and hence must be removed. Such structures are frequently of frame construction and contain sheathing, roofing, flooring, and similar boards which would have value for reuse. Usually, however, no attempt is made to salvage this material, and the whole structure is torn apart by a wrecking crane and hauled away as trash to be disposed of. Sometimes this is due to the pressure of time within which the new work must be accomplished, but very often it is simply because the reclamation of such used lumber is not economically feasible. The cost of the labor needed to disassemble a structure in a way which preserves usable materials is one factor, and another factor is the relatively low yield of usable material due, for example, to splitting of boards incidental to the wrecking process. The usual tools employed in demolition are hammers and wrecking bars: occasionally nail pullers are used, but pulling nails individually is a tedious process which is slow and hence expensive in labor costs. The concentrated impact of hammer blows mars the boards, and often causes breakage, while wrecking bars are almost ideally designed to split boards lengthwise in the act of removing them.
I have invented a tool for use in demolishing frame buildings, which is inexpensive, efficient, and easy to use, and which acts on substantially the entire width of the board being removed, rather than along one edge only, to continuously and smoothly separate the board from the timber to which it is nailed. My tool is usable in any position, to remove sheathing, roofing, of flooring boards, wherever access can be had to the rear surface of the boards and the timbers to which they are nailed. My tool involves no impact forces and no cross grain leverage forces, and hence its use results in a high proportion of undamaged boards fit for salvage.
SUMMARY OF THE INVENTION
My demolition tool comprises a frame and means for clamping the frame to a timber behind a board to be removed. Linearly movable in the frame is a member which includes a pressure foot of length only slightly less than the width of the board being removed, and means are provided for causing movement of the member so that the pressure foot first engages the back surface of the board and then forces it away from the timber, thus drawing the nails without splitting the board or damaging either of its faces.
Various advantages and features of novelty which characterize my invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects attained by its use, reference should be had to the drawing which forms a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing,
FIG. 1 is a plan view showing my demolition tool in use;
FIG. 2 is a side elevation;
FIG. 3 is a fragmentary view taken along the line 3--3 of FIG. 1;
FIG. 4 is a sectional view taken along the line 4--4 of FIG. 2;
FIG. 5 is a sectional view taken along the line 5--5 of FIG. 2;
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 2; and
FIG. 7 is a fragmentary view of the tool showing a modification.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the drawings, my invention comprises an elongated frame 20 having a longitudinal axis 21 and a longitudinal guideway 22 extending between a first end 23 and a second end 24 of the frame. A member 25 is linearly movable along axis 21, and extends beyond the end 23 of the frame 20 at 26. Member 25 is fastened as by a threaded connection 27 to the body of a nut 30 which slides in guideway 22 without rotating about axis 21. Cooperating with nut 30 is a screw 31. While elements 30 and 31 are shown as cooperating with a plurality of steel balls 32 and recirculating tube 33 to comprise a low friction connection of a well known type, a simple nut and screw with standard Acme or square threads may be used if desired. Screw 31 has an enlarged collar 34 beyond which it extends as a shaft 35 passing through a thrust bearing 36, end 24 of frame 20, and a thrust washer 37. An outer hub 40 is secured to shaft 35 as at 41, and is cross bored to receive a crank 42 having a rotatable knob 43, and secured in hub 40 as at 44.
Member 25 is hollow and the portion of screw 31 which extends beyond nut 30 is contained within the member and carries at its outer end 45 a disc 46 which is a loose fit in the hollow 47 of the member. Frame 20 has a face 50 which is parallel with axis 21. A plurality of teeth 51 extend away from face 50 and are secured to end 23 of frame 20 by suitable fasteners 52.
A pressure foot 53 is removably retained in the end 26 of member 25 beyond end 23 by means such as a ball detent 58, and extends perpendicular to axis 21. It is desirable that the length of this foot be different for different applications, and FIG. 2 shows a second, longer foot 54 as being removably secured on foot 53 by means such as a ball detent 59.
An arm 60 is secured to frame 20 near end 24, and extends from the frame in the same direction as teeth 51. Arm 60 has a pair of substantially parallel faces 61 and 62 generally orthogonal to axis 21, and a carrier 63 is movable along arm 60. At one end, carrier 63 rigidly is connected to a pair of shoes 64 and 65 having first parallel surfaces 66 and 67 spaced by substantially the distance between surfaces 61 and 62. A second pair of surfaces 70 and 71 make dihedral angles with the surfaces 66 and 67, respectively. The vertices of these angles are substantially in a plane parallel to axis 21, but may be slightly offset so that the vertex of shoe 64 is slightly further from, and that of shoe 65 is slightly nearer to, frame 20. The distance between parallel surfaces 70 and 71 is greater than that between surfaces 66 and 67 so that if carrier 63 is rotated in a counter-clockwise direction the fit of the shoes on arm 60 is perceptably looser. A set screw 72 is provided in shoe 65 to hold the carrier in any desired position along arm 60.
A jaw 73 is pivoted to carrier 63 at 74, and a handle 75 is pivoted to carrier 73 at 76. The end of handle 75 is connected to jaw 73 by a link 77, pivoted to the handle at 80 and to the jaw at 81. Members 73 - 81 comprise an overcenter mechanism 82 for locking arm 73 in a desired position. Link 77 may be configured as at 83 to provide a stop in the overcenter condition of the assembly.
In order to make the use of my tool more convenient where boards are to be removed from wider timbers, I provide an extension 84 for member 25, as is shown in FIG. 7. This extension is arranged to cooperate with ball detent 58, and has a similar ball detent 85 for cooperating with pressure foot 53.
OPERATION
My tool is used, as shown in FIG. 1, in the following fashion. It is desired to remove from a timber 90, such as a two-by-four, a board 91 which is held to the timber by nails 92. Set screw 72 is loosened to allow movement of carrier 63 along arm 60, and a foot 54 slightly shorter than the width of the board to be removed is used. With member 25 retracted as far as possible into frame 20 by the use of crank 42, the tool is positioned so that foot 54 is against board 91 near timber 90, and face 50 is toward the timber with teeth 51 touching it. With handle 75 in the broken line position of FIG. 1, carrier 63 is moved along arm 60 toward timber 90 until jaw 73 is close to or touching the timber, and handle 75 is then moved to its solid line position. The causes faces 66 and 67 to engage faces 61 and 62 securely, and draws teeth 51 into the timber. Set screw 72 may be tightened, and the tool is now secured to timber 90. Operation of crank 42 rotates screw 31 to drive nut 30, and with it member 25, toward board 91. Powerful forces are put into action and the board is displaced smoothly from the timber, the nails usually being drawn as well. Sometimes in old work, the head of a badly rusted nail may be pulled through the board, but the hole thus produced is a relatively minor imperfection in used lumber.
Handle 75 is now reversed to allow the teeth to be extracted from the timber, the tool is repositioned, and the work continues. It will be apparent that the operation just described is simple to perform, requires no great strength of the operator, is free from the noise and dust which accompany impact operations, and has no tendency to split the boards.
While I have shown a screw as the driving element for member 25, it will be apparent that mechanical equivalents may be used as preferred. I also contemplate that for major demolition projects, my member 25 may be arranged for pneumatic or hydraulic actuation, when this additional complication is felt justified.
From the above it will be evident that I have invented a demolition tool which is simple, easy to use, relatively inexpensive, quiet and clean, which may be used to remove boards of various widths from timbers of various thicknesses, which causes minimum damage to the lumber being reclaimed, and which may be arranged for either manual or fluidic actuation.
Numerous characteristics and advantages of my invention have been set forth in the foregoing description, together with details of the structure and function of the invention, and the novel features thereof are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A tool for use in demolition of frame structures to preserve the lumber for reuse. A frame is secured to a timber, to which a board to be removed is nailed, by quick acting means including an overcenter connection. A pressure foot projecting from the frame bears against the back of the board to be removed. By a screw-acting mechanism in the frame the board is forced away from the timber over its entire width without splitting, pulling the nails as it does so. | 4 |
SUMMARY OF THE PRIOR ART
The closest known prior art is U.S. Pat. No. 3,656,445 which decribes a multi-hull boat having a mast which can be swung to 180° and locked in either position. The present invention differs primarily from said prior patent in that the patent shows a boat with hulls having horizontal and vertical symmetry while the present invention shows an improved form of boat wherein conventional hulls are employed which can be swung through 180°.
SUMMARY OF THE INVENTION
Catamarans are popular boats primarily because of their great speed and light weight but they suffer from the deficiency that once capsized the boat is almost impossible to right, particularly when sailed by a single person.
It has previously been proposed to provide a catamaran with a sail on a mast wherein the mast can be swung to 180° and locked in either of the positions. This provides some degree of safety but does not provide a fully satisfactory boat since the hulls extend equally above and below the spars and thus the spars connecting the hulls including the deck area must of necessity be undesirably close to the water.
In accordance with the present invention, a catamaran is provided with hulls which normally extend entirely or almost in their entirety below the spars so that the spars are always maintained at a substantial distance above the water surface. The hulls are provided with pivots and locking members so that they can extend at right angles either above or below the spar. This means that if the boat capsizes, the hulls, which would then be sticking up in the air, can be unlocked, and swung 180° so that they are now again beneath the spars; this is easily done by a single person. The mast is similarly swung to 180° so that the catamaran has substantially the same water clearance and sailability regardless of which side of the spars the mast and hulls are on.
Other features and advantages of the present invention will be brought out in the balance of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a catamaran embodying the present invention.
FIG. 2 is a plan view of the catamaran shown in FIG. 1.
FIG. 3 is a diagrammatic view showing the method of swinging the hulls and the mast.
FIG. 4 shows an alternative embodiment of the invention using an A-frame mast which is a necessity in applying this self-rescuing principle to a trimaran as the A-frame mast can swing around the center hull. It should be noted that the A-frame mast can also be mounted on a catamaran to give thwartship rigidity not possible with an unstayed conventional mast.
FIG. 5 is a side view of the boat shown in FIG. 4 showing the position of the parts after the boat has been righted.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings by reference characters, a boat is shown having hulls 7 and 9 which are supported in spaced relationship by means of a forward spar 11 and an aft spar 13. The spars also support a net 15 or other suitable decking. The forward spar supports a mast 17 which is mounted for rotation on a bearing 19 and which is held in position by bow and stern stays 21 and 22 respectively or other suitable means.
Hulls 7 and 9 are provided with bearings for attachment to the spars 13 and 19. Since all four connections are substantially the same, only one is described in detail. Thus, referring particularly to FIG. 2, bearings 23 and 25 are provided on the upper surface of the hull and the end of the spar 13 is enlarged and supports a mating bearing 27. Shaft 28 passes through bearings 23, 27 and 25 so that hull 9 can rotate with respect to spar 13. A removable pin 29 extends through bearing 23 and into a selected one of two mating holes in spar 13. These holes 30 and 32 are 180° apart in the end of bearing 23. Thus, the pin 29 will hold the hull in either of two selected positions 180° apart.
In a practical embodiment of the invention, the craft would ordinarily have a pair of rudders 31 and 33 which swing on the removable pins 35 and 37. The rudders would incorporate the usual steering apparatus generally designated 39.
Normally of course, the mast would extend above the spars 11 and 13 and the two hulls would extend below spars 11 and 13, the mast and hulls being held in their respective positions by means of the stays and pins described. If the boat capsizes, it is easily restored to sailing condition even if it is only sailed by one person. Thus, referring particularly to FIGS. 1 and 3, the boat is shown with the mast 17 in solid lines under the water and the hull 7 extending above the water, in a position which these parts would assume when the boat capsizes. Obviously the hull 9 would also normally be above the spars 11 and 13. However, the right-hand hull 9 in FIGS. 1 and 3 has been shown as it would be in the first stage of righting the craft. In other words, the pin 29 has been withdrawn and the hull 9 swung through 180° and locked by replacing the pin 29 in hole 30. Obviously it is necessary to first free the connecting rod 32 from the tillers before the hulls can be inverted. Now one repeats the operation with hull 7, swinging it from the position shown in solid lines in FIG. 3 to the position shown in dot-dash lines. The hull is locked in place with a pin as previously described. Now one disconnects the stern stays so that the mast is free to swing forward and upward through 180° bringing it from the position shown in solid lines in FIGS. 1 and 3 to the position shown in dot-dash lines and then locks the mast in the new position shown in dot-dash lines and then secures the mast in the new position by reattaching the stern stays. The connecting rod 32 can now be reconnected to the tillers as a final preparatory step to realizing a self-rescuing capability in this inverted position.
As is shown in FIGS. 4 and 5, the invention is applicable to a boat having an A-frame mast and illustrated as applied to a trimaran although the A-frame mast might be used on a craft having two hulls. Here, the A-frame mast generally designated 41 is journaled on the spar 43 near the outer extremities of the spar with bow and stern stays (not shown) for securing the A-frame mast in either of the positions shown in solid lines or in dot-dash lines. The hulls 45 and 47 are fastened to the spars with connections which can be swung and locked 180° apart as previously described. In the case of a trimaran, the center hull 49 is fastened to the spars. If the boat capsizes the hulls 45 and 47 can be inverted as previously described and the A-frame mast can be similarly swung to 180° and secured. The center hull 49 will remain inverted but clear of the water due to the buoyancy of hulls 45 and 47 which are now in a normal sailing position, below the spars and inverted center hull, making it possible to sail the trimaran unaided to a safe port.
Although certain specific embodiments of the invention have been shown, it is obvious to those skilled in the art that many departures can be made from the exact structure shown without departing from the spirit of this invention. For instance, locking pins have been shown for locking the hulls and the mast at desired positions and other fastening means can be employed. | A multiple hull craft such as a catamaran is provided having outrigger hulls which can be swung to either of two positions 180° apart and locked in either position. The mast is swingable about a center structure through an angle of 180° and is secured at either extreme. These features allow one to sail a boat after it has capsized as is hereinafter described in detail. | 1 |
FIELD OF THE INVENTION
[0001] The invention is directed to a polymer thick film (PTF) silver conductor composition for use in Radio Frequency Identification Devices (RFID) and other applications. In one embodiment, the PTF silver composition is used as a screen-printed conductor on a flexible low temperature substrate, such as polyester, where the PTF silver composition functions as an antenna. This composition may further be used for any other application where extremely high conductivity and low resistivity is required.
BACKGROUND OF THE INVENTION
[0002] Polymer thick film silver compositions are used in RFID devices as well as other applications such as Membrane Touch Switches, Appliance Circuitry, or any uses where a high conductivity polymer thick film silver conductor is required. Such products are typically used as the printed antenna of the cell. An antenna pattern of the polymer thick film silver composition is printed on top of the appropriate substrate. RFID circuit performance is dependent on both the conductivity of the printed antenna and the resistance of the circuit. The lower the resistivity (inverse of conductivity) the better the performance of any polymer thick film composition used is such circuitry. It is desirable to use a composition that has low restivity and is suitable for coating at thicknesses necessary for RFID applications.
SUMMARY OF THE INVENTION
[0003] The present invention is directed to a polymer thick film composition comprising: (a) silver flake (b) organic medium comprising (1) organic polymeric binder; (2) solvent; and (3) printing aids that have low restivity. The composition may be processed at a time and temperature necessary to remove all solvent. Specifically, the composition comprises (a) 50-85% by weight silver flake with an average particle size of at least 3 microns, at least 10% of the particles greater than 7 microns, and stearic acid surfactant
[0000] (b) 15-50% by weight organic medium comprising
(1) 16-25% by weight vinyl copolymer resin (2) 75-84% by weight organic solvent.
[0006] The composition may also contain up to 1% by weight of gold, silver, copper, nickel, aluminum, platinum, palladium, molybdenum, tungsten, tantalum, tin, indium, lanthanum, gadolinium, boron, ruthenium, cobalt, titanium, yttrium, europium, gallium, sulfur, zinc, silicon, magnesium, barium, cerium, strontium, lead, antimony, conductive carbon, and combinations thereof.
[0007] The invention is further directed to method(s) of electrode formation on RFID or other circuits using such composition and to articles formed from such methods and/or composition.
DETAILED DESCRIPTION OF INVENTION
[0008] Generally, a thick film composition comprises a functional phase that imparts appropriate electrically functional properties to the composition. The functional phase comprises electrically functional powders dispersed in an organic medium that acts as a carrier for the functional phase. In general, a thick film composition is fired to burn out the organics and to impart the electrically functional properties. However, in the case of a polymer thick film composition, the organics remain as an integral part of the composition after drying. Such “organics” comprise polymer, resin or binder components of a thick film composition. These terms may be used interchangeably.
[0009] The main components of the thick film conductor composition are a conductor powder dispersed in an organic medium, which is comprised of polymer resin and solvent. The components are discussed herein below.
A. Conductor Powder
[0010] The electrically functional powders in the present thick film composition are Ag conductor powders and may comprise Ag metal powder, alloys of Ag metal powder, or mixtures thereof. The particle diameter, shape, and surfactant used on the metal powder are particularly important and have to be appropriate to the application method.
[0011] The particle size distribution of the metal particles is itself critical with respect to the effectiveness of the invention. As a practical matter, it is preferred that the particles size be in the range of 1 to 100 microns. The minimum particle size is within the range of 1-10 microns, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 microns. The maximum size of the particles is within the range of 18-100 microns, such as 18, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 100 microns. In one advantageous embodiment the silver flake ranges from 2-18 microns.
[0012] The metal particles are present at from 50-85% by weight of the total composition.
[0013] It is also important that a surfactant be used in the composition to facilitate the effective alignment of the flaked silver particles herein. Stearic acid is the preferred surfactant for the flaked silver.
[0014] Furthermore, it is well known in the art that small amounts of other metals may be added to silver conductor compositions to improve the properties of the conductor. Some examples of such metals include: gold, silver, copper, nickel, aluminum, platinum, palladium, molybdenum, tungsten, tantalum, tin, indium, lanthanum, gadolinium, boron, ruthenium, cobalt, titanium, yttrium, europium, gallium, sulfur, zinc, silicon, magnesium, barium, cerium, strontium, lead, antimony, conductive carbon, and combinations thereof and others common in the art of thick film compositions. The additional metal(s) may comprise up to about 1.0 percent by weight of the total composition.
B. Organic Medium
[0015] The powders herein are typically mixed with an organic medium (vehicle) by mechanical mixing to form a paste-like composition, called “polymer thick film silver compositions” or “pastes” herein, having suitable consistency and rheology for printing. A wide variety of inert liquids can be used as an organic medium. The organic medium must be one in which the solids are dispersible with an adequate degree of stability. The rheological properties of the medium must be such that they lend good application properties to the composition. Such properties include: dispersion of solids with an adequate degree of stability, good application of composition, appropriate viscosity, thixotropy, appropriate wet ability of the substrate and the solids, a good drying rate, and dried film strength sufficient to withstand rough handling.
[0016] The polymer resin of the present invention is particularly important. The resin used in the present invention is a vinyl co-polymer which allows high weight loading of silver flake and thus helps achieve both good adhesion to polyester substrates and low resistivity (high conductivity), two critical properties for silver electrodes in RFID circuitry.
[0017] Vinyl-copolymer is herein defined as polymers produced by polymerizing the vinyl group of a vinyl monomer with at least one co monomer. Suitable vinyl monomers include but are not limited to vinyl acetate, vinyl alcohol, vinyl chloride, vinylidene chloride and styrene. Suitable co monomers include but are not limited to a second vinyl monomer, acrylates and nitrides. Vinylidene chloride copolymer with at least one of vinyl chloride, acrylonitrile, alkyl acrylate is a suitable polymer resin.
[0018] The most widely used organic solvents found in thick film compositions are ethyl acetate and terpenes such as alpha- or beta-terpineol or mixtures thereof with other solvents such as kerosene, dibutylphthalate, butyl carbitol, butyl carbitol acetate, hexylene glycol and high boiling alcohols and alcohol esters. In addition, volatile liquids for promoting rapid hardening after application on the substrate can be included in the vehicle. In many embodiments of the present invention, solvents such as glycol ethers, ketones, esters and other solvents of like boiling points (in the range of 180° C. to 250° C.), and mixtures thereof may be used. In one advantageous embodiment the medium includes dibasic esters and C-11 ketone.
[0019] The medium comprises 16-25% by weight of the vinyl copolymer resin and 75-84% by weight organic solvent.
Application of Thick Films
[0020] The polymer thick film silver composition or paste herein is typically deposited on a substrate, such as a polyester, that is essentially impermeable to gases and moisture. The substrate can also be a sheet of flexible material, such as an impermeable plastic, such as a composite material made up of a combination of plastic sheet with optional metallic or dielectric layers deposited thereupon. In one embodiment, the substrate can be a build-up of layers inclusing metalized silver.
[0021] The deposition of the polymer thick film silver composition is performed in one embodiment by screen printing, and in other embodiments by deposition techniques such as stencil printing, syringe dispensing or coating techniques. In the case of screen-printing, the screen mesh size controls the thickness of deposited thick film.
[0022] The deposited thick film is dried or the organic solvent is evaporated, such as by exposure to heat, for example 10-15 min at 120-140° C.
[0023] The present composition particly suitable for RFID related uses because of its:
[0024] (1) Unusually low resistivity observed (4.6 milliohm/sq/mil); and
[0025] (2) The thickness of the print (9-10 microns using a 280 Stainless Steel screen) which is very important for RFID and other applications. The net result of (1) and (2) is very low circuit resistance, which is an extremely desirable and advantageous characteristic.
[0026] The present invention will be discussed in further detail by the below examples. The scope of the present invention, however, is not limited in any way by these examples.
EXAMPLE 1
[0027] The PTF silver electrode paste was prepared by mixing silver flake with an average particle size of 4 micron (range was 1-18 microns) that contains stearic acid as a surfactant, with an organic medium composed of a co-polymer of vinylidene chloride and acrylonitrile resin (also known as Saran F-310 resin, Dow Chemical, Midland, Mich.). The molecular weight of the resin was approximately 25,000. The surface area/weight ratio of the silver particles is in the range of 0.8-1.3 m 2 /g.
[0028] A solvent was used to dissolve the resin completely prior to adding the silver flake. That solvent was a 50/50 blend of DiBasic Esters (DuPont, Wilmington, Del.) and C-11 Ketone solvent (Eastman Chemical Company, Kingsport, Tenn.). A small amount of additional C-11 Ketone was added to the formulation.
[0029] The polymer thick film composition was:
[0000]
64.00%
Flaked Silver with Stearic Acid surfactant
35.50
Organic Medium (19.5% resin/80.5% solvent)
0.50
C-11 Solvent
[0030] This composition was mixed for 30 minutes on a planetary mixer. The composition was then transferred to a three-roll mill where it was subjected to a first pass at 150 PSI and a second pass at 250 PSI. At this point, the composition was used to screen print a silver pattern on polyester. Using a 280 mesh stainless steel screen, a series of lines were printed, and the silver paste was dried at 140° C. for 15 min. in a forced air box oven. The resistivity was then measured as 4.6 milliohm/sq/mil at a thickness of 10 microns. As a comparison, a standard composition such as DuPont product 5025 was measured as 13.6 milliohm/sq/mil. Another high conductivity standard product such as DuPont 5028 showed 9.8 milliohm/sq/mil, which is 2× higher resistivity than the example given above. This unexpectedly large improvement (lowering) in resistivity, a key property for all silver compositions, enables it to be used for most applications and improves RFID antenna performance. Also note that the value observed, 4.6 mohm/sq/mil, is approaching that of high temperature fired (850° C.) silver conductors. A comparison table appears below:
[0000]
Adhesion
to
Resistivity
Silver Composition
Polyester
mohm/sq/mil
5025
Good
13.6
5028
Good
9.8
Example 1
Excellent
4.6
High Temp.
Not
1.5
(850° C.) Ag
applicable
EXAMPLE 2
[0031] Another PTF silver composition was prepared, except that the surfactant on the silver flake was changed from stearic acid to oleic acid. All other properties of the formulation, silver powder distribution, and the subsequent processing were the same as Example 1. That is, the same organic medium was used as in Example 1. The normalized resistivity for this composition was 42.8 mohm/sq/mil. It is apparent that a change in surfactant chemistry on the silver flake has a significant (negative) impact on the resistivity of the composition.
EXAMPLE 3
[0032] Another PTF silver composition was prepared except that the particle size distribution was shifted to smaller particles. Here, the average particle size was reduced to approximately 2 microns and there were virtually no particles greater than 7 microns. The surfactant of Example 2, oleic acid, was used on the silver flake. All other processing conditions were the same as example 1. The normalized resistivity for this composition was 20.2 mohm/sq/mil again showing the criticality of the particle size of the silver chosen and the surfactant used.
EXAMPLE 4
[0033] Another PTF silver composition was prepared as per Example 1 except the resin used was changed from the vinyl co-polymer described in Example 1 to a thermoplastic polyester resin of molecular weight 25000. All other conditions and processing were the same. The normalized resistivity measured was 22.7 mohm/sq/mil establishing the criticality of the resin used in Example 1 in concert with the silver powder. | Disclosed are thick film silver compositions comprised of silver flake and organic medium useful in radio frequency identification devices (RFID). The invention is further directed to method(s) of antenna formation using RFID circuits or other circuits using polymer thick film (PTF). | 7 |
BACKGROUND OF THE INVENTION
The present invention relates in general to a support member for use with a planting container arrangement for supporting decorative dressings placed within the plant container and around a planting contained therein and pertains, more particularly to a support member for placement around a plant that supports decorative finishes used in the plant container. The support member of this invention is an improvement over the conventional systems and methods used to provide a desired decorative finish with conventional materials, such as, mulch, bark, and moss.
With the conventional planter arrangements it is generally necessary to cover a planter with decorative materials to hide a gap between an outer decorative pot and an inner grow pot. The conventional grow pot is placed within the outer decorative container leaving the intermediate gap into which the decorative covering falls and collects.
This is a conventional arrangement for interior plants placed in office settings. However, the conventional planter and grow pot arrangement does not permit easily placing a decorative mulch, bark, or moss directly around the plant as described above.
Installing and maintaining interior plantings is a time and labor intensive business. A nursery, florist or other business may supply, service and maintain plants in several offices or business. Maintaining plantings often require the removal of the existing plant from the decorative container and exchanging the old with a new plant. The old plant can then be brought back to the shop to undergo additional procedures such as re-potting, grafting or trimming.
Maintenance of these decorative plantings requires the removal of the grow pot from within the decorative container. The decorative topping or dressing material (e.g., mulch, bark, decorative stones, or moss) that was added to provide an aesthetically pleasing presentation must be removed. This operation is time consuming and often produces a mess around the decorative pot.
Another drawback associated with conventional decorative plantings is that the gap between the grow pot and the outer decorative container contains a filler to keep the dressing material from between the pots. The filler may include styrofoam particles or blocks shoved or wedged in between the pots.
The conventional arrangment includes a further drawback especially when the dressing is taken out and the pots separated, then it is desirable to separate the quantity of dressing from the filler. As a result, maintaining the planting becomes a two-step process for both removing and replacing the plant and its grow pot in the ornamental outer pot.
Presently, there is no product specifically designed to assist in the operation of removing the decorative mulch or bark or moss from around the plant. Prior art teaches various types of pots and decorative containers, jardiniere, supports for pots, substrates and pot coverings.
Accordingly, it is the object of the present invention to provide a support member for supporting a decorative dressing material used in conjunction with a decorative pot for a plant or another pot and its plant. With the support member of this invention it has been found that the top dressing material is easily removed with little mess or waste of the dressing material.
Another object of the present invention is to provide a support member having an associated structure and functional appendages for generally stabilizing the support member, supporting the top dressing actually above the pot, and locking the support member in a generally circular shape. The support member of this invention assists in reducing the labor and time involved in removing a plant and its associated grow pot from a decorative container and, if desired, placing another grow pot and plant in the decorative container.
A further object of the present invention is to provide a support member that is adjustable and thereby adaptable for use with various sizes of grow pot and decorative containers combinations.
Still another object of the present invention is to provide a support member that is economical to use and inexpensive to manufacture.
Still a further object of the present invention is to provide a support member that provides a supporting surface for conventional top dressing materials.
Another object of the present invention is to provide a support member that may be used more than once. The support member is manufactured from a material that can be periodically cleaned.
SUMMARY OF THE INVENTION
To accomplish the foregoing and other objects of this invention there is provided support member further referred to as a support member for supporting decorative material or top dressings, typically for use in conjunction with a grow pot and decorative container. The support member comprises a collar means for generally enclosing a plant within the container.
The collar means in the illustrated embodiment includes extensions from the collar means adaptable for insertion into a soil portion of the container and projections also extending from the collar means for supporting a quantity of the dressing material. The support member of this invention substantially separate the top dressing from the plant and associated containers by supporting the decorative material generally above the plant and container arrangement.
The collar member generally defines an opening through which the plant may extend. In the disclosed embodiment described herein, there are provided tabs that are bent generally upwards to form a bowl shaped support surface for containing the dressing material. When two plant containers are used, an inner grow pot and an outer decorative container, the grow pot nests inside the outer container and the tabs extend across the gap created by the nesting arrangement. The tabs obstruct the dressing material from descending into the gap.
The collar means includes a closure means for maintaining the support member in a desired overall shape. In the described embodiment the collar is generally circular.
In operation, the support member is generally circular and planar with a center opening through which a plant may extend. Two ends are provided for allowing the collar to be placed around a plant. The collar is slightly bent or twisted to space apart the opposing ends and to allow the collar to be placed around the plant.
The collar being made of a material that will allow such bending and twisting to occur and return back to its original shape. The collar is then lowered to the top of the grow pot within the decorative container and the decorative mulch, bark, moss or other top dressing is placed on the support. The decorative mulch, bark or the like can then be easily removed by raising the collar and tilting the pot or pot and container while brushing off the decorative material. The collar is opened and removed allowing the plant to be changed or maintained.
Upon completion of plant maintenance, the collar is replaced and the same top dressing replaced on the support collar, if desired, or new top dressing may be applied.
These and other objects and features of the present invention will be better understood and appreciated from the following detailed description of one embodiment thereof, selected for purposes of illustration and shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a support member constructed in accordance with the present invention;
FIG. 2 is a partial plan view of the support member depicted in FIG. 1 with a closure system illustrated in a closed position; and
FIG. 3 is a sectional side view of the support member in use with a grow pot and decorative container.
DETAILED DESCRIPTION
Referring now to the drawing there is shown a preferred embodiment for the support member or plant collar of this invention. The plant collar is described in connection with a conventional nested grow pot and decorative pot arrangement. It should be recognized that the plant collar of the present invention can be made in various sizes to accommodate the variety of sizes in pots and decorative container and that the physical design and shape of the plant collar can be varied from the illustrations included herewith.
The drawings show a support member or plant collar 10 that generally encloses a plant as further described below. A collar means includes a generally circular collar portion 12. The collar portion defines a center opening 14 for receiving a plant. The collar means further includes extensions from the collar portion. The extensions stabilize the collar within its respective planting arrangement. In a preferred embodiment the extensions are fingers 16-22 that extend into the interior opening of the collar.
The support member or collar includes projections that are adapted to support a quantity of decorative or dressing material and maintain the material separate from and generally above the plant and pot arrangement. In a preferred embodiment the plant collar 10 includes a plurality of tabs 24 extending outward from the plant collar 10. The collar 10 is preferably of a material that allows tabs 24 to be bent generally upward so as to form a bowl shaped support surface for containing the decorative material.
It will be understood that as tabs 24 are bent upwards the outer diameter of the plant collar 10 is reduced. This feature allows a plant collar 10 to be used with a variety of container sizes. Bending the tabs further facilitates the formation of the bowl shaped support surface and, it will be recognized, the bent tabs function to hold and stabilize the plant collar 10 in position. This feature assists the finger extensions to stabilize the collar.
The plant collar 10 provides a closure means 26 used to fix the plant collar 10 in position. The plant collar 10 includes a opposing collar ends 28 and 30 defined by a separation of the collar portion 14 by an imaginary line. In a preferred embodiment the line is along a radii from a center of the collar.
The opposing collar ends 28 and 30 are readily separable, for example, by slightly bending or twisting the plant collar 10. This provides for easy plant collar installation. The opposing collar ends 28 and 30 provide the closure means and are designed such that a fastener portion is formed. In use, the closure means allows repeated installation and removal of the collar 10. The opposing collar ends provide respective closure means.
A closure tab 32 defines a first respective wing member 34 and a second respective wing member 36. Another closure tab member 38 on opposing collar end 30 defines its first respective wing member 40 and its second respective wing member 42. A plurality of wing receiving openings 44-50 are provided to receive their respective tab members. Operation of the closure means is described in greater detail below in cooperation with FIG. 2.
The closure means is incorporated into the collar while still providing a desired end tab 52. Thus, the closure means is readily adapted to the support member without interfering with use of the present invention. The one end tab overlays the other end tab. The wings of the upper end insert down and into the receiving openings. The other, lower end tab wings are inserted up and into the receiving openings. This provides one preferred closure means that does not interfere with the other operation of the collar 10.
In operation, in connection with a conventional grow pot 56, the pot 56 contains soil 58 and a plant 60. An annular channel or gap 62 results from nesting the grow pot 56 in an outer or decorative container 54. The desired effect is illustrated in FIG. 3 in which a quantity of a decorative cover or top dressing 64 is indicated. The top dressing may be a mulch, bark, moss, or stone material used in conventional plantings, particularly in office or commercial environments.
The collar 10 is initially placed around the plant 60. The extensions or finger members 16-22 are bent about the broken lines shown in FIGS. 1 and 2 generally at the base of each extension. These extensions go into the soil to support and stabilize the collar 10. In the preferred embodiment four extensions are illustrated in FIG. 1 and an embodiment illustrated in FIG. 3 includes additional tabs and extensions.
Once the plant collar 10 is placed around the plant 60, the plant collar 10 is lowered into the decorative container 54 and the extensions inserted into the soil. The tabs 24 are bent upwards so that the plant collar 10 will fit substantially inside the decorative container 54. The tabs 24 are bent upwards so that the plant collar 10 will fit inside of the decorative container 54 and rest upon upper edge of the container 54 and generally above the grow pot 56. Decorative cover 64 rests on top of the collar 10 to provide the desired aesthetically pleasing appearance.
The decorative cover or dressing 64 is readily removed by lifting the plant collar 10 and brushing the cover onto the floor or container for re-use.
From the foregoing description those skilled in the art will appreciate that all of the objects of the present invention are realized. A support member for supporting a decorative dressing material for use in conjunction with a decorative pot for a plant or another pot and its plant are provided. With the support member of this invention the top dressing material is easily removed with little mess or waste of the dressing material.
The collar or support member provides associated structure and functional appendages for generally stabilizing the support member, supporting the top dressing actually above the pot, and locking the support member in a generally circular shape. The result is a support member that reduces the labor and time involved in removing a plant and its associated grow pot from a decorative container and, if desired, placing another grow pot and plant in the decorative container.
The collar or support member is adjustable and thereby adaptable for use with various sizes of grow pot and decorative containers combinations. It will be understood that the support member provides a convenient supporting surface for conventional top dressing materials. The collar of this invention may be reused and periodically cleaned if manufactured from a suitable material.
While a specific embodiment has been shown and described, many variations are possible. The particular shape and design of the plant collar may vary as can the particular shape and design of the associated extensions and projections associated with the ends and center opening of this invention. The collar materials may vary although a flexible, fire-resistant or fire-retardant material is preferred. The configuration, size and number of extensions and projections may vary. It is preferred to manufacture this invention in a number of sizes than can be used in a variety of pot and containers.
Having described the invention in detail, those skilled in the art will appreciate that modifications may be made of the invention without departing from its spirit. Therefore, it is not intended that the scope of the invention be limited to the specific embodiment illustrated and described. Rather, it is intended that the scope of this invention be determined by the appended claims and their equivalents. | A support member for a plant container for supporting decorative dressings placed within the plant container around a planting contained therein and pertains, has a collar for placement around a plant. The collar includes extensions and projections that support conventional decorative finishes used with the associated plant container or containers, for example, mulch, bark, moss, or similar materials. | 0 |
This application claims benefit of the provisional application filed Nov. 2, 1998, having Ser. No. 60/106,687.
FIELD OF THE INVENTION
This invention relates to biological permeable barriers for creating a “bio-trench” or “bio-curtain” to clean contaminated groundwater. Specifically, the present invention relates to an apparatus and method to biodegrade contaminates in groundwater as the groundwater contacts and passes through the immobilized cells of the “bio-trench” or “bio-curtain” during groundwater flow or movement.
BACKGROUND OF THE INVENTION
Today's release of the contaminants to the groundwater is increasing. With over 50% of the fresh water used in the United States coming from groundwater, contamination of this resource by xenobiotic chemicals represents a potential serious health and environmental problem. Toxicity, accumulation, and persistence of contaminants found in groundwater are just a few of the reasons for concerns.
Several methods of on-site aquifer restoration have been utilized recently to remove contaminates from groundwater. Chief among these methods are the pump and treat method in which the water is pumped out and treated, and the permeable barrier in which some type of filtering agent or reactive agent is placed in the ground to contact the contaminated water.
Conventional aquifer restoration alternatives such as pump and treat or on site remediation are not generally commercially effective for most forms of contamination. These technologies have numerous problems associated with them which include: management of large volumes of water, potential production of undesirable by-products from the reaction with the contaminate, production of waste sludge from the reaction of the filtering agent with the contaminate, the exhaustion of the filtering agent or reactive agent and need to replace it to continue treatment, undesirable effects on hydraulic characteristics in uncontaminated parts of the aquifer (change in direction of water movement), and the labor or energy intensive nature of the process.
An alternative to conventional groundwater treatment processes is the use of barriers which are permeable to water, but prevent the migration of contaminants. They are referred to as permeable barriers. In-situ permeable barriers are a relatively new cost-effective technology that can be used in groundwater remediation of shallow aquifers. Permeable barriers are installed as permanent, semi-permanent, or replaceable units across the flow path of a contaminant plume. Permeable barriers allow water to move passively through while precipitating, sorbing, or degrading the contaminants. These mechanically simple barriers may contain metal-based catalysts for degrading volatile organics, chelators for immobilizing metals, nutrients and oxygen for microorganisms to enhance bioremediation, or other agents. Degradation reactions may break down the contaminants in the plume into harmless byproducts. Crushed limestone, peat, and powdered activated carbon are also several effective barrier mediums that have been used to adsorb or precipitate contaminants.
Advantages of these barriers include the following: simple installation, simple recovery and replacement of the material, low operation maintenance, less surface disruption, less labor, and less energy are required than other remediation technologies; and comparatively quick installation and containment of contaminants.
One example of such non-biological permeable barrier is a mixture of powdered activated carbon (PAC) and sand. The PAC/sand mixture has been shown to be a successful medium for benzene removal in trench-based permeable barrier. The physical uptake of different mixtures (3% and 10%) of PAC/sand and nonabsorbent material such as sand and zeolite have been used. Another non-biological permeable barrier containing an iron-based catalyst has been used to reduce the concentration of trichloroethene (TCE) by 95% and the tetrachloroethene (PCE) concentration by 91%.
Rael evaluated possible permeable barrier media designed to remove benzene in-situ from ground water. Effectiveness of several common material including coal, powdered-activated carbon (PAC), peat, and zeolite were evaluated in a series of batch and column studies with an initial benzene concentration of 50 mg/L. Silica sand was used as an inert matrix and was mixed with PAC to produce either 3% (by weight) or 10% PAC/sand mixtures. Based on their results, a mixture of PAC and sand was considered the most successful candidate. However, these authors observed that when the barrier reached its treatment capacity it had to be replaced with fresh media. The barrier medium allowed the flow of contaminated water but adsorbed the contaminant preventing further migration. This technology is limited to the depth accessible by trenching equipment and therefore would be applicable in shallow aquifer systems of less than 30 m.
Morrison and Spangler have explored chemical barriers as a passive in-situ water-treatment system. Precipitation barriers (hydrated lime) and sorption barriers (ferric oxyhydroxide) for removing uranium from ground water were studied. Chemicals used in the barrier were placed in the subsurface either by lining a disposal site, by trench and fill, or by injection. Dissolved contaminants became part of the immobile solids of the aquifer, by either precipitation or adsorption, as the contaminated groundwater passed through the chemical barrier.
In 1991 Thomson et al. examined the concept of designing permeable barriers to remove groundwater contaminants in-situ. Permeable barriers constructed by trenching had two advantages: 1) accessibility of the medium placement and 2) ease of recovery of medium by re-excavation. Permeable barriers were classified as either passive or active. An active barrier required continuous operation and maintenance while a passive barrier required no operation or maintenance once the medium is in place. An example of active barrier, in-situ air stripper was investigated and compared with conventional packed tower air stripping. It was determined that: 1) the trench-based stripping needed high pressure air compressors, but no water pumping equipment was needed which made the operating cost less; and 2) biostimulation did occur from the oxygen, resulting in a combined air stripping and biodegradation of volatile organic contaminants.
The drawbacks of physical or chemical barriers that were mentioned above are production of waste sludge from the reaction of the filtering agent with the contaminants, the exhaustion of the filtering agent or reactive agent and need to replace it to continue treatment.
One known method to completely destroy the contaminants into the harmless by products in the water is biological degredation. Biological processes are carried out by bacterial species that are capable of using organic compounds as their carbon source. Because of numerous advantages of biological processes, bioremediation has emerged as a viable technology to use microorganisms as effective agents to remove organic compounds from groundwater. The most common approach for large-scale bioremediation has been to inject nutrients into the ground water to simulate contaminant-degrading organisms. This approach has not proven to be reliable due to biofouling the stimulated population and contaminants into contact.
Another approach, called bioagugmentation, involves the addition of bacteria and nutrients to contaminated ground water. In this approach the microorganisms are exposed to the stress conditions in the environment where they are introduced. The losses of viable microorganisms as a result of stress conditions and migration of microorganisms are the major problems with this technology. Inadequate controls over the microorganisms under specific environmental conditions limit the biological process and result in incomplete contaminant transformation.
Key requirements for success of any bioremediation process are complete detoxification of the contaminants, high removal efficiencies, and process stability and control. Known in the art is the immobilization of cells can offer stability and control for biological processes. Also known in the art is different carriers have been investigated to entrap mixed microbial cells for removal of organics from wastewater.
Cell immobilization can be defined as any technique that limits the free movement of cells. Cell mobility can be restricted by aggregating the cells or by confining them into, or attaching them to, a solid support. Historically, immobilized cells have been widely used in the wastewater treatment industry, generally through the use of undefined mixed cultures immobilized by natural flocculating tendencies or as films on solid surfaces.
Polyvinyl alcohol has proved to be a useful means of immobilization of cells. PVA-immobilization of cells is the entrapment of microorganisms within a porous polymeric matrix of polyvinyl alcohol. The porous matrix captures the microorganism cell and allows diffusion of contaminate substrates toward the cells where they can be metabolized by the cells. The matrix also permits metabolism products the pass from the entrapped microorganisms. It has been determined that entrapped microorganisms are protected against the effects of toxic chemicals compared to free cells.
Granular Activated Carbon(GAC) immobilization of cells is the attachment or adsorption of microorganisms on the surface of activated carbon. The activated carbon operates like a “buffer and depot.” It protects the microorganisms and sets low quantities of toxicant for biodegradation. In contrast to a nonadsorbent material such as sand, activated carbon allows storage of substances that are difficult to biodegrade. Such storage provides a longer contact time between the microbial population and the substrates and could promote microbial acclimation and subsequent biodegradation.
Different carriers have been investigated to entrap mixed microbial cells for removal of organics from wastewater. The polymeric materials tested included cellulose triacetate (mono-carrier), polyacrylamide, K-carrageenan and a combination of cellulose triacetate and calcium alginate (bi-carrier). The mono-carrier was used to determine long term operational performance because it had better mechanical strength. The bi-carrier was more porous and more elastic than the mono-carrier. It was determined that K-carrageenan and calcium alginate were weak in mechanical strength.
Immobilized Pseudomonas sp. in alginate and polyacrylamide-hydrazide (PAAH) has been used to degrade phenol at initial concentrations of up to 2 g/L in less than two days. A sieve-like container within a fermenter held the immobilized cells in order to simulate entrapped microorganisms in a packed column. It was found that immobilization acts as a protective cover against phenol toxicity.
Biodegradation of PCP by Flavobacterium cells immobilized within polyurethane has been studied and compared PCP degradation capacities of free and immobilized cells at various initial PCP concentrations. Results showed that immobilized cells were able to degrade PCP up to a concentration of 200 mg/L, whereas free cells were unable to mineralize PCP during the four-day course of the experiment. Experiments were conducted in batch, semicontinuous batch, and continous-culture bioreactors. It was concluded that twice the amount of PCP was degraded per gram of polyurethane in the continuous-culture reactors than in the semi-continuous batch reactors. Polyurethane was determined to be an effective immobilization matrix as indicated by its protection against toxicity.
One researcher, Sofer, has studied an activated sludge of a mixed microbial population immobilized in calcium alginate gel for biodegradation of chlorophenol. Sofer was able to obtain a physically strong bead structure by optimizing the concentrations of sodium alginate and calcium chloride. The immobilized cells in Sofer's study showed the ability to degrade chlorophenol in various concentrations (up to 100 ppm).
Various methods of producing carriers for immobilizing cells have been examined by researchers. Hashimoto and Furukawa have developed a method for immobilization of activated sludge known as the polyvinyl alcohol (PVA)-boric acid method. The preparation of this method involved mixing one portion of concentrated activated sludge (mixed microbial cell population) with one portion of an aqueous PVA solution. This mixture was dropped into a gently stirred saturated boric acid solution to form spherical beads. The beads were cured in the solution for 15-24 hours and then washed with tap water. The beads produced were used to determine removal rates of total organic carbon (TOC) and total nitrogen (T-N) from a synthetic wastewater.
The method developed by Hashimoto and Furukawa does not produce PVA beads which are long lasting and which can withstand the stress and pressures presented when the PVA beads formed by the method of Hashimoto and Furukawa are formed into a permeable barrier. The Hashimoto and Furukawa method beads fracture and compress under the pressure and generally will dissolve in less than thirty (30) days. However, the PVA-boric acid method is inexpensive compared to other methods and allows operation of an immobilized cell system at 2-3 times the contaminate loading rate of conventional systems. Since activated sludge cells become surrounded by extracellular polymer, microbial activity is not reduced during the immobilization process where the pH was 4.0 for 24 hours.
Wu and Wisecarver have prepared PVA beads using a modification of the PVA-boric acid method but added a small amount of sodium alginate to prevent or minimize the tendency for the beads to agglomerate. The viability of Pseudomonas immobilized cells was demonstrated by utilizing them in a fluidized bed bioreactor for a period of two weeks. The beads were able to withstand high shears with no sign of breakage when an 8-L fluidized bed column was sparged at an air flow rate of 1.4 L/min.
Kindzierski investigated the use of activated carbon and two other synthetic ion-exchange resins as support materials for an anaerobic phenol-degrading microorganisms. Rapid adsorption of phenol on activated carbon without bacteria occurred over the first 33 minutes. The adsorption of phenol on activated carbon with bacteria was 3.9 times smaller than on activated carbon without bacteria. Kindzierski demonstrated that activated carbon exhibited favorable qualities as a biological support for the rapid development of attached biomass. Also, a substantial decrease in the rate of phenol adsorption by activated carbon due to the colonization of the bacteria was observed.
Ehrhardt and Rehm studied the adsorption of phenol as well as Pseudomonas sp. and Candida sp. on activated carbon, and the phenol degradation by these immobilized microorganisms was compared to that of free microorganisms. They observed that one gram of activated carbon adsorbed 4×10E9 Pseudomonas cells and 3×10E8 Candida cells in about 10 hours. Results of the degradation studies showed that free cells did not tolerate more than 1.5 g/L phenol, while the immobilized microorganisms survived at temporary 2.0 hour of high phenol concentrations up to 15 g/L, and they ultimately degraded about 90% of the adsorbed phenol.
Ehrhardt and Rehm (1989) studied phenol degradation in a semi-continuous and continuous reactor by Pseudomonas putida P8 adsorbed on activated carbon. They stated that phenol introduced into the reactor was initially removed from the media by a combination of degradation and adsorption. As the biomass in the reactor increased, adsorption decreased and the degradation rate increased. They were able to show that immobilized cells on activated carbon can tolerate high concentration of phenol up to 15 g/L. They concluded that protection in the activated carbon system was afforded by adsorption of phenol onto the immobilization substrate, which reduced the aqueous concentration to which the organisms were exposed. As the phenol in solution was degraded, desorption occurred, allowing the organisms to metabolize the substrate released from the carbon.
The polymeric materials tested included cellulose triacetate (mono-carrier), polyacrylamide, K-carrageenan and a combination of cellulose triacetate and calcium alginate (bi-carrier). The mono-carrier was used to determine long term operational performance because it had better mechanical strength. The bi-carrier was more porous and more elastic than the mono-carrier. It was determined that K-carrageenan and calcium alginate were weak in mechanical strength. It is also known in the art that in contrast to a nonadsorbent material such as sand, activated carbon allows storage of substances that are difficult to biodegrade. Such storage provides a longer contact time between the microbial population and the substrates and could promote microbial acclimation and subsequent biodegradation.
The invention has advantages over the prior art in that, (1) it can reduce organic contaminants into harmless by-products by using immobilized cells; (2) it has demonstrated continuous high stability and control under many different operating conditions than previous methods; (3) it provides a very cost effective process for treatment of contaminated groundwater; (4) it has demonstrated high tolerance against environmental stresses.
The present invention solves or substantially reduces in critical importance problems in the prior art by providing a biological processes that uses immobilized cells system to treat contaminated groundwater efficiently and cost-effectively. Known in the art that immobilized cells can limit the movement of microorganisms and protect them against environmental stresses.
OBJECTS OF THE INVENTION
The present invention encompasses a method of providing a biological permeable barrier comprising a permeable barrier of encapsulated microorganisms having an affinity for a contaminate that is polluting a water supply. The invention provides decontamination of a water supply, such as a groundwater, by allowing the groundwater to flow through the biological permeable barrier comprising an encapsulated microorganism so that the microorganism selected for use in the permeable barrier can biodegrade the contaminate. During the biodegradation the microorganism converts the contaminate into a less harmful or non-harmful moiety.
This invention entails immobilizing microbial organisms which are acclimated to the target contaminants in unique immobilized systems. Immobilization is key to the ability of this process to concentrate a large active bacteria mass for treatment of contaminated water. This superior ability to concentrate active bacterial mass in the barrier offers considerable benefits to the performance of the barrier.
Entrapped or encapsulated cells are shielded from their surroundings while the target pollutants still can flow into the supports and be metabolized there. Immobilization can be a form of biocontainment since it provides a way to control the spreading of recombinant cells in the environment. Additionally, the immobilization of high cell densities in compact reactors results in enhanced biodegradation rates when compared to conventional systems. Since such a system is much less dependent on the growth rates of the microorganisms involved, short retention times can be applied and thus high removal rates attained. These characteristics make the use of the immobilized cells systems particularly attractive for the treatment of groundwater and aquifers heavily contaminated with toxic, relatively soluble pollutants.
The present invention is demonstrated by immobilizing microorganisms on example carrier materials or matrices. One example is a polyvinyl alcohol (PVA) carrier material to produce PVA-immobilized cells. A second example of a suitable carrier material is Granular Activated Carbon (GAC) which is used to provide GAC-immobilized cells. Both the PVA-immobilized cells and the GAC-immobilized cells were then formed into biological permeable barriers to clean up groundwater which had been spiked or contaminated with trichlorophenol (TCP).
The present invention thereby fulfills the following objectives: providing a biological permeable barrier media comprising a carrier material and a microorganism suitable to biotransformation of a contaminate in groundwater; providing a biological permeable barrier media which is easy to operate and lower in cost than previously used methods of treating contaminated groundwater.
In the example embodiments of the invention, described hereinafter, biodegradation of 2,4,6 trichlorophenol (TCP) is demonstrated using polyvinyl alcohol (PVA)-immobilized cells and granular activated carbon (GAC)-immobilized cells as biological permeable barrier media. A variety of conditions such as different flow rates and different contaminant influent concentrations were used to compare these to embodiments on the basis of removal efficiency, relative ease of operation, and capital cost.
The following detailed description of the present invention on two embodiments demonstrates the substantial improvement of the present invention over the prior art methods. In addition the following important operational benefits are provided by the present invention such as no precipitation of solid contaminates, no need to replace the barrier, no need to remove the barrier once it has been in operation due to collection of contaminates, no by-product contaminates are produced, complete detoxification of the contaminate can be obtained, low operation cost and maintenance cost of the barrier is presented, no sludge is produced which must be removed from the site and destroyed and no hazardous waste is produced.
The foregoing and other objects are not meant in a limiting sense, and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention.
It is a principal object of the present invention to provide unique media to immobilize microbial organisms that are acclimated to the target contaminants.
It is another object of this invention to provide an economical and environmentally safe process to biodegrdate organic compounds in contaminated groundwater. The method involves the entrapment of active microorganisms into a media that would provide controlled environment for their attachment and growth.
A further object of the invention is to provide a very stable and efficient process to treat contaminated groundwater by using immobilized cells without formation of any harmfull by-products.
These and other objects of the invention wil become apparent as a detailed description of representative embodiments proceeds.
DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention, illustrative of the best modes in which the applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
FIG. 1 is a schematic representation of a biological permeable barrier placed to intercept underground water for treatment by immobilized cells.
FIG. 2 is a schematic representation of a small biological permeable barrier (column) placed above ground for treatment of contaminated groundwater
FIG. 3 is a graph showing TCP removal by PVA on Column 1.
FIG. 4 is a graph showing TCP removal by PVA on Column 2.
FIG. 5 is a graph showing TCP removal by GAC on Column 3.
FIG. 6 is a graph showing TCP removal by GAC on Column 4.
FIG. 7 is a graph showing dissolved oxygen uptake by PVA on Column 1.
FIG. 8 is a graph showing dissolved oxygen uptake by PVA on Column 2.
FIG. 9 is a graph showing dissolved oxygen uptake by GAC on Column 3.
FIG. 10 is a graph showing dissolved oxygen uptake by GAC on Column 4.
FIG. 11 is a graph showing a comparison of the percent removal of TCP by PVA Column 1, as measured and calculated from gas chromatograph.
FIG. 12 is a graph showing percent TCP removal by PVA on Column 2, as measured and calculated from gas chromatograph results.
FIG. 13 is a graph showing a comparison of percent TCP removal by GAC Column 3, as measured and calculated from gas chromatograph results.
FIG. 14 is a graph showing percent TCP removal by GAC Column 4, as measured and calculated from gas chromatograph results.
FIG. 15 is a graph showing pH drop by PVA on Column 1.
FIG. 16 is a graph showing pH drop by PVA on Column 2.
FIG. 17 is a graph showing pH drop by GAC on Column 3.
FIG. 18 is a graph showing pH drop by GAC on Column 4.
FIG. 19 is a graph showing TCP concentrations on PVA Column 2 in response to the high shock loads of TCP.
FIG. 20 is a graph showing dissolved oxygen changes during high shock loads on PVA Column #2.
FIG. 21 is a graph showing chloride release changes during high shock loads on PVA Column 2.
FIG. 22 is a graph showing pH changes during high shock loads on PVA Column 2.
FIG. 23 is a graph showing TCP concentrations in response to high shock loads on GAC Column #4.
FIG. 24 is a graph showing dissolved oxygen changes on GAC Column #4 during high shock loads.
FIG. 25 is a graph showing chloride release changes during high shock loads on GAC Column #4.
FIG. 26 is a graph showing pH changes during the high shock loads on GAC Columns.
FIG. 27 is a graph showing effluent TCP concentrations as a response to low dissolved oxygen.
FIG. 28 is a graph showing dissolved oxygen uptake responses to influent dissolved oxygen interruptions.
FIG. 29 is a graph showing chloride releases during and after influent dissolved oxygen upsets on PVA Column #1.
FIG. 30 is a graph showing effluent pH changes during and after influent dissolved oxygen upsets on PVA Column #1.
FIG. 31 is a graph showing TCP concentrations in response to low dissolved oxygen on GAC Column #3.
FIG. 32 is a graph showing dissolved oxygen uptake responses to influent dissolved oxygen interruptions on GAC Column #3.
FIG. 33 is a graph showing chloride releases during and after influent dissolved oxygen upsets on GAC Column #3.
FIG. 34 is a graph showing effluent pH changes during and after influent dissolved oxygen upsets on GAC Column #3.
FIG. 35 is a scanning electron micrograph showing biofilm formation inside of a PVA bead at nine months.
FIG. 36 is a scanning electron micrograph showing microcolonies inside PVA beads at nine months.
FIG. 37 is a scanning electron micrograph showing immobilized cells on GAC at 14 days.
FIG. 38 is a scanning electron micrograph showing bacteria colonization on GAC.
FIG. 39 is a gas chromatograph with attached mass spectrometer analysis of the column influent.
FIG. 40 is a gas chromatograph with mass spectrometer attached analysis of the effluent of PVA Column #1.
FIG. 41 is a gas chromatograph with mass spectrometer attached analysis of the effluent of Column #2.
FIG. 42 is a gas chromatograph with mass spectrometer attached analysis of the effluent of GAC Column #3.
FIG. 43 is a gas chromatograph and mass spectrometer analysis of the effluent of GAC Column #4.
DETAILED DESCRIPTION
In general the present invention comprises a biological permeable barrier comprising a microorganism that is immobilized on a carrier material, or matrix, to provide biotransformation of a contaminate molecule or substance contained in groundwater. The groundwater can be treated with the permeable barrier in-situ or it can be treated by removal of the groundwater from the ground and allowing the groundwater to flow across the biological permeable barrier of the invention. In the case of in-situ treatment, the groundwater is allowed to flow across the biological permeable barrier of the invention by excavating a hole or trench in the ground to intercept the direction of flow of the groundwater and filling the hole or trench with the biological permeable barrier having a microorganism immobilized thereon which is capable of biotransformation of the contaminate in the groundwater.
The microorganism is immobilized on a solid or semi-sold carrier material or matrix which provides structure and stability to the microorganism colonies. The carrier material or matrix can be of any suitable material which provides a surface to which the microorganism colonies can attach and grow. The carrier material or matrix need not provide any nutrients for the microorganism. Typically, suitable carrier materials provide a convolute structure having clefts or holes or tunnel spaces in which the microorganism can take hold and be somewhat protected from exposure to the contaminate. In this manner the microorganism can tolerate contact with much higher concentrations of the contaminate than would be possible when the microorganism is directly presented with the contaminate.
A further feature of the carrier material is that it also provides a physically resilient structure for the microorganism and allows the cell colony to be placed in a trench or a test column for experiments without causing compression and damage to the microorganism colonies. Two embodiments of the biological permeable barrier were prepared and used to demonstrate the effectiveness of the barrier on a contaminate. The contaminate selected for these examples of the invention was 2,4,6 trichlorophenol (TCP). TCP is widely used and has been determined to be carcinogenic. The aerobic degredation of pathway involves the dehogenation or degredation of TCP to dichlorophenol to 4-chlorophenol, which in turn produces 1,2,4-benzenetriol, and finally a mixture of polyquinoid acids. A microorganism was selected which had received previous exposure to higher than normal environmental concentrations of TCP and the microorganism was immobilized on two different carrier media: a polyvinyl alcohol bead (PVA beads); and granulated activated carbon (GAC). Groundwater was obtained from a well located in Lincoln County; Oklahoma was used to test the two embodiments of the biological permeable barrier. The groundwaterwas initially analyzed by the State of Oklahoma, Department of Environmental Quality, Water Laboratory, and the total organic carbon was analyzed by The Stover Group, Analytical/Toxicology Laboratories, Stillwater, Okla. The groundwater analysis is given below in Table 1.
TABLE 1
Groundwater Analysis
EPA Method
Parameter
Concentration
40 CFR Part 136
Specific Conductance
1045.7
mhos/cm
120.1
pH
7.9
std unit
150.1
Alkalinity (total)
237.3
mg/L
310.2
Solids (total dissolved)
515.1
mg/L
160.1
Nitrite-Nitrate as N
0.5
mg/L
353.2
Hardness (total)
106.9
mg/L
130.1
Chloride
143.9
mg/L
325.2
Sulfate
32.9
mg/L
375.2
Activated sludge containing microorganisms was obtained from the Georgia-Pacific Leaf River Pulp Mill, New Augusta, Miss. The activated sludge was obtained from the recirculation line where there is a high cell concentration. The mill operation included a bleaching process which would unintentionally produce some chlorophenols. The microorganisms from this mill were assumed to have had some exposure to chlorophenols which would allow quicker acclimation for the purpose of this project. The microorganisms were further acclimated by feeding them TCP (10 mg/L) as their sole carbon source with continuous aeration and additional nutrients consisting of a phosphate buffer solution, a magnesium sulfate solution, a calcium chloride solution, and a ferric chloride solution. One mL of each of the following nutrient solutions was added to each liter of (13 liter volume) activated sludge every day which provided the microorganisms the weight ratio of C:N:P of 100:18:188:
Phosphate buffer solution.
8.5 g KH 2 PO 4 , 21.75 g K 2 HPO 4 , 33.4 g Na 2 HPO 4 .7H 2 O, and 1.7 g NH 4 Cl dissolved in distilled water and diluted to 1 liter.
Magnesium sulfate Solution.
22.5 g MgSO 4 .7H 2 O dissolved in distilled water then diluted to 1 liter.
Calcium chloride solution.
27.5 g CaCl 2 dissolved in distilled water and diluted to 1 liter.
Ferric chloride solution.
0.25 g FeCl 3 , 6H 2 O in distilled water and diluted to 1 liter.
A standard ratio of the weights of carbon (C), nitrogen (N), and phosphorous (P), was used to ensure that microorganisms in the activated sludge were receiving minimal amounts of nutrients and carbon for growth. The carbon source for microorganisms is TCP. The activated sludge was centrifuged using an international Equipment Co. Clinical Centrifuge for 10 minutes at 4000 rpm to obtain biomass for immobilization into polyvinyl alcohol and granular activated carbon.
Preparation of Polyvinyl Alcohol (PVA) Beads Having Immobilized Cells
Distilled water was added to 43.7 g of PVA to obtain a 330 mL solution. The solution was heated to 60 degree C while stirring constantly until the PVA was dissolved. A 3.5 mL volume of a 1-3% sodium alginate solution was added to the PVA solution. The PVA-sodium alginate solution was cooled to 35 degree C. The centrifuged cells (43.7 g wet weight) and 10 mLs distilled water mixed with 1.3 mLs of nutrient medium were added to the cooled PVA-sodium alginate solution and stirred thoroughly. The solution was then drawn through tygon tubing (ID 3.1 mm) by a peristaltic pump (Cole-Parmer 7553-30) and extruded through a tubing connector with a 1.0 mm diameter opening inserted into the end of the tubing. As droplets formed, they fell into a gently stirred boric acid solution to form beads. The beads were cured in the gently stirred boric acid solution for 24 hours. The beads were then rinsed and soaked thoroughly in distilled water several times to remove all of the boric acid solution from the beads. The PVA beads were prepared using this method produced porous, rubber-like, elastic beads for the purpose of immobilizing cells and using them as a biological permeable barrier medium. A bed of beads was characterized with its density, porosity, permeability, and compressibility or deformation.
Preparation of GAC-Immobilized Cells/Silica Sand
GAC was washed with distilled water several times and dried completely in 103° C. oven before use. A portion of activated sludge, from the continuously maintained batch culture, was centrifuged at 4000 rpm for 10.0 minutes to obtain the desired amount of biomass (wet weight). The amount of biomass used for immobilization on both permeable barriers (GAC and PVA beads) was 43.7 grams for short columns and 86.0 grams for the long columns. The amounts of GAC for short and long column were 21.0 and 10.5 grams, respectively, for the 3% mixture of GAC/sand. The biomass and GAC were then agitated vigorously in 100 mLs distilled water for 24 hours. The GAC that settled by gravity was mixed with sand and used in column studies (3% GAC/sand mixture). Silica sand was washed with distilled water and oven dried at 103° C. separately. The two materials were then blended to achieve the desired weight ratio.
Physical Characteristics of PVA-immobilized Cells and GAC-immobilized Cells
The physical characteristics of PVA-immobilized cells and GAC-immobilized cells/sand were determined prior to evaluation of these media as biological permeable barriers. Table 2. Summarizes the physical characteristics of both PVA and GAC immobilized cells systems.
TABLE 2
Characteristics of PVA Beads
and Mixture of (3%) GAC/Silica Sand
Packed Bed of
Packed Bed of
Parameter
PNA Beads
(3%) GAC/Sand
pH
8.1
8.1
Specific Gravity
1.008
1.63
Density () (g/cm 3 )
0.987
1.62
Porosity (%)
25
30
Permeability Coefficient (K) (cm/s)
0.1425
0.0162
Compressibility Index (C c ) (m 2 /kN)
4.08 × 10 −3
2.87 × 10 −5
Particle Size (mm)
3.8
0.4
Soil Classification
uniform round-
Uniform rounded
ed fine gravel
medium sand
Table 2. Characteristics of PVA Beads and Mixture of (3%) GAC/Silica Sand
Evaluation of PVA and GAC Immobilized Cells as Biological Permeable Barriers
Since successful application of any biological permeable barrier requires complete characterization of the medium under variety of operating condition and aging conditions, column studies were conducted for over 240 days of continuous operation. The present invention proposes a method of use of PVA-immobilized cells and 3% GAC-immobilized cells/sand mixture as two novel candidates for biological permeable barrier media to biodegrade contaminated groundwater.
Therefore the following column studies were designed to account for any significant changes in removal efficiency of these biological permeable barriers due to hydraulic retention time, applied loading, availability of dissolved oxygen and nutrient availability.
Table 3. Summarizes the eight different operating conditions to simulate biodegradation of TCP contaminated groundwater using PAV and GAC immobilized cells as biological permeable barriers. A total of four acrylic columns were set up as aerobic, continuous flow packed-bed reactors. Columns #1 and #2 consisted of 10 and 20-cm beds of PVA -immobilized cells beads (3-5 mm), Columns #3 and #4 consisted of 10 and 20-cm beds of 3% GAC immobilized cells and 97% clean silica sand. These columns had an inside diameter of 5.0 cm. A 5.0 cm diameter 200-sieve mesh copper screen was placed at the top and bottom of each of the columns. The groundwater was spiked with TCP to provide the various TCP concentrations used during these studies and was prepared in 25.0 liter bottles and covered to prevent photolytic degradation.
Nutrient solutions were added to the TCP-spiked groundwater: phosphate buffer solution; magnesium sulfate solution; calcium chloride solution; and ferric chloride solution. A peristaltic pump (Cole-Parmer 7553-30) with four heads (Model 7013) and tygon tubing was used to pump the groundwater into the base of the columns (upflow mode). A schematic diagram of the columns used in the study is shown in FIG. 2 .
The effects of external disturbances such as a high shock load and low dissolved oxygen (DO) were evaluated on PVA and GAC immobilized cells systems. Columns #2 and #4 were subjected to a high influent TCP concentration (>550 mg/L), C:P:N ratio of 100:10:3, flow rate of 2.0 mL/min, and dissolved oxygen above 30.0 mg/L for 50.0 hours. The experimental condition of columns #1 and #3 were adjusted to a very low dissolved oxygen (DO) around <2 mg/L, TCP concentration of 40.0 mg/L, and flow rate of 2mL/min. for 50.0 hours. During these 50.0 hours influent and effluent samples were taken to determine TCP concentration, DO, pH, and Cl − concentrations. After 48.0 hours experimental condition were adjusted back to TCP=40.0 mg/L, DO=above 25.0 mg/L, flow rate=2 mL/min, and C:P:N ratio of 100:10:3.
The columns were monitored in terms of TCP concentration, DO, pH, and Cl concentration until all the columns reached steady state (where there is no change in effluents concentration). Once the columns reached steady state, the stress conditions (shock load and low DO) on specified column were repeated one more time for another 50.0 hours. After 50.0 hours of the shock load on columns (2,4) and low DO on columns (1,3), once again all the columns were subjected to TCP=40.0 mg/L, DO˜30.0 mg/L, and flow rate of 2.0 mL/min. In this study, the effects of external disturbances such as high shock load and low DO were evaluated on PVA and GAC immobilized cells systems.
Simulation of Biological Permeable Barrier by Column Studies
Column studies were set up to evaluate and compare aerobic biodegradation of TCP by proposed biological permeable barriers, PVA-immobilized cells columns (#1, #2) and GAC-immobilized cells columns (#3, #4) under varying operational conditions. PVA columns #1 and #2 contained 10.0 cm and 20.0-cm beds of 3-5 mm PVA- immobilized cells beads, respectively. The GAC columns #3 and #4 contained 10.0 cm and 20.0 cm bed of (3%) GAC-immobilized cells/silica sand (97%) mixture, respectively
A minimum two-week experiment period was considered adequate to collect the required data. During the experiments, between 100-300 mL of influent and effluent samples were collected every other day and tested for TCP concentration, DO, chloride release, and pH. The data were collected during the transition and steady state periods.
TABLE 3
Experimental Conditions for Column Studies (1-8)
Column
Experiment
Experiment
Experiment
Experiment
Experiment
Experiment
Experiment
Experiment
Experiments
No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
No. 7
No. 8
Influent
10.0
20.0
20.0
20.0
30.0
20.0
20.0
40.0
Concentration
(mg/L)
Influent
1.0
1.0
1.0
1.0
1.0
2.0
4.0
4.0
Flow Rate
(mL/min.)
Residence
Columns
Columns
Columns
Columns
Columns
Columns
Columns
Columns
Time (min)
#1 = 49
#1 = 49
#1 = 49
#1 = 49
#1 = 49
#1 = 24.5
#1 = 12.3
#1 = 12.3
#2 = 98
#2 = 98
#2 = 98
#2 = 98
#2 = 98
#2 = 49
#2 = 24.5
#2 = 24.5
#3 = 59
#3 = 59
#3 = 59
#3 = 59
#3 = 59
#3 = 29.5
#3 = 14.8
#3 = 14.8
#4 = 118
#4 = 118
#4 = 118
#4 = 118
#4 = 118
#4 = 58.9
#4 = 29.5
#4 = 29.5
C:N:P
100:18:188
100:18:188
100:18:188
100:10:3
100:10:3
100:10:3
100:10:3
100:10:3
Ratio
Dissolved
8.0-9.0
8.0-9.0
above 20.0
above 20.0
above 27.0
above 20.0
above 20.0
above 30.0
Oxygen
(mg/L)
Loading
Columns
Columns
Columns
Columns
Columns
Columns
Columns
Columns
Rage g L −1 .d −1
#1, #3 = .074
#1, #3 = 0.15
#1, #3 = .15
#1, #3 = 0.15
#1, #3 = 0.22
#1, #3 = 0.3
#1, #3 = 0.6
#1, #3 = 1.2
#2, #4 = .037
#2, #4 = .074
#2, #4 = .074
#2, #4 = .074
#2, #4 = .11
#2, #4 = 0.148
#2, #4 = 0.3
#2, #4 = 0.6
Operating Condition No. 1
Biodegradation of TCP by PVA and GAC Immobilized Cells
The removal mechanism of TCP from groundwater by PVA-immobilized cells (columns #1, #2) and 3% GAC-immobilized cells/sand mixture (#3, #4) was examined. In this study the average influent TCP concentration was 10.50±0.83 mg/L. The C:N:P ratio was kept at 100:18:188 by adding nutrients to the influent feed solution. The influent solution was aerated with laboratory compressed air 24.0 hours a day to maintain the DO above 8.4 mg/L. The flow rate for all four columns was 1.0 mL/min. Applied loading in this experiment for columns #1, and #3 and for columns #2, and #4 were 0.074 and 0.037 g L −1 d −1 , respectively.
PVA columns #1 and #2 reduced the influent TCP concentration to zero on day 17 and 13, respectively. PVA column #2 with a 20.0-cm bed height provides longer contact time between cells and TCP than PVA column #1 with a 10.0-cm bed height. Both PVA columns maintained 100% TCP removal for remaining time of this experiment. No TCP was ever detected in the effluents of GAC columns over entire course of this experiment. The explanation might be that during this period, TCP was removed initially by adsorption on GAC that is no leakage was seen, and later by biodegradation (supported by change in DO, Cl release, and pH data).
For aerobic mineralization of each mg of TCP, 0.89 mg of oxygen is expected to be consumed by bacteria. All four columns consumed oxygen to about the same extent (2.5 mg/L), except PVA #1, which had a slightly higher consumption (3.3 mg/L). The reduction in DO in the effluent is an indication of the biodegradation process that is going on in these columns. During the 5.0 hour required to collect the effluent sample (300 mLs), the samples were exposed to the air, which probably yield a residual oxygen concentration different than that expected based on stiochiometry.
The Cl − concentrations in the effluents of all four columns showed an increase of about 6.0 to 8.0 mg/L. The increase in chloride concentration supports aerobic dehalogenation of TCP. For the idea of aerobic dehalogenation of each mg of TCP, 0.54 mg of chloride is expected to be release based on stiochiometry.
Aerobic dehalogenation of TCP produced HCl which would cause the drop in effluent pH. The influent feed solution had a pH range from 8.1-8.3. The approximate average pH in the effluents from columns #1, #2, #3, and #4 are 7.7, 7.7, 7.9, and 7.6, respectively. The estimated amounts of Cl − concentration in the effluents of columns #1, #2, #3, and #4 needed to cause the observed drops in pH are 10.6, 10.6, 7.1, and 12.4 mg/L, respectively. The Cl − concentrations obtained from the pH curve are (15-35%) higher than Cl − concentrations measured which ranged from 6.0-8.0 mg/L chloride. The possible explanation could be the formation of acids other than HCl. The drop in pH supports the dehalogenation of TCP and formation of HCl.
Operating Condition No. 2
Performance of Biological Permeable Barriers under Insufficient Dissolved Oxygen
The performance of all four columns was evaluated by changing the average TCP influent concentration from 10.5±0.83 mg/L to 20.34±0.45 mg/L. The flow rates for all columns remained at 1.0 ml/min. The applied loading for columns (#1, #3) and (#2, #4) were 0.15 and 0.074 g L −1 d −1 , respectively. The addition of nutrients to the influent feed solution kept the C:N:P ratio at 100:18:188. The influent solution was aerated with compressed laboratory air 24.0 hours a day to maintain DO levels above 8.4 mg/L. The amount of DO provided for this experiment was less than the DO needed for complete degradation of 20.0 mg/L of TCP. This experiment lasted 25 days.
Both PVA columns were able to remove TCP from the influent for up to a week. On day 40 TCP was detected in the effluent of both PVA columns. The effluent TCP concentration in column #1 was 1.2 mg/L on day 40. The TCP effluent concentration in column #1 continued to rise and reached 6.5 mg/L on day 58. The TCP effluent concentration in column #2 also started to rise on day 40 and reached its maximum concentration of 4.9 mg/L on day 58. The removal efficiencies of column #1 and #2 reduced from 100% to 68.0% and 76.0%, respectively. The explanation for this occurrence during this period is that the dissolved oxygen (DO) was insufficient for complete biodegradation of 20.0 mg/L of TCP.
No TCP was ever detected in the effluents of GAC columns #3 and #4 over the entire period of this experiment. An explanation for this might be that TCP removal was occurring by both adsorption and biodegradation.
The effluents of PVA columns #1 and #2 have an average effluent DO of 2.9±0.5 mg/L and 3.1±0.4 mg/L, respectively. This was a clear indication of biological activity occurring in both PVA columns. The cells in PVA columns #1 and #2 were able to consume about 66% and 64% of the average 8.6 mg/L DO in the influent, respectively. The average DO provided for this experiment is about 50% less than the DO needed for aerobic mineralization of 20.0 mg/L TCP.
The effluents of GAC columns #3 and #4 had an average DO of 3.0 mg/L and 3.1 mg/L, respectively. The cells in GAC columns #3 and #4 were also able to consume about 66% and 64%, respectively, of the average 8.6 mg/L DO in the influent.
The ICl concentrations of influent and effluents were measured and all four columns showed an increase in the chloride concentrations in their effluent. This supports the idea that dechlorination of the TCP is occurring. Average chloride releases were 10.8 mg/L, 9.2 mg/L, 8.8 mg/L, and 10.1 mg/L for PVA (#1), PVA (#2), GAC (#3), GAC (#4), respectively. For complete dehalogenation of 20.35±1.2 mg/L of TCP, an average of 10.99-mg/L inorganic chloride release was expected. During the first 11 days of this experiment, the average chloride releases for columns #1, #2, #3, and #4 were 12.4, 10.1, 9.7, and 11.5 mg/L, respectively. From day 44 to day 58, the average chloride releases were reduced to 7.9, 8.1, 7.8, and 8.7 mg/L for columns #1, #2, #3, and #4, respectively. The reduction in chloride releases in all four columns tends to support the reduction in biodegradation of TCP because of insufficient DO for complete mineralization of TCP.
The drop in pH for the first 11 days was greater than for the last 14 days for all four columns. The approximate average effluent pH for the first 11 days of the experiment for columns #1, #2, #3, and #4 were 7.6, 7.4, 7.7, and 7.6, respectively. For the last 14 days of the effluent pHs for all four columns were 8.1. The drop in pH tends to support the concept of dehalogenation of TCP and formation of HCl in the effluents. The smaller drop in pHs of all four columns from day 11 to day 58 correlates well with the smaller chloride release measured possibly due to insufficient DO for complete mineralization of 20.0 mg/L TCP.
Operating Condition No. 3
Responses of Biological Permeable Barriers to sufficient Dissolved Oxygen
Improvement of column performance was examined by providing additional oxygen. For aerobic biodegradation of 20.0 mg/L of TCP, at least 17.8 mg/L of DO are needed. In order to provide sufficient DO for the immobilized cells, the influent feed solution was oxygenate with pure oxygen for at least 10.0 minutes every day (beginning day 63) during the course of this experiment. The influent bottle was almost completely capped to reduce loss of oxygen. The C:P:N ratio was maintained at 100:18:188 by addition of appropriate nutrients to the influentfeed solution. The influent flow rates for all four columns were 1.0 mL/min. The PVA and GAC immobilized cells columns reduced the average influent TCP concentration of 20.0 mg/L to zero during the entire period of the experiment. The removal efficiencies of all four columns were 100% which can be due to the sufficient DO provided for the immobilized cells.
An average influent DO of 23.5±3.5 mg/L was reduced to an average effluent value of 2.9±1.4, 3.2±1.7, 3.0±1.1, and 2.9±1.2 mg/L by columns #1, #2, #3, and was a clear indication of microbial activity present in both the PVA (#1, #2) and GAC (#3, #4) columns.
Average chloride releases in the PVA columns #1, #2 and GAC columns #3, #4 were 9.19±2.11, 10.25±1.97 and 10.73±2.5, 11.1±1.8 mg/L, respectively. The measured chloride concentration in both PVA and GAC columns effluents were very close in value to the theoretical chloride release expected for dehalogenation of 20.0 mg/L of TCP.
The pH values were measured in the influent and effluent of all four the influent feed solution had an average pH of 8.0. Columns #1, #2, #3, and #4 had approximate average effluent pH values of 7.5, 7.5, and 7.6. and 7.5, respectively. The drop in pH from an influent of 8.0 to 7.5 in the effluents shows that a 2.8-mL volume of 0.1 N HCl would be required. This is a 10.3 mg/L chloride concentration (2.9 mL/L×3.55 mg/mL) which is similar in value to the chloride concentration of 10.8 mg/L expected based on the stoichiometric dehalogenation of 20.0 mg/L TCP. This tended to support the dehalogenation of TCP.
Operating Condition No. 4
Responses of Biological Permeable Barriers to the Change of Nutrients Availability
The C:N:P nutrient ratio used in the first three column studies was 100:18:188. The standard ratio for C:N:P for microorganisms to grow is 100:10:3. In order to avoid unnecessary addition of nutrients, the C:N:P ratio was adjusted from 100:18:188 to 100:10:3. The effect of varying the C:N:P ratio on biodegradation of 20.0 mg/L TCP was evaluated. The flow rates for all columns remained at 1 mL/min. The applied loading for all the columns remained the same as column conditions No. 2. and 3. The influent feed solution was aerated with pure oxygen for 10.0 minutes every day to maintain a DO above 20.0 mg/L.
No TCP was detected during the entire period of this experiment. The change in C:N:P ratio did not negatively effect the removal of 20.0 mg/L TCP by both PVA and GAC columns.
The dissolved oxygen for the influent and effluents of PVA columns (#1, #2) and GAC columns (#3, #4) were measured. All four columns (#1, #2, #3, #4) continued to reduced the DO of 22.8±3.3 mg/L in feed solution to effluent value of 4.0±0.7, 4.0±0.51, 4.0±0.6, and 3.9±0.7 mg/L, respectively. The consumption of DO was a clear indication of biological activity in the columns. The immobilized cells in all four columns were able to use DO efficiently and remove 20.0 mg/L of TCP during the entire course of this experiment.
The average chloride increase in the effluents for columns #1, #2, #3, and #4 are 11.1±1.9, 11.6±1.8, 11.3±3.5, and 11.2±2.2 mg/L, respectively. Aerobic dehalogenation of 20.0 mg/L TCP should theoretically release 10.8 mg/L inorganic chloride, which is very close to measured inorganic chloride of both PVA and GAC columns.
The influent feed solution had an approximate average pH of 7.9. The approximate average of the effluent pH for both PVA columns #1 and #2 was 7.5. The approximate average of the effluent pH for both GAC columns #3 and #4 was 7.6. According to the pH curve, the drop in pH from 7.9 to 7.5 shows that a 2.9 mL volume of 0.1 N HCl would be required. This is a 10.3 mg/L chloride concentration (2.9 mL/L×3.55 mg/mL) which is similar in value to the theoretical chloride concentration of 10.8 mg/L expected from the complete dehalogenation of 20.0 mg/L TCP. This supports the theory of complete dehalogenation of TCP.
Condition No. 5
Responses of Biological Permeable Barriers to the Increase of TCP Concentration
The removal efficiency of all four columns was evaluated as TCP concentration increased to 30.0 mg/L. The flow rate for all columns remained at 1 mL/min. The applied loading for the columns (#1, #3) and (#2, #4) were 0.22 g L −1 d −1 and 0.11 g L −1 d −1 , respectively. The influent feed solution was aerated with pure oxygen for 10.0-15.0 minutes every day to maintain DO of above 27.0 mg/L. The influent bottle was almost completely capped to reduce loss of oxygen.
The TCP removal efficiency for PVA columns #1 and #2 was 98-100%. The removal efficiency of both GAC columns was 100% during the entire period of the experiment. It is clear that the increase in TCP concentration did not effect the removal efficiencies of both the PVA and GAC immobilized cells columns.
All four columns (#1, #2, #3, #4) continued to reduce the influent DO of 30.3±1.6 mg/L in feed solution to 3.0±0.6, 2.9±0.7, 2.9±0.5, and 2.4±0.5 mg/L, respectively, was an indication of biological activity in the columns. The immobilized cells in all four columns were able to use DO efficiently and removed 30.0 mg/L of TCP during the entire course of this experiment.
Average chloride concentrations in the effluent for columns #1, #2, #3, and #4 were 15.7±4.5, 17.1±4.9,18.1±3.3, and 18.9±3.2 mg/L, respectively. Aerobic dehalogenation of 30.0 of TCP should release 16.2 mg/L chloride. The measured values for all four columns are close to theoretical chloride release for 30.0 mg/L TCP.
The influent feed solution had approximate average pH of 8.0. The approximate average effluent pH for both PVA column #1, #2 was 7.2. An approximate average effluent pH for both GAC columns #3 and #4 was 7.3. According to the pH curve, the drop in pH from 8.0 to 7.2, and 7.3 show that 5.0 mL and 4.0 mL volume of 0.1 N HCl would be required. This is a 17.8 mg/L chloride concentration (5.0 mL/L×3.55 mg/mL) for the PVA columns which is close to the chloride concentration of 16.2 mg/L expected from the dehalogenation of 30.0 mg/L TCP. According to the pH curve, both GAC columns #3 and #4 were expected to release 14.2 mg/L chloride (4.0 mL/L×3.55 mg/mL). The drop in pH supports inorganic chloride release which resulted from dehalogenation of TCP and formation of HCl.
Condition No. 6
Responses of Biological Permeable Barriers to the Reduction of Residence Time
The effect of increased flow rate on biodegradation of TCP in both PVA and GAC columns was examined. The average influent feed concentration was 22.0 mg/L. The flow rate was increased to 2 mL/min. The applied loading for the columns (#1, #3) and columns (#2, #4) were 0.3 and 0.148 g L −1 d −1 , respectively. The flow rate increase to 2 mL/min which reduced the HRTs for columns #1-#4 to 24.5, 49.0, 29.5, and 58.9 minutes, respectively. The effect of contact time for the immobilized cells with TCP for all four columns were evaluated. Both PVA columns (#1, #2) reacted to the change in HRT. It took at least 8-10 days for PVA column #1, with an HRT of 24.5 minutes to reach steady state and reduce the TCP concentration to zero. PVA column #2, with an HRT of 49.0 minutes, took 6.0 days to reduce the TCP concentration to zero. There was no TCP detected in both PVA columns throughout out the end of the experiment (after day 123). In the effluent of the GAC columns, no TCP was ever detected during the entire period of this experiment. It is clear that the change in flow rate affected both PVA columns. The increase in TCP concentration in the effluent of PVA column #1 shows the impact of short residence time on this column.
The high DO readings during the transition state (days 113-119) for PVA column #1 is due to incomplete TCP removal, which is the result of a possible upset caused by the flow increase. All four columns (#1, #2, #3, #4) continued to reduced the DO of 25.6±2.9 mg/L in feed solution to 4.7±1.8, 4.9±1.4, 4.1±1.4, and 4.3±1.7 mg/L, respectively.
During the transition period (days 113-119), the average effluent chloride concentration for PVA column #1 was 5.2 mg/L only. This is also consistent with the incomplete TCP removal and high DO reading in the PVA column #1. During steady state conditions (days 119-127), the average effluent inorganic chloride concentration for columns #1, #2, #3, and #4 were 10.3±4.2, 10.6±2.8, 10.6±1.6, and 12.3±1.6, respectively. Aerobic dehalogenation of 20.0 mg/L should release 10.8 mg/L of inorganic chloride which is close to measured inorganic chloride in the effluent of all four columns.
The influent feed solution had an average pH of 7.9. The approximate average effluent pH for PVA column #1 during the transition period (days 113-119) was 7.5. According to pH curve, a drop in pH from 7.9 to 7.5 shows that 2.0 mL volume of 0.1 N HCl would be required. This is a 7.1 mg/L chloride concentration (2.0 mL/L×3.55 mg/mL). This was expected due to partial TCP removal and high DO reading during the transition period. An approximate average pH value for columns #2, #3, and #4 was 7.3. This equals 10.7 mg/L of chloride (3.0 mL/L×3.55 mg/mL) which is similar to the theoretical chloride concentration of 10.8 mg/L expected from the dehalogenation of 20.0 mg/L TCP. The drop in pHs supports the concept of dehalogenation of TCP and release of chloride (HCl).
Condition No. 7
Responses of Biological Permeable Barriers to another Reduction in Residence Time
Another influent flow rate was instituted to examine changes the biodegradation of TCP (20.0 mg/L) in both the PVA and GAC columns. The average influent feed concentration was 21.0±0.9 mg/L. The applied loading for columns (#1, #3) and columns (#2, #4) are 0.6 and 0.3 g L −1 d −1 , respectively. The influent bottle was aerated with pure oxygen for 10.0 minutes every day to maintain DO of around 27.0 mg/L. The influent bottle was completely capped to prevent the loss of oxygen. In this experiment the flow rate increased to 4 mL/min which reduced HRTs for column #1-#4 to 12.3, 24.5, 14.7, and 29.5 minutes, respectively.
Both PVA columns (#1, #2) reacted to the change in HRT starting on the first day of the experiment. It took almost 8 days for PVA column #1 with HRT of 12.3 minutes to reduce the TCP concentration to 2.3 mg/L. Average removal efficiency during the transition period (days 128-134) for this column was about 78%. The removal efficiency of PVA column #1 increased to 91% once the column reached steady state (day 8 of the experiment). The PVA column #2 with an HRT of 24.5 minutes had a TCP removal efficiency of 93% during the first four days of this experiment. The TCP removal efficiency of PVA column #2 increased to 100% once the column reached steady state (day 6 of the experiment). In the effluent of GAC columns, no TCP was ever detected during the entire period of this experiment. It is clear that the change in flow rate affected both PVA columns removal efficiency. The change in flow rate had greater impact (in terms of removal efficiency) on PVA column #1 than PVA column #2.
All four columns (#1, #2, #3, #4) continued to reduced DO of 27.9±1.5 in the feed solution to 8.1±0.8, 7.5±0.9, 6.8±0.6, and 6.4±1.1 mg/L, respectively. The results indicate that the effluent DO of all four columns were higher than compared to previous experiments. The DO provided in this experiment was around 27.9 mg/L, which is higher than the theoretical DO (around 18.9 mg/L) needed for complete biodegradation of 20.0 mg/L of TCP in influent. The consumption of DO is a clear indication of biological activity in the columns.
The average inorganic chloride release for columns #1, #2, #3, and #4 were 8.3±4.2, 10.6±2.8, 10.6±1.6, and 12.3±1.6, respectively. Aerobic dehalogenation of 20.0 mg/L releases 10.8 mg/L inorganic chloride which is close to the measured inorganic chloride in the effluent of all four columns.
The influent feed solution had an approximate average pH of 7.9. An effluent pH for the PVA columns #1 and #2 was 7.2 and 7.1. The approximate average of effluent pH for GAC columns #3 and #4 was 7.1 and 6.9. The effluent pH drop from 7.9 to 7.2, 7.1, and 6.9 showed that 4.0, 5.0, and 8.0 mL volume of 0.1 N HCl would be required, respectively to account for this pH change. These equal 14.2, 17.8, 17.8, and 28.4 mg/L chloride concentration in columns #1-#4 effluent respectively. The effluent chloride concentration measured in all four columns was higher than expected especially in PVA column #2 and GAC column #3 and #4. This increase over theoretical was 40%, 40%, and 65%, for PVA column #1, GAC column #3, and GAC column #4, respectively. The change in flow rate might wash out some inorganic chloride that had retained in the columns. It is also possible that the columns had some anoxic zones which might dehalogenate TCP and release chloride.
Condition No. 8
Responses of Biological Permeable Barriers to another Increase of TCP Concentration
The removal efficiency of all four columns where the TCP concentration was increased to 40.0 mg/L was examined. The flow rate for all columns remained at 4 mL/min. The applied loading for columns (#1, #3) and columns (#2, #4) was 1.2 and 0.6 g L −1 d −1 , respectively. feed bottle was aerated with pure oxygen for 10.0 -15.0 minutes every day to maintain DO of around 27.0 mg/L. The influent bottle was completely capped to prevent the loss of oxygen.
The average influent feed TCP concentration was 40.6±0.71 mg/L. An average effluent TCP concentration for PVA columns #1 and #2 was 15.5±3.6 and 8.9±1.2 mg/L, respectively. As seen the change of influent TCP concentration had an impact on both PVA columns in terms of TCP removal efficiency. For the first time during the column studies, the overall removal efficiency of PVA columns #1 and #2 was decreased to 61% and 80%, respectively. TCP removal by PVA column #1 improved over the course of this experiment. TCP removal efficiency for PVA column #1 over the first week was 54% and increased to 67% during the last 10 days of the experiment. PVA column #2 had a removal efficiency of 76% in the first week which was increased to 81% during the last 10 days of the experiment. The removal efficiency of both GAC columns was 100% during the entire period of this experiment. All four columns (#1, #2, #3, #4) continued to reduced the DO of the feed solution 27.8±1.2 mg/L to 9.9±1.2, 6.0±1.7, 4.6±1.1, and 4.1±1.4 mg/L, respectively. The consumption of DO by microorganisms is a clear indication of biological activity in the columns. The effluent DO in both PVA columns was higher than in both GAC columns. All four columns consumed DO available to them, but the PVA column consumption of DO was lower than GAC column consumption. It should be noted that for aerobic dehalogenation of 40.0 mg/L of TCP, the cells needed at least 35.6 mg/L of DO. Dissolved oxygen provided was around 27.8 mg/L, which are about 22% less than DO needed. This may have had an impact on the PVA columns removal efficiency of 40.0 mg/L TCP.
The average inorganic chloride release for columns #1, #2, #3, and #4 was 12.5±1.9, 18.6±2.9, 21.3±2.6, and 20.7±4.8 mg/L, respectively. Aerobic dehalogenation of 40.0 mg/L of TCP should theoretically releases 21.6 mg/L inorganic chloride. The average measured values for inorganic chloride release in the GAC columns effluent are close to theoretical chloride release. The average measured values for inorganic chloride release in the PVA columns #1 and #2 effluent are 42% and 14% less than the theoretical chloride release. The PVA column #1 also had lowest DO usage. This supports the observed TCP removal efficiencies of these columns.
The influent feed solution had an approximate average pH 8.2. An approximate average pH for PVA columns #1 and #2 was 7.0 and 6.9, respectively. An approximate average pH for the GAC columns #3 and #4 was 6.7 and 6.9, respectively. The drop in pH from 8.2 to 7.0, 6.9, 6.7 shows that an 8.0, 8.0, and 11.0 mL volume of 0.1 N HCl would be required, respectively to account for such a pH change. The expected chloride concentration in columns #1, #2, #3, and #4 should have been 28.4, 28.4, 28.4, and 42.6 mg/L, respectively, which is about 24-50% higher than the theoretical chloride release. The anaerobic activity might be present as localized pockets (since DO in the effluent was between 4 and 9 mg/L) in the columns which would also cause the release of acids. The release of acids should show up in effluent pH value.
The drop in pH support inorganic chloride release resulting from dehalogenation of TCP and the formation of HCl.
Overall Performance of Biological Permeable Barriers during 166 Days of Continuous Operation
Effluent and influent TCP concentrations were monitored during 166 days of continuous operation. The TCP concentration in the effluent of PVA column #1 was higher than PVA column #2 which had a longer HRT compared to PVA column #1. The increase in influent flow rate on days 113 and 128 had the greater impact on PVA column #1 effluent quality than any other column. Both PVA columns were affected by changes in the influent flow rate. The effect of TCP loading rate on effluent quality of the PVA columns (#1, #2) and GAC columns (#3, #4), as examined on days 97, 113, 128, 150, shows that the loading was related to the TCP appearance in the effluent. The TCP loading increase on day 97 had no effect on any of the columns. On day 113, a partial breakthrough of TCP was observed in PVA column #1 after increasing the flow rate from 1 to 2 ml/min, with a corresponding increase of TCP loading rate from 0.22 to 0.3 g L −1 d −1 . PVA column #2 showed an increase in TCP concentration in the effluent on day 113, after increasing the TCP loading rate from 0.11 to 0.15 g L −1 d −1 . The increase in the flow rate on day 113 had greater impact on PVA column #1 than PVA column #2. Both PVA columns (#1, #2) showed an increase in TCP concentration in their effluents after increasing the flow rate from 2 to 4 mL/min, with the corresponding increase in TCP loading rate from 0.3 to 0.6 g L −1 d −1 and from 0.15 to 0.3 g L −1 d −1 , respectively. On day 150, both PVA columns #1 and #2 experienced the highest loading rate, 1.2 g L −1 d −1 and 0.6 g L −1 d −1 , respectively during the entire 166 days of operation. The removal efficiency of the PVA columns #1 and #2 reduced to 67% and 81%, respectively, during days 150-166. The GAC columns #3 and #4 remained unaffected by any increase in loading rate during entire 166 days of continuous operation. The results are presented in FIGS. 3, 4 , 5 , and 6 . During period 2 (column study 2), all of the columns experienced the shortage of dissolved oxygen. The PVA columns #1 and #2 reacted to insufficient DO, which resulted to higher TCP concentration in their effluents. The elimination for PVA columns #1 and #2 reduced from 100% to 68% and 76%, respectively.
The dissolved oxygen consumption of the PVA columns decreased on day 113 due to flow rate increase and partial TCP removal. The oxygen consumption of both PVA columns and GAC columns decreased by increasing applied loading during periods 6-8 (column study 6-8). The impact of high loading on the PVA column #1 was greater than the PVA column #2. The decrease in oxygen consumption of both GAC columns (#3 and #4) during periods 6-8 (column study 6-8) had no impact on their elimination capacities. The consumption of dissolved oxygen by the columns is clear indication of biological activity under aerobic conditions. The results are presented in FIGS. 7, 8 , 9 , and 10 .
Dehalogenation of TCP was monitored in terms of chloride release in the columns effluent. During period 1(0-29 days), the chloride released by the GAC columns was less than the PVA columns, which indicate TCP removal by adsorption rather than biodegradation. During periods 2-6 (33-113 days), the chloride release increased in proportion to increasing TCP concentration. This gave further evidence of TCP biodegradation in both PVA and GAC columns. During periods 6-8 (113-166 days), the chloride release by both PVA columns decreased with increasing TCP loading, which support the partial removal of TCP by the PVA columns. The chloride released by the GAC columns increased as the applied loading increased during periods 6 and 7 (113-150 days), regardless of HRT, and applied loading. The chloride release increase with the corresponding increase in TCP concentration during period 8 (days 150-166), despite insufficient DO in the influent indicates the possibility of anaerobic dehalogenation of TCP by both GAC columns. The results are presented in FIGS. 11, 12 , 13 and 14 .
Evolution of H + by HCl production in the effluents of all four columns gave further evidence of TCP dehalogenation. The influent(s) and effluents pHs were monitored during the 166 days of the operation. The influent(s) pHs dropped for all four columns. During days 150-166, GAC columns continued to decrease the effluent pH, regardless of loading. Unlike the GAC columns, the PVA columns were affected by high loading and partial TCP removal resulted in a smaller pH drop in the effluents. The results are presented in FIGS. 15, 16 , 17 and 18 .
Responses of Biological Permeable Barriers to a Toxic Shock Loads of TCP
To study the effects of a external disturbance such as a TCP shock load on the PVA and GAC columns removal performance and recovery, the PVA (long) column #2 and GAC (long) column #4 were subjected twice (at two different times) to a high concentration (>550 mg/L) of TCP for 50.0 hr. During this 50.0 hr period, the PVA (short) column #1 and GAC (short) column #3 were subjected to low DO (˜2.0 mg/L) conditions. This external disturbance study lasted 74 days.
During the steady state process monitoring periods (days 168-179), (days 182-223), and (days 228-240), the TCP influent feed concentration was around 40.0 mg/L. With a flow rate of 2 mL/min, this resulted in the TCP loading of 0.3 g L−1d−1 for both PVA and GAC immobilized columns. The feed bottle was oxygenated by bottled pure oxygen everyday (during 74 days) for at least 15 minutes. The influent bottle was capped to prevent oxygen loss.
Both columns responded to high concentration of TCP in the influent. During the 50.0 hr shock loading, the degradation of TCP by the immobilized cells in the PVA column #2 was susceptible to the high shock load as seen in FIG. 19 . The removal efficiency of the PVA column #2 reduced from 90% before shock load to 0% during shock load. The applied loading during the first 50 hours high shock load was 4.12 g L −1 d −1 The PVA column #2 recovered within 16 days as seen by the decreasing TCP concentration in the effluent. When the next shock load (50 hr) was applied on day 224, TCP concentration in the effluent of PVA column #2 increased and decreased in the same pattern as in the first shock load. This time, the recovery time was much shorter. The recovery time of the PVA column #2 from the second shock load was about 5 days.
These results demonstrated that the cells entrapped inside PVA column #2 tolerated high shock load and were protected to a certain extent by immobilization. The minimum concentration of TCP, which completely inhibited the growth of free cells (0.0 TCP removal) was found earlier to be 20.0 mg/L. Based on the TCP mass balance (influent-effluent) the cells entrapped inside PVA column #2, were not able to consume any TCP during the first shock load. While there was a rise in the effluent DO during the first shock load along with no change of the effluent chloride concentration or pH.
The mass balance on TCP (influent-effluent) during the second shock load indicate that the cells were active and biodegrade 169 mg of TCP which is about 15% of total 1154 mg of influent TCP. The cells in the PVA column remained active indicated by DO uptake, chloride release, and pH drop in the effluent during the second shock load. The results also indicate that the process recovered within 5 days as seen by 100% removal of TCP in the effluent. Simultaneous oxygen uptake, chloride releases, and pH drop of the effluent shown in FIGS. 20, 21 and 22 . gave further support to the occurrence of TCP biodegradation by PVA column #2.
Based on the TCP mass balance (influent-effluent), the GAC column was able to take 33% (368.4 mg) and 96% (1143 mg) of influent TCP (1132 mg, 1154.3 mg) during the first and second shock load, respectively. As seen in FIG. 23, during the first shock load, limited removal of TCP took place. This indicates that the GAC adsorption capacity was virtually exhausted (influent TCP=effluent TCP), and the biological activity was low as shown by the rise of effluent DO, low chloride release, and small drop of pH in the effluent. On day 183, the effluent from the GAC column contained a higher TCP concentration than incoming influent. This indicates that desorption was taking place in the GAC column. As seen in FIGS. 24, 25 and 26 , the increased oxygen uptake, chloride release, and pH drop in the GAC column effluent between day 194 and day 213 seemed to be caused mostly by biodegradation of desorbed TCP. Dehalogenation of 40.0 mg/L TCP should release about 21.6 mg/L of chloride. During this period the average chloride release was about 57 mg/L in the effluent. The 60% extra chloride release is believed to be mostly as the result of biodegradation of desorbed TCP (bioregeneration). Between day 226 and day 240, the average daily influent TCP loading rate was 116 mg TCP/d (40.0 mg/L TCP at 2 mL/min), whereas the effluent TCP was zero. The average daily chloride release rate expected to be 62.6 mg Cl − /d for complete dehalogenation of 116 mg TCP/d. The average daily chloride production rate was 160 mg Cl − /d. Therefore, approximately 97.4 mg Cl − /d extra chloride release was obtained that was not accounted for by the influent TCP. This extra chloride release must come from dehalogenation of TCP already adsorbed by carbon. Approximately 3427.0 mg TCP was removed from GAC (bioregenerated) between two shock loads (days 194-213). The average GAC column effluent pH between day 26 and day 45 was 6.6. The effluent average pH drop from 8.1 to 6.6 would have required a 23 mL volume of 0.1 N HCl to have the same pH drop. This is 60.4 mg/L Cl − concentration which was close to the chloride measured (57 mg/L) during this period. The pH drop in the effluent along with chloride release (measured) supports complete dehalogenation of TCP. Aerobic mineralization of 40.0 mg/L TCP requires at least 35.6 mg/L of DO to release 21.6 mg/L chloride subsequently. It is clear that the DO provided was insufficient to biodegrade TCP already adsorbed by the carbon and released an average 35.5 mg/L extra chloride during days 194-213. Therefore, the dehalogenation of TCP already adsorbed was believed to be mostly the result of anaerobic biodegradation.
The immobilized cells in GAC column #4 continued to biodegrade already adsorbed TCP until day 213. The samples taken on day 217 indicated that there was no extra chloride release in the effluent which was consistent with rise of the effluent pH. Therefore, the cells remained active and survived the shock load and continued bioregenerate the carbon completely during 19 days under DO deficiency (anaerobic condition).
During the second shock load (day 224 and 225), the GAC column #4 adsorbed a total of 3120 mg TCP out of 3237 mg TCP applied in the influent. The immobilized cells remained very active during the second shock load and continued to dehalogenate TCP. The cells were able to biodegrade (aerobic condition) approximately 32.0 mg/L of TCP with the corresponding DO usage, chloride release, and effluent pH drop. Within the first week after the second shock load, the immobilized cells started to biodegrade TCP already adsorbed on GAC column during the second shock load. The extra chloride released by GAC column and the effluent pH drop during 233-240 followed the same pattern as seen during days 194-213. The immobilized cells in GAC column #4, remained active during the second shock load and continued to biodegrade TCP under both aerobic and anaerobic conditions.
Responses of Biological Permeable Barriers to a very low Supply of Dissolve Oxygen
To study the effects of low DO on TCP degradation performances and recovery, the oxygen supply to the PVA column #1 and GAC column #3 was discontinued twice during 74 days for 50 hours each time. During the steady state operation, TCP concentration in the influent was 40.0 mg/L and the flow rate was 2 ml/min. The DO during the steady state operation (days 167-179, 182-224, and 228-240) was maintained above 27.0 mg/L. PVA column # 1 reacted quickly to the low DO during both interruptions of DO. In both cases, increases and recoveries of effluent TCP concentrations followed the same pattern. The recovery time was shorter after the second interruption of DO. After the first interruption of DO, PVA column #1 took about 21 days to reduce the influent TCP concentration down to 4.0 mg/L. This is 90% removal of the 40.0 mg/L influent TCP. As seen in FIG. 27, the percent removal increased from 90% to 95% between day 203-217. During the first interruption, effluent shown zero TCP removal supported with corresponding results of pH drop, DO change or chloride release.
After the second interruption, immobilized cells in PVA column #1 recovered within 11 days and reduced TCP concentration by 90% with corresponding DO consumption, chloride release and pH drop in the effluent as shown in FIGS. 28, 29 and 30 . These results demonstrated the sensitivity of immobilized cells in PVA column and, at same time, the tolerance of the immobilized cells toward the low DO influent.
The GAC column also reacted to the interruption of DO. The influent TCP continued to be biodegraded despite the deficiency of dissolved oxygen as indicated by chloride release, effluent pH drop, and 100% TCP removed as shown in FIG. 31 . Both anaerobic activity and adsorption were responsible for the removal of influent TCP during the deficiency of DO as indicated by chloride release and pH drop of the effluent. The results support the partial removal of TCP by anaerobic bacteria. The amount of chloride release and pH drop in the effluent correspond with only 40% of influent TCP dehalogenated by anaerobic bacteria (insufficient DO). Once the oxygen was restarted after each interruption of DO, the aerobic bacteria began to recover and start to consume influent TCP. The activity of aerobic bacteria was evident from oxygen uptake by the GAC immobilized cells.
Theoretically, dehalogenation of 40.0 mg/LTCP releases about 21.6 mg/L Cl − . During day 189-217, the average chloride release was 33.0 mg/L chloride. A possible explanation for extra 45% chloride release is the result of biodegradation of TCP already adsorbed on GAC by anaerobic bacteria. The average GAC column effluent pH was 6.8. The effluent pH drop from 8.1 to 6.8 show that 10.5 mL volume of 0.1 N HCl would be required for this drop. This is 37.3 mg/L Cl − concentration which was close to the chloride release (measured). The pH drop in the effluent along with chloride release support dehalogenation of TCP. It is clear that the DO provided was insufficient for aerobic bacteria to biodegrade TCP already adsorbed by carbon and release an extra 45% chloride. Therefore, the dehalogenation of TCP already adsorbed is believed to be the result of anaerobic biodegradation. During the second interruption of DO (day 224, 225), the aerobic immobilized cells in the GAC column #3 unlike anaerobic bacteria were inactive. Adsorption and anaerobic dehalogenation were responsible for 100% removal of TCP on days 224 and 225. It is theorized that anaerobic dehalogenation of some TCP resulted in the effluent chloride release and pH drop during the second DO interruption.
These results demonstrated the sensitivity of aerobic immobilized cells and, at the same time, the tolerances of these cells toward low DO. The PVA-immobilized cells were unable to degrade TCP during oxygen upset. In both cases of DO interruption, increases and recoveries of effluent TCP concentrations followed the same pattern. The second time recovery times were shorter.
The GAC column #3 offered both adsorption and anaerobic biodegradation during the interruptions of DO. The adsorption capacity of GAC offered 100% removal of TCP. The TCP adsorbed onto carbon subsequently was released and consumed by bacteria (bioregeneration). Insufficient DO promoted the activity of anaerobic bacteria which resulted to biodegradation of TCP, release of chloride, and drop of pH. Since anaerobic bacteria are slower growers they could not grow to a significant enough number in 50 hrs to do any good for TCP removal so then either they are present in the column all the time or some of the degraders may be facultative. Once the oxygen supply restarted, the GAC immobilized cells resumed their activity and continued to biodegrade TCP. GAC-immobilized cells responses to insufficient DO are shown in FIGS. 31, 32 , 33 and 34 .
The capabilities of PVA-immobilized cells and 3% GAC-immobilized cells/sand as two novel biological permeable barrier media to biodegrade a target contaminant (TCP) in groundwater under a variety of operating conditions has been demonstrated. The effects of loading rate, HRT, shock load, and low DO on the removal efficiency of PVA-immobilized cells and 3% GAC-immobilized cells have been shown.
The use of immobilized cells on PVA and GAC as biological permeable barrier media has never been investigated. In order to investigate GAC-immobilized cells and PVA-immobilized cells as biological permeable barrier media, it was necessary to design and test these barriers under different operating conditions found in groundwater such as different loading rates, HRT's, deficiency of DO, and high shock loading for extended period of time. PVA-immobilized cells and 3% GAC-immobilized cells/sand were characterized and tested during 166 days of continuous operation under different loading rates, HRT's, and nutrient (C:N:P) ratios. Both PVA and GAC immobilized cells were subsequently tested under high shock load and low DO conditions. The discussion of the various experimental results conducted during the study is presented as follows.
The results from the 166 days of continuous column experiments on PVA-immobilized cells (Table 9) proved that an elimination capacity of 100% TCP is feasible for loads up to 0.3 g L −1 d −1 (HRT=24.5 minutes). At the loading rate of 0.6 g L −1 d −1 (HRT=12.3 minute), the TCP removal efficiency of PVA-immobilized cells was reduced to 91%. At the highest loading rate of 1.2 g L −1 d −1 (HRT=12.3 minutes), the total TCP removal was 67%. Valo et al. (1990) used a semi batch biofilter using Rhodococcus bacteria to remove TCP, TeCP, and PCP from synthetic groundwater in pilot scale plant. Partial (30-60%) degradation of chlorophenols was achieved at the average loading rate of 0.01-0.07 g L −1 d −1 (HRT=80 h). Makinen et al. (1993) achieved 99.7% chlorophenols (TCP, TeCP PCP) removal in an aerobic fluidized-bed reactor at a maximum loading rate of 0.45 g L −1 d −1 and a hydraulic retention time of 5 h. As compared to earlier studies, PVA-immobilized cells in this project operated at higher TCP loading rates and lower HRTs and produced a better quality effluent. The PVA-immobilized cells survived high shock loads of 4.12 and 4.7 g L −1 d −1 of TCP and recovered within 16 and 5 days, respectively. The immobilization of cells into PVA in this research was shown to protect the microorganisms against the toxicity of high concentration of TCP. An adequate oxygen supply was crucial, as shown in column experiments No.2 and No.9. PVA-immobilized cells removal efficiency of TCP was affected by low DO in the influent. PVA-immobilized cells recovered within 21 and 11 days from first and second interruption of DO, respectively, and continued to biodegrade TCP. Increases and recoveries of effluent TCP concentrations followed the same pattern. A significantly lower elimination capacity of PVA-immobilized cells columns could generally be to traced to an insufficient oxygen supply, and high loading rates with a corresponding decrease in HRT.
The elimination capacity of GAC-immobilized cells of 100% TCP is feasible regardless of the organic load (up to 1.2 g L −1 d −1 ). The results confirm that GAC, even with a substantial development of bacterial activity shown by biodegradation of TCP during 166 days of operation, maintains a substantial adsorption capacity. In this study immobilized cells on GAC were surveyed high shock loads (50.0 hr each) and DO interruptions (twice 50.0 hr each). GAC protected immobilized cells from shock loading through rapid initial adsorption into pores and slow subsequent release by desorption. This desorption accompanied by biodegradation of the desorbed TCP (bioregeneration) was shown during column study No. 9 after the first and second shock load. During the interruption of DO, the microorganisms were unable to biodegrade TCP influent TCP was removed by adsorption on GAC (as shown with no chloride released, or pH dropped in the effluent). During steady state operations extra chloride was released in the effluent as the result of dehalogenation of TCP already adsorbed on GAC by attached microorganisms (bioregeneration).
Biological degradation of chlorophenols under aerobic conditions is known to release chloride, decrease DO and pH in the effluent. The results obtained from running PVA-immobilized cells and GAC-immobilized cells systems for approximately 240 days, indicated that the contribution of chloride release, DO consumption, and pH drop in the effluent were all important in the evaluation of removal efficiency of TCP in this study. During this study, the measured chloride release from dehalogenation of TCP under aerobic conditions agreed well with those calculated from GC results as shown in FIGS. 11, 12 , 13 and 14 .
Jarvinen et al. (1994) concluded that aerobic chlorophenol biodegradation does not result in partially dechlorinated metabolites. They claim mineralization of chlorophenols (CP) since all CP removals were confirmed by chloride release and no chlorinated intermediates were found. Makinin et al. (1993) concluded that the chloride release and H + generation (pH decrease) is an indication of chlorophenol mineralization. The results of this research can be directly compared to the above studies. The results of GC/MS confirm that no chlorinated intermediates or phenol was found in the PVA and GAC columns effluent. Amounts of CO 2 and methane gas greater than found in ambient air were detected in the GAC columns as the results of anaerobic biodegradation of TCP already adsorbed on GAC. This provides a possible explanation for the extra chloride release with the corresponding pH drop in the GAC columns effluent. The presence of aerobic and anaerobic activities in both GAC and PVA columns were confirmed by GC/MS after at the end of this research.
Comparison of GAC-Immobilized Cells with PVA-lmmobilized Cells
It is useful to examine a comparison of the performance of GAC-immobilized cells to PVA-immobilized cells as two biological permeable barrier matrices on the basis of elimination capacity, ease of operation, stability over extended period of time, tolerance under toxic shock loads and low DO, and capital cost.
The results of the previously discussed example applications of these two barrier matrices demonstrates that 3% GAC -immobilized cells/sand has added advantage to PVA-immobilized cells for its adsorption capabilities. The 3% GAC-immobilized cells/sand recovered from the high shock loads faster than PVA-immobilized cells, and the GAC-immobilized cells were able biodegrade TCP already adsorbed on GAC which can extend the life of GAC (bioregeneration). Both PVA-immobilized cells and 3% GAC-immobilized cells as biological permeable barriers compare favorably to conventional surface treatment process. The PVA-immobilized cells and 3% GAC-immobilized cells offer low cost and efficient processes to remove contaminates from groundwater, both in-situ and when the groundwater is first extracted from the ground.
TABLE 4
Comparison of PVA-immobilized cells and
3% GAC-immobilized cells/sand
Basis of
PVA-immobilized
Comparison
cells
3% GAC immobilized cells
Removal efficiency
100% for load up to
100%
300 mg L −1 .d −1
Ease of operation
easy to handle
easy to handle
Stability
most of the beads re-
no physical damage was
mained firm and elas-
observed.
tic. a few of the beads
severely damaged
during 240 days of
continuous operation.
Tolerance
survived high shock
survived high shock load
load and deficiency
and low DO, low DO and
of DO, recovered
high shock affected bio-
from high shock
degradation of TCP. main-
load and low DO
tained 100% efficient
within 11-21 days.
by adsorption and
biodegradation during
high shock load
and low DO.
Capital Cost
chemicals needed
$ 8.0/ft 3
(boric acid, PVA) =
(3% GAC/Silica sand)
$55.0/ft 3 .
Biological permeable barriers using PVA-immobilized cells and 3% GAC-immobilized cells are able to biodegrade contaminates, of which TCP is merely one, from groundwater under various operational conditions. The immobilized cells are protected against toxic shock loads of contaminates by the PVA and GAC. PVA-immobilized cells system is a successful media for use in a trench-based permeable barrier to remove contaminates. PVA-immobilized cells can tolerate low DO and recovered (100% efficiency) within 11-21 days.
Those skilled in the art will recognize from the foregoing description of two embodiments that bioregeneration occurred in GAC-immobilized cells system. The adsorption capacity and biodegradation activity of GAC provided an added advantage to the PVA-immobilized cells system. This bioregeneration of GAC by immobilized cells extent the life of GAC and eliminate the need to excavate and replace the media.
It also will be appreciated by those skilled in the art that the foregoing examples of two embodiments of biological permeable barriers demonstrate the following advantages of PVA-immobilized cells and 3% GAC-immobilized cells as biological permeable barriers. PVA-immobilized cells and 3% GAC-immobilized cells are two successful media for use in a trench-based permeable barrier to remove TCP and/or other contaminates from groundwater either in-situ or ex-situ. PVA-immobilized cells provided up to 100% removal efficiency for TCP loading up to 300 mg/liter per day and GAC-immobilized cells provided 100% removal efficiency for TCP loading up to 1200 mg/liter per day.
Microorganisms were protected against high shock loads by immobilization on PVA beads and recovered to steady state conversion within 11-21 days. PVA-immobilized cells tolerated deficiency of dissolved oxygen and regained their activity once they received adequate DO.
GAC maintained substantial adsorption capacity even with development of bacterial growth. The survival of the immobilized cells in spite of the addition of a shock load was the result of rapid adsorption of the contaminate by GAC. Bioregeneration occurred as the adsorbed contaminate was desorbed and metabolized by immobilized cells. Bioregeneration was shown by the extra chloride release, with corresponding pH drop in the effluent, after adsorption capacity of GAC was exhausted by a high shock load of contaminate. PVA-immobilized cells were unable to offer any of the adsorption advantages provided by GAC-immobilized cells.
Stability, control, detoxification of contaminants, and high performance shown by both PVA-immobilized and GAC-immobilized cells systems under variety of operating conditions represent biological permeable barrier systems that eliminate the need to excavate and replace the media from trench reclamation sites which represents a substantial improvement over the prior art barriers.
After 240 days of continuous operation, over 99% of PVA-immobilized cells appeared to be resilient, firm, and structurally sound. Micrographs of the beads showed them to be more porous than initial beads. The channels and pockets within the beads appeared larger than initial beads. FIGS. 35 and 36 are scanning electron micrographs of the beads after 240 days showing mirocolonies formed inside the PVA beads. FIGS. 37 and 38 are scanning electron micrographs of GAC-immobilized cells showing microcolonies of the cells on inner surfaces of GAC.
PVA-immobilized cells remained permeable and structurally sound over time (240 days). PVA-immobilized cells tolerated high shock load, low DO and resumed its biological activity to a steady state in a matter of a few days. PVA-immobilized cells remained 100-91% efficient at applied loadings of 300 mg L −1 .d −1 and 600 mgL −1 d −1 , respectively. On the selected contaminate (TCP) for the above-described embodiments , PVA-immobilized cells completely dehalogenated TCP without formation of chlorinated intermediates or phenol. The lack of chloride intermediates or phenols is demonstrated in FIGS. 39, 40 , 41 , 42 and 43 which are gas chromatograph/mass spectra readouts of PVA column effluents.
GAC-immobilized cells offered 100% removal of TCP by a combination of biological degradation and physical adsorption. The cells functioned as biological processors and the GAC functioned as a support and adsorbent barrier. GAC-immobilization protected cells from high shock loads by rapid TCP adsorption. Biodegradation of TCP by GAC-immobilized cells dehalogenated TCP without formation of chlorinated intermediates or phenol.
Therefore, the use of PVA-immobilized cells and 3% GAC-immobilized cells/sand as two biological permeable barrier media to remove contaminates from groundwater is an important improvement over the prior art methods and provides important operational benefits such as no precipitation of solid contaminates, no need to replace the barrier, no need to remove the barrier once it has been in operation due to collection of contaminates, no by-product contaminates are produced, complete detoxification of the contaminate can be obtained, low operation cost and maintenance cost of the barrier is presented, no sludge is produced which must be removed from the site and destroyed and no hazardous waste is produced.
In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the inventions is by way of example, and the scope of the inventions is not limited to the exact details shown or described.
Certain changes may be made in embodying the above invention, and in the construction thereof, without departing from the spirit and scope of the invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not meant in a limiting sense.
Having now described the features, discoveries and principles of the invention, the manner in which the inventive permeable barrier is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims. 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. | A method of removing contaminates from ground water is provided which places a biological permeable barrier in the path of the ground water flow to contact the contaminated groundwater with encapsulated microorganisms which act to decontaminate the contacted groundwater. | 1 |
FIELD OF THE INVENTION
The present invention relates to a system for managing the bulk material inside a silo, applicable to the industrial hulk material distribution sectors for bulk materials arc stored in metal silos, such as for example, cement, plaster, dried mortar, flour, cereal grains, etc. This system, in addition to monitoring the amount of material inside the silo at all times, manages this amount to warn the user of possible out-of-stock risks and helps the user by recommending the optimal time for stocking the silo. Once configured, the system is completely autonomous, i.e., it is self-sufficient in its use, as there is no in need for an electric power supply to operate, or batteries, or an installation of data communication cables for transmitting the information of the weight of the material in the silo to other equipment.
BACKGROUND OF THE INVENTION
Using metal silos in the industry for storing materials such as cement, mortar, plaster, wheat germ, etc., is a common practice. It is very important to know at all times the amount of material in the silo to ensure correct use thereof. There are various techniques for measuring this amount, some of which arc based on weighing the silo by installing load cells that adhere to the legs of the silo, others which are based on measuring the fill level by ultrasound, radar, laser, etc. The present invention relates to the former, i.e., silos in which load cells adhered to their legs are installed for measuring by weight the amount of material in the silo.
Today, when a silo is to be implemented for adding therein a measuring system for the purpose of being able to monitor the amount of material therein, the most common practice is to install load cells by screwing them on and adhering them to their legs, which are usually beams with HEB section, or structural metal tubes. These cells are connected to electronic equipment which in turn is connected to the electric network for powering it and communication cables are also installed from the silo to the control cabin for transmitting the data to a weight monitoring system. Today, the most advanced systems have a central server application which connects the sensors of the plant with the sensors of the headquarters through the Internet, or other telecommunication networks.
In the case of moveable silos which are moved with a truck to the work site, the complexity increases since the operation of transporting and erecting the silo causes strong impacts on the legs of the silo which would misadjust and/or break the load cells that are installed thereon. For this reason, movable silos today do not have cells or other measuring systems installed in the legs.
This type of installations will now be described. The silo ( 1 ) has therein the bulk to material the amount of which is to be monitored at all times. When it has more material, its legs ( 3 ) are subjected to more tension. This tension is measured by installing load cells ( 4 ) on said legs. In fixed silos, cells ( 4 ) are usually installed on all the legs or only on some of them. The signals of these cells are pulled together in a summation box ( 5 ), and the signal ( 6 ) is channeled towards the control cabin ( 2 ) from this box. Many times Is there is a to pass the cables through underground conduits ( 9 ) to take the cables ( 10 ) to the electronic control equipment ( 11 ) which performs the weighing and displays it on a viewfinder ( 12 ). The silo has a motor with a worm screw ( 7 ) and electric connection ( 8 ) for extracting the material from the silo.
Today, the load cells are screwed onto and adhered to the web of the beam. To that end, there is a need to make two completely normal precise boreholes of the exact diameter in the web of the beam. These boreholes are usually made with a special tool. Once the cell is completely screwed thereon and the cementing adhesive has hardened, they are connected and channeled to the electrical installation. This installation process is laborious, complex and manual, which in business terms means that it is slow and expensive. Furthermore, it complicates the subsequent maintenance as it complicates the replacement of load cells that may be broken.
As a result, nowadays these installations are usually complex and expensive. Many times it is necessary to channel the cables through underground ditches to take the power supply and the data to the control cabin, where the visualization equipment is usually installed so that they are close to the plant operator. As a result, in reality, very few silos have this equipment and as no measuring system is provided, the plant operator tracks the operating procedures to deduce the amount of material in the silo and to decide when he has to order material to fill the silo. If the plant has more than one silo of the same material, this task of the operator is simpler, as he can order material when one silo is emptied, and while the supply arrives, work with the other silo, but in this case the investment for having and maintaining the installation is higher, and the cost of the inventory is also higher, affecting the circulating capital.
SUMMARY OF THE INVENTION
The present invention develops an autonomous system for managing the bulk material in a silo, which is installed in the silo, and is characterized in that:
An application for managing the silo built into the equipment itself which is installed in the silo, which monitors the fill level at all times, warns of future out-of-stock situations and recommends when to order material to stock the silo. There is no need for an electric power supply installation, or battery, or installation of communication cables for transmitting the weighing data. It can be installed in moveable silos without risks of breaking and/or misadjustments. It can be connected to the Internet through a radio communication gateway. It can report any event through the Internet, even send messages to end users. It can be installed at any time without the need to wait for the silo to be emptied, or for its operation to be stopped. In moveable silos, it detects if the silo moves, if it moves, it detects if the movement is horizontal or vertical and its inclination. It develops a method for installing the load cells which gives robustness to the system, prevents breaks, shortens installation times and improves the subsequent maintenance. It detects if the silo is being filled by a supplier other than the corresponding supplier.
Other features and advantages of the present invention will be understood from the following detailed description of illustrative embodiments of its object in relation to the attached figures.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a diagram of a silo in which a conventional system for measuring the weight of the material in the silo according to the prior art of the present invention has been installed. The silo ( 1 ) has load cells ( 4 ) which measure the weight of all the entire assembly installed on its legs ( 3 ). These load cells are pulled together in the summation to box ( 5 ) and the total analog signal ( 6 ) is channeled by means of an underground ditch ( 9 ) to the control cabin ( 2 ) to which the cables of the silo ( 10 ) which are connected to the electronic equipment ( 11 ) which in turn has a weight viewfinder ( 12 ) reach.
FIG. 2 shows a diagram of a load cell ( 4 ) installed on one leg of a silo ( 3 ), which in this example is an HEB 140 beam, according to the prior art described in the present is invention. The cell is screwed onto and also adhered ( 14 ) to the web of the beam at its two ends ( 13 ). The cell is connected to the summation box ( 5 ) by means of a duct cable ( 15 ).
FIG. 3 shows a diagram of a silo in which the system object of the present invention has been installed. The invention eliminates the wiring and the power supply from the equipment. The load cells ( 16 ) are connected to the electronic equipment ( 17 ), which is powered by solar energy ( 18 ) from the sun ( 22 ). This equipment ( 17 ) is communicated via radio ( 19 ) with the electronic equipment of the cabin ( 25 ). The equipment of the cabin ( 25 ) has a connection ( 20 ) to the Internet ( 21 ). The invention has a second method for measuring the bulk material stock in the silo for monitoring the consumption. To that end it has a sensor ( 23 ) connected to the motor of the worm screw ( 26 ) which extracts the material from the silo. This sensor ( 23 ) measures the consumption of the motor and discriminates depending on the consumption of amperes thereof, when it is and when it is not extracting material. By integrating this information over time, it deduces the material that has been extracted from the silo and therefore the material remaining in the silo. The sensor ( 23 ) sends this information to the equipment ( 17 ) by means of radio communication ( 24 ).
FIG. 4 shows a diagram of a load cell ( 16 ) installed on a leg of a silo which in this example is the web of an HEB 140 beam, as described in the present invention. This cell is screwed at one end ( 36 ) by means of the screw ( 28 ) to a support ( 35 ) which is welded to the web of the beam by means of weld beads ( 34 ). The support has a notch ( 32 ) which prevents displacement in cell shearing when it is inserted into a recess ( 33 ) of the load cell. At the other end of the cell ( 37 ), it is screwed ( 31 ) and fixed by means of nut ( 29 ) and locknut ( 30 ). The strain gauges formed by the cell are protected in a box ( 27 ) coated with a waterproof resin to prevent cell degradation.
FIG. 5 shows a diagram of operational blocks for performing the system according to the present invention. The load cells ( 16 ) are connected to analog-to-digital converters ( 53 ) which further amplify the signals and take them to a secondary microprocessor ( 38 ) that is responsible for calculating and converting these tensions into weight. This microprocessor ( 38 ) is connected by means of ( 55 ) to the main microprocessor ( 39 ).
The system is powered by solar energy ( 18 ) as a result of the photovoltaic panel ( 40 ). The system stores energy so that it can continue to operate at night by means of a set of supercaps ( 41 ).
The main microprocessor ( 39 ) detects the correct operation of the solar panel ( 40 ) as a result of an electronic stage ( 52 ), and it also detects the charge level in the supercaps as a result of the stage ( 42 ).
The solar panel ( 40 ) and the set of supercaps ( 41 ) are connected to an energy management unit ( 44 ) which in turn is connected to the general DC/DC power supply of the electronics ( 54 ). It also has a rapid recharging unit ( 43 ) for the supercaps by means of applying an external source (chute).
The system has an XYZ, accelerometer ( 46 ), a set of digital inputs and outputs ( 47 ), a PCD cell for measuring the brightness of the environment ( 48 ), a stage for adapting digital inputs ( 49 ) for a reed relay ( 51 ), and a stage for sensing the temperature of the system ( 50 ).
The system has a sensor which measures the pressure inside the silo ( 57 ) and which sends this pressure value by means of radio communication ( 56 ) to the microprocessor ( 39 ).
The system has a serial communication channel with a conversion stage via radio ( 45 ) which allows the system to communicate with other external devices.
DETAILED DESCRIPTION OF THE INVENTION
Embodiment of the system object of the present invention ( FIG. 5 )
A first preferred embodiment of the present invention will be detailed below. The system object of the present invention thus comprises the following elements:
Sensing the weight of the bulk material in the silo
This is performed with a set of load cells ( 16 ) which are installed on the legs ( 3 ) of the silo. A single load cell can be installed on one leg or up to four cells can be installed on the four legs.
The load cells are installed on the legs of the silo ( 3 ), but not in the current manner described ( 4 ), but rather as will be described in the present invention ( 16 ). To that end. instead of drilling, screwing and adhering the load cell to the web of the beam, a support ( 26 ) is welded to the web of the beam. Once the support is welded at both ends ( 34 ), the load cell ( 16 ) is screwed onto the support. The support has a notch ( 32 ) which engages with a groove ( 33 ) of the load cell assuring the immobility of the cell at the end when a tightening torque suited to the screw ( 28 ) is applied. Complete immobility of the cell on one of its sides is thus assured, without having to make precise boreholes and without having to use cementing adhesives. The other end of the cell is screwed onto the support ( 26 ) by means of another screw ( 31 ) using a nut ( 29 ) and a locknut ( 30 ).
This invention further allows the load cell to be electrically insulated by designing the ends of the cell ( 36 ) and ( 37 ) from insulating material, for example, from ceramic. A high number of breaks are prevented since the load cell is entirely electrically insulated from other metal parts of the installation. It is common for the cells to break in current installations due to electric storms or welding works in the installation. These breaks will be prevented by means of this improvement provided by the present invention.
This invention also prevents breaking and/or misadjusting the load cells as it allows them to be left free at one end by loosening the screw ( 31 ) and the nuts ( 29 ) and ( 30 ) during transport of the silo, therefore resolving and providing a solution to moveable silos which currently do not use load cells on the legs since they break from the impacts of positioning the silo.
Stage 1: Measuring the weight from the load cells
The set of load cells installed according to the present invention is connected to the electronic equipment ( 17 ) having four load cell inputs. The load cells are a set of strain gauges connected in a Wheatstone bridge which, when they are supplied with energy, for example at 0-10V, deliver an output voltage of +/−20 mV, proportional to the voltage to which they arc subjected. These inputs are connected to adaptation, amplification stages ( 53 ) which in turn are connected to a microprocessor ( 38 ). The microprocessor ( 38 ) internally has at least four analog-to-digital converters and a firmware which scans the four mentioned A/D channels such that it senses the value of the tension in each of the load cells ( 16 ) and weight conversion is performed. Its firmware has a calibration process for adjusting the actual weight of the material in the silo to the value of the electric voltage delivered by the load cells.
Stage 2: Power supply through photovoltaic panel, supercaps and energy management system.
The system is supplied with a photovoltaic solar panel ( 40 ). Given that it is a low-consumption electronic, it is estimated that it is more than sufficient to supply the system with a 15×15 cm and 2 watt panel.
The photovoltaic panel is not sufficient as it does not work at night when light is absent, as the system must operate at all time. To that end, an energy storage means is necessary. For robustness purposes, instead of using rechargeable batteries a set of supercaps ( 41 ) is preferred. These supercaps will be charged from the solar panel from solar radiation and they will store electric energy which will be used at night. The electronic stage ( 41 ) is responsible for coordinating the different energy sources depending on the system status.
Stage 3: Built-in management application of the System.
One great innovation of the present invention is that the developed system comprises a built-in application which covers the entire functionality by firmware in two microprocessors ( 38 ) and ( 39 ), allowing the system to be self-sufficient, i.e. without the need to use computers or additional computational equipment, or central computational equipment. The users are connected by the Internet to ( 39 ) and this microprocessor implements a Web Server accessible from the Internet using standard technology.
To that end, the secondary microprocessor which manages the weighing ( 38 ) has a connection with the main microprocessor ( 39 ). For the embodiment, an SPI (Serial Peripheral Interface) type connection is selected, the secondary microprocessor ( 38 ) acting as slave and the main microprocessor ( 39 ) as master. The microprocessor ( 39 ) thus has access to the information of the weighing delivered to it ( 38 ).
The microprocessor ( 38 ) executes a firmware which implements the following functionality:
1.—Performing self-diagnostic operations of the weighing system based on the load cells. 2.—Handling up to 4 digital analog channels for converting the electric voltages in the cells to weight variables. 3.—Handling each load cell independently and performs digital summation thereof. 4.—Performing digital correlation operations for the signal that each load cell delivers, which allows it to detect if any of the cells is malfunctioning. In the event that this occurs, the malfunctioning cell can be digitally eliminated, this can be reported and the operation with the remaining cells can continue. 5.—By analyzing correlation deviations in the weighing, predicting the future malfunction in one or some of the load cells and reports by estimating when it will malfunction in the future, processing the gradient of degradation over time. 6.—Accepting commands of the main microprocessor ( 39 ) through the connection ( 55 ) which implements a slave SPI. The microprocessor ( 39 ) executes the main firmware of the system by implementing the following functionality: 1.—Performing self-diagnostic functions of all the system components. 2.—Collecting the information from the weighing of ( 38 ) through the connection ( 55 ). 3.—Implementing a calibration application for the weighing, with a user interface through an Internet browser. 4.—Detecting the temperature of the system as a result of ( 50 ) and performing temperature compensations for adjusting the values of the weighing. 5.—Detecting, as a result of ( 48 ) the brightness of the room and checking that the photovoltaic panel is operating correctly. If it is not, generating alarms over Internet to report the malfunction. 6.—Allowing entering in system configuration mode by means of using reed relays ( 49 ) and ( 51 ). 7.—Calculating according to the material in the silo, the configuration data, the schedule for using the silo and the planned consumption demands, the time till the stock runs out, if the silo is or is not stocked, and reporting it through the Internet. 8.—Warning the user through Internet of significant stock variations that do not coincide with the demand planning foreseen and configured in the system. 9.—One of the features of the present invention is that this system can be installed at any time. The silo does not need to be empty. To that end, when the system is being configured, there is a need to simply enter the amount of bulk material of the silo in the system and apply tension on each of the cells by tightening the screw ( 31 ). The configuration application which runs in ( 39 ) will indicate the tension to be applied. The cells are thus placed in the operating interval, assuring the traceability of the system which simplifies and makes the calibration system more efficient. Currently, calibrating one of these systems in the prior art of this invention could take weeks as it depends on the availability of the plant and waiting for the time when the silo is empty. This calibration operation can be performed at any time and in less than half an hour as a result of this invention. This calibration can further be performed from anywhere, provided that a connection to the Internet is available. 10.—Detecting the position of the silo by means of the accelerometer. The silo must be completely vertical for it to operate reliably and safely. If the silo is moved, for example by a flash flood which debilitates the ground, the system will detect it and warn the user through Internet. Malfunctions of this type occur more commonly in moveable silos causing damages to the installation. In this case the system provides traceability that the silo was correctly positioned upon delivery. 11.—Maintaining a schedule for supplying material to stock the silo and since it has a real-time clock, detecting failures to supply material which is reported through Internet. In other words, it knows that stocking must occur on certain date and at a certain time. If it does not detect a surge pressure in the silo and increment in the stock in a confidence interval, it generates an alarm through Internet. If the amount increased after stocking is less than that ordered, within a confidence interval, it generates an alarm through Internet. 12.—Allowing the automatic generation of orders for stocking the silo through Internet in a B2B (business to business) environment depending on the established configuration, the demand planning and the material stock in the silo. 13.—Allowing tracking an SLA (Service Level Agreement) in which the manner in which the supplier will supply the material to stock the silo is controlled and agreed upon. The SLA is parameterized and is transformed into process variables and state machines linked to temporary events. The firmware of ( 39 ) maintains a task dedicated to tracking these events, which allows it to discriminate if the SLA is being complied with. In the case where failure to meet the SLA is detected, it informs the user through Internet. 14.—Maintaining radio communication ( 24 ) with equipment ( 23 ) which measures the electric consumption in the motor of the worm screw for extracting material from the silo. When the worm screw is extracting material, the electric consumption in the motor will be in an identifiable ampere interval. When the silo is empty, the energy consumption in amperes will be significantly lower. This proportions a second method for identifying that the silo is empty. The microprocessor ( 39 ) monitors this consumption and integrates it over time. It executes an algorithm which filters the motor stop and breakdown transients for the purpose of fine-tuning the integration of the consumption over time. It is furthermore possible to correlate it with the information from the weighing. This provides a second method for determining the weight in the silo which could be applied to silos not implemented with load cells. 15.—Detecting when the silo is being filled either by the increment of weight of material in the silo, or by detecting a surge pressure inside the silo by means of the sensor ( 57 ), which transmits this information via radio ( 56 ) to the microprocessor ( 39 ). It further detects that this pressure is within a range of appropriate values. If the truck is applying . more pressure than necessary for pneumatically tilling the silo, it can put the pipes or equipment of the silo at risk. Thus it detects whether the silo is correctly stocked. 16.—Implementing a sleeping mode and active mode cycle to the electronics for the purpose of saving electric consumption. When the electronics are in a sleeping mode the energy consumption is minimized. When they arc in an active mode, the energy consumption is higher, it can even be greater than the 2 watts expected to be delivered by the 15×15 cm 2 photovoltaic panel. During this time, the supercaps secure the power supply. The working cycle allows the electronics to be in sleeping mode most of the time. The cycle is configurable by the user. 16.—Maintaining radio communication ( 19 ) with the communication gateway towards the Internet ( 25 ). The radio protocol chosen for the embodiment is a communication layer on a MAC 802.15.4. If there are many silos in mesh networking connected to the gateway, this gateway would act as coordinator and therefore ZigBee will be used on top of this MAC. 17.—The microprocessor ( 39 ) implements a built-in Web Server which allows access thereto through Internet, once the access control is overcome by means of user name and password. It also implements a management application for managing this Web Server, with the following functionality:
Calibrating the weighing system: weighing values for full silo, empty silo. Calibrating consumption in the worm screw: Ampere interval when empty, when loaded, summation of times, breakdown and stop filtering. Scheduling for the use of the silo. Determining optimal stocking time and of out-of-stock prevention. Optimal stocking recommendation messages. Consumption history record. Consumption trend graphs. Alarms for consumption outside prefixed hour. Alarms for filling the silo by other non-authorized suppliers. Silo movement alarms.
Stage 4: Transmitting data via radio towards the communication gateway.
The microprocessor ( 39 ) maintains radio communication at 2.4 GHz implementing a MAC 802.15.4 protocol with the communication gateway ( 25 ). This is a short distance radio communication, maximum 300 meters outdoors in a free band, therefore a license for use is not necessary.
Stage 5: Transmitting data from the communication gateway towards any equipment connected to the Internet.
The communication gateway ( 25 ) is installed in the control cabin. It has a physical connection to the electric network for the power supply and ADSL connection towards the Internet ( 21 ). It implements a gateway with protocol conversion which transfers everything reaching it via radio towards Internet ADSL and everything reaching it from the Internet ADSL towards the radio. It thus puts the management system for the silo on the Internet. | Management System for managing bulk material inside a silo, that includes: load cells bolted to brackets that are welded to the legs of the silo; an electronic device that measures the weight from the load cells and transmits that information via radio to a gateway that connects to the Internet, a photovoltaic panel to obtain power from solar energy; a set of Supercaps to operate at night-time, a thermistor to compensate for temperature, a XYZ accelerometer to detect movement of the silo and its inclination, a real time clock and a radio communications channel. | 8 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention relates to cold cathode field emission displays, more particularly high resolution field emission displays.
(2) Description of the Prior Art
Cold cathode electron emission devices are based on the phenomenon of high field emission wherein electrons can be emitted into a vacuum from a room temperature source if the local electric field at the surface in question is high enough. The creation of such high local electric fields does not necessarily require the application of very high voltage, provided the emitting surface has a sufficiently small radius of curvature.
The advent of semiconductor integrated circuit technology made possible the development and mass production of arrays of cold cathode emitters of this type. In most cases, cold cathode field emission displays comprise an array of very small conical emitters, each of which is connected to a source of negative voltage via a cathode conductor line (or column). Another set of conductive lines (called gate lines) is located a short distance above the cathode columns at an angle (usually 90°) to them, intersecting with them at the locations of the conical emitters or microtips, and connected to a source of positive voltage. Both the cathode and the gate line that relate to a particular microtip must be activated before there will be sufficient voltage to cause cold cathode emission.
The electrons that are emitted by the cold cathodes accelerate past openings in the gate lines and strike an electroluminescent panel that is located a short distance above the gate lines. In general, even though the local electric field in the immediate vicinity of a microtip is in excess of 1 million volts/cm., the externally applied voltage is only of the order of 100 volts. However, even a relatively low voltage of this order can obviously lead to catastrophic consequences, if short circuited.
The early prior art in this technology used external resistors, placed between the cathode or gate lines and the power supply, as ballast to limit the current in the event of a short circuit occurring somewhere within the display. While this approach protected the power supply, it could not discriminate between individual microtips on a given cathode column or gate line. Thus, in situations where one (or a small number) of the microtips is emitting more than its intended current, no limitation of its individual emission is possible. Such excessive emission can occur as a result of too small a radius of curvature for a particular microtip or the local presence of gas, particularly when a cold system is first turned on. Consequently the more recent art in this technology has been directed towards ways of providing individual ballast resistors, preferably one per pixel.
The approach favored by Borel et al. (U.S. Pat. No. 4,940,916 July 1990) is illustrated in FIG. 1. This shows a schematic cross-section through a single pixel. As already discussed, current to an individual microtip 2 is carried by a cathode line 1 and a gate line 4. However, a high resistance layer 3 has been interposed between the base of the microtip and the cathode line, thereby providing the needed ballast resistor. While this invention satisfies the objective of providing each microtip with its own ballast resistor, as well as not reducing the resolution of the display, it has a number of limitations.
The resistivity that layer 3 will need in order to serve as a ballast resistor is of the order of 5×10 4 ohm cm. This significantly limits the choice of available materials. Furthermore, sustained transmission of current across a film is substantially less reliable than transmission along a film. The possibility of failure as a result of local contamination or local variations in thickness is much greater for the first case. Consequently, later inventions have focussed on providing individual ballast resistors wherein current flows along the resistive layer, rather than across it.
Kane (U.S. Pat. No. 5,142,184 August 1992) used semiconductor integrated circuit technology to generate his cold cathode display so that individual ballast resistors could be provided in the same way that resistors are provided within integrated circuits in general. This approach meets the requirement of current transmission along, rather than across, the resistive layer but makes for a more expensive system since an additional mask and diffusion step are required. Furthermore, additional space must be made available for the diffused resistors, which lie on either side of the cathode columns, thereby decreasing the resolution of the system.
The approach taken by Meyer (U.S. Pat. No. 5,194,780 Mar. 1993) utilizes a cathode distribution mesh and is illustrated in FIG. 2. This shows, in plan view, a portion of a single cathode line which, instead of being a continuous sheet, has been formed into a network of lines 15 intersecting with lines 16. A resistive layer 17 has been interposed between the mesh and the substrate (not shown here). Microtips 12 have been formed on the resistive layer and located within the interstices of the mesh. A single gate line intersects the cathode distribution mesh, and current from the mesh must first travel along resistive layer 17 before it reaches the microtips. An important disadvantage of this approach is that the presence of the mesh limits the resolution of the display. Another disadvantage is that the values of the ballast resistors associated with the various microtips vary widely because of the geometry of this design.
SUMMARY OF THE INVENTION
It has been an object of the present invention to provide a cold cathode field emission display whose resolution is not limited by the provision of individual ballast resistors for each pixel or by the wiring system used to deliver voltage to the cold cathodes.
A further object of the invention has been to provide individual ballast resistors that have high reliability and are capable of meeting tight tolerances.
These objects have been achieved by providing additional layers beneath the cold cathodes arrays so that said resistors and voltage delivery systems may be located directly below the cold cathode arrays instead of alongside of them. Six different embodiments of the invention are described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 illustrate prior art that teaches the technology of built-in ballast resistors for cold cathode displays.
FIGS. 3A and B show a first embodiment of the invention based on a distributed ballast resistor and a cathode distribution mesh.
FIGS. 4A and B show a second embodiment of the invention based on a serpentine thin film resistor and a cathode distribution line.
FIG. 5 shows a third embodiment of the invention based on a spiral thin film resistor and a cathode distribution line.
FIGS. 6A and B show a fourth embodiment of the invention based on a distributed ballast resistor and a cathode distribution plane.
FIGS. 7A and B show a fifth embodiment of the invention based on a serpentine thin film resistor and a cathode distribution plane.
FIGS. 8A and B show a sixth embodiment of the invention based on a spiral thin film resistor and a cathode distribution plane.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is aimed at providing individual ballast resistors for the groups of microtips that comprise pixels without sacrificing the resolution of the overall display. This has been achieved by placing the ballast resistors and cathode voltage supply system (cathode columns or distribution mesh) underneath the microtips instead of alongside them.
Referring now FIG. 3A. This shows, in schematic cross-section, a first embodiment of the present invention. Resistive layer 32 has been deposited onto insulating substrate 31. Cathode distribution mesh 33 (seen end-on in the figure) sits above, beneath, or in, and makes contact with, resistive layer 32. Dielectric layer 34 has been deposited over layers 32 and 33 and cathode column 35 (seen end-on) lies over layer 34. Via hole 36 allows material from layer 35 to make contact with resistive layer 32. Microtips such as 37 rest on cathode column 35 and extend through openings in gate line 38 which is separated from layer 35 by second dielectric layer 39. Note that it is necessary to planarize the upper surface of layer 35 prior to the placement of the microtips. We have found the most effective way to achieve this to be by means of Chemical Mechanical Polishing (CMP). The CMP process comprises the application of a chemical etchant, which loosens the surface, in combination with a fine abrasive slurry that removes the modified surface as it is undermined.
FIG. 3B is a partial plan view of the structure illustrated in FIG. 3A. It is readily apparent that, other things being equal, the structure of FIG. 3B can be made smaller than the prior art structure illustrated in FIG. 2. The size of cathode distribution mesh 18 in FIG. 2 is limited by how close lines 15 and 16 can come to the array of microtips (such as 12) and still provide adequate resistance in series with them. Furthermore, the closer lines 15 and/or 16 come to microtip 12 the greater will be the disparity in ballast resistor values associated with these two microtips. By contrast, all microtips in FIGS. 3 are associated with the same value of ballast resistance and the size of the cathode distribution mesh can be reduced to less than that of the cathode columns, eliminating it as a factor in limiting the overall resolution.
Preferred materials for manufacturing this embodiment have included silicon, silicon/chrome alloy, indium tin oxide, and tantalum nitride for the resistive layer, laid down to provide a sheet resistance in the range of from 10 7 to 10 3 ohms/square and silicon oxide, aluminum oxide, silicon nitride, iron oxide, indium oxide, stannous oxide, and tantalum oxide for the dielectric layers.
FIG. 4A is a schematic cross-section of a second embodiment of the present invention in which a more conventional aspect ratio for the ballast resistor has been used. Resistor 42 is a thin film resistor that has been deposited and patterned on substrate 41. One end of each resistor is connected to a cathode distribution line such as 43 (seen end-on) while the other end is connected to a cathode column (also seen end-on) through via hole 46. FIG. 4B is a plan view of part of FIG. 4A.
This embodiment makes the value of the ballast resistor easier to control and allows resistive layers having lower sheet resistance to be used. Also, since only a single line is needed for the voltage supply (as opposed to the multiple lines of a mesh), this embodiment occupies less space than the embodiment illustrated in FIG. 3.
FIG. 5 is a plan view of a third embodiment that is a variant of the embodiment illustrated in FIGS. 4. In FIG. 4 the resistor followed a serpentine path in going from the cathode distribution line to the via hole. In FIG. 5, the path of resistor 52 can be seen to be a spiral that begins at the cathode distribution line 53 and then spirals inwards till it reaches the via hole 56 at the center.
Preferred materials for manufacturing this embodiment have included silicon, silicon/chrome alloy, indium tin oxide, and tantalum nitride for the resistive layer, laid down to provide a sheet resistance in the range of from 10 7 to 10 9 ohms/square and silicon oxide, aluminum oxide, silicon nitride, iron oxide, indium oxide, stannous oxide, and tantalum oxide for the dielectric layers.
FIG. 6A shows a schematic cross-section of a fourth embodiment of the present invention. Conductive layer 60 has been deposited on substrate 61 and has been covered by dielectric layer 64 on which resistive layer 62 lies. Cathode distribution mesh 67, comprised of the same material as resistive layer 62, connects conductive layer 60 to resistive layer 62. Dielectric layer 69 corresponds to dielectric layer 34 in FIG. 3A and the parts of the structure that lie above layer 69 correspond to the parts that lie above layer 34 in FIG. 3A. FIG. 6B is a plan view of part of FIG. 6A showing cathode distribution mesh 67 and via hole 66. As already mentioned, a CMP process is employed to planarize the surface prior to the formation of the microtips.
Preferred materials for manufacturing this embodiment have included silicon, silicon/chrome alloy, indium tin oxide, and tantalum nitride for the resistive layer, laid down to provide a sheet resistance in the range of from 10 7 to 10 9 ohms/square and silicon oxide, aluminum oxide, silicon nitride, iron oxide, indium oxide, stannous oxide, and tantalum oxide for the dielectric layers.
FIGS. 7A and 7B and FIGS. 8A and 8B show fifth and sixth embodiments, respectively, that bear the same relationship to FIGS. 6 as do FIGS. 4 and 5 to FIGS. 3. The additional third dielectric layer that is a feature of the fifth and sixth embodiments allows for an even more compact design. Note that layer 71 in FIG. 7 represents a single cathode line. Said cathode line connects to one end of thin film resistor 72 through via hole 77, the other end of resistor 72 being connected to cathode column 75 through via hole 76, as in the earlier embodiments.
Preferred materials for manufacturing this embodiment have included silicon, silicon/chrome alloy, indium tin oxide, and tantalum nitride for the resistive layer, laid down to provide a sheet resistance in the range of from 10 7 to 10 9 ohms/square and silicon oxide, aluminum oxide, silicon nitride, iron oxide, indium oxide, stannous oxide, and tantalum oxide for the dielectric layers.
While the invention has been particularly shown and described with reference to the preferred embodiments described above, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention. | The object of the present invention is to provide a cold cathode field emission display whose resolution is not limited by the provision of individual ballast resistors for each pixel or by the wiring system used to deliver voltage to the cold cathodes. This has been achieved by providing additional layers beneath the cold cathodes arrays so that said resistors and voltage delivery systems are located directly below the cold cathode arrays instead of alongside of them. Six different embodiments of the invention are described. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of, and clams the benefit of, the applicants' prior parent regular utility patent application, entitled Safety Apparatus and Method of Use, Ser. No. 11/233,675, filed Sep. 22, 2005, now U.S. Pat. No. 7,150,054 which prior parent regular utility patent application claimed the benefit of the applicants' prior U.S. provisional patent application of the same title, Safety Apparatus and Method of Use, Ser. No. 60/719,671, filed Sep. 21, 2005. The contents the above-referenced prior parent regular utility application and prior U.S. provisional patent are hereby incorporated by reference in their entirety.
FIELD
This application concerns a device for orienting a body with respect to another object and method of use. In one embodiment, the application concerns a device for relatively securely orienting a human body, such as a sleeping infant for example, with respect to an adjacent blanket or sheet and method of use.
BACKGROUND
A common problem faced by caregivers and parents of an infant, particularly a young infant, is that the infant typically is unable to keep a blanket over a lower portion of the infant while the infant is asleep. This arises because the infant may move around during sleep or kick off the blanket. This can result in the infant becoming cold during sleep and therefore waking, requiring the attention of an adult to re-cover the infant. In more serious cases, the blanket can be moved up over the face of the infant or the infant may slip down under the blanket thus increasing the risk of overheating and suffocation of the infant.
A further problem commonly faced by caregivers and parents of infants is that the infant may roll over onto its stomach during sleep thus also increasing the risk of suffocation. Also, the infant may roll over during sleep and wedge their face against the side of a cot in which it sleeps, again increasing the risk of suffocation.
Yet another problem for caregivers and parents is the possible loss of oxygen and other problems (such as falling out of bed) that may arise for an infant if it moves toward the sides or headboard of bed.
One solution known in the art is to tuck a blanket tightly around an infant and hope that the infant does not have enough strength to remove the blanket. However, there is a risk that the blanket could be tucked too tight and thus restrict the infant's breathing. A further known solution is to simply not cover the infant during sleep, but provide a very warm room in which the infant can sleep. However, the cost of heating a room to a suitable temperature, and maintaining the same, renders such a solution impractical to most parents. Also, the use of heaters to maintain such a temperature increases the risk of fire thus endangering the infant.
SUMMARY
Certain embodiments of the present invention address one or more of the above mentioned problems and provide a solution which reduces the risk of suffocation to an infant while also reducing the infant's discomfort.
Some embodiments provide a safety device for offering increased safety to a sleeping infant comprising cover means operable to cover at least a portion of an infant and securing means operable to secure at least a portion of an infant to the cover means.
In certain embodiments, the cover means comprise a blanket or sheet. The cover means may be formed of a soft material which may be a fabric material. The cover means may be formed from any natural or synthetic fabric, or any woven or non-woven fabric. Examples of a soft fabric material include brushed cotton and fleece.
In certain embodiments, the securing means are adjustable. The securing means may comprise a support member that may be adapted to fit between the legs of an infant. The support member may comprise a seat that is preferably adapted to support the seat of an infant. The support member may be attached to a first face of the sheet, such as, for example, toward a first end thereof. The support member may comprise a crotch strap or support.
In some embodiments, the securing means comprises strapping means, which strapping means may be adapted to strap an infant to the cover means. The strapping means may comprise a strap, a center section of which may be attached toward a second end of the support member. The securing means can generally triangularly or T-shaped. The securing means may comprise a harness that may fit between an infant's legs and around an infant's waist or torso.
The cover means may comprise at least one aperture. Alternatively, the cover means may comprise at least two apertures. The strapping means may be adapted to pass through the at least one aperture in the cover means. The strapping means can be adapted to pass through the at least two apertures in the cover means.
In some embodiments, the securing means is operable to secure at least a portion of an infant to a first face of the cover means. The securing means can be operable to be adjusted at a second face of the cover means.
The safety device may also further comprise strap retaining means operable to secure the strapping means to the cover means. The strap retaining means can be attached to the second face of the cover means.
In certain embodiments, toward a first end of the strapping means are attachment means operable to removably attach the first end of the strapping means to the strap retaining means. Toward a first end of the strapping means may be strap attachment means operable to removably attach a second end of the strapping means thereto. In addition, toward a second end of the strapping means may be attachment means operable to removably attach the second end of the strapping means to the first end of the strapping means.
In certain embodiments, the safety device is adapted to be attached to or incorporated within a surface, which surface may be substantially planar. In certain embodiments, the surface is a surface upon which an infant sleeps. Alternatively, the safety device may be sized and used with other than infants, in order to more reliably secure a non-infant in position, such as infirm elderly person.
The safety device may be attached to or incorporated within a bed sheet or mattress such that an infant (or other body) may be held in position relative to the bed sheet or mattress by the safety device. The safety device can be attached to or incorporated within a bed sheet or mattress so as to form a pocket. The pocket can be adapted to receive an infant therein and may be locate to maintain the infant in a desired position with respect to the bed or other structure, including the bed sheet.
In some embodiments, the support member is attached to an internal face of the cover means when the safety device is attached to or incorporated within a bed sheet or mattress. By internal face of the cover means it is meant a face of the cover means which directly abuts the mattress or bed sheet. The strapping means may be operable to be secured to an external face of the cover means when the safety device is attached to a mattress or bed sheet (and in this application, the term “sheet” includes blankets as well as conventional bed sheets).
In certain embodiments, a method of securing an infant (or other body) to a surface comprises the steps of: attaching a safety device comprising cover means and securing means to a surface, placing an infant or other body between the safety device and the surface, adjusting the securing means to fit the infant or other body, and securing the infant or other body to the safety device using the securing means. The method may instead or in addition comprise placing a cover on the infant or other body after first placing the infant or other body in the security means, such as a harness, and securing the harness in place. Other methods are disclosed.
In certain embodiments, the surface is a mattress or bed sheet.
All of the above aspects may be combined with any of the features disclosed herein in any combination.
The foregoing is a brief summary of aspects of the various embodiments disclosed in this specification. There are additional aspects that will become apparent as this specification proceeds. In addition, it is to be understood that embodiments of the invention need not include all such aspects or address all issues in the Background above.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred and other embodiments are shown in the accompanying drawing in which:
FIG. 1 shows a perspective view of a front surface of a safety (or securing) device;
FIG. 2 shows a perspective view of a rear surface of a safety device;
FIG. 3 shows a perspective view of a safety device attached to a mattress cap;
FIG. 4 shows a perspective view of a safety device attached to a fitted bed sheet in a predetermined position (for example to secure an infant adjacent the foot of a bed or at least away from the head or head board of a bed);
FIG. 5 shows a partial cross-sectional view from the top of a safety device attached to a bed sheet, the bed sheet being fitted to a mattress;
FIG. 6 shows a perspective view of a rear surface of a second embodiment of a safety device;
FIG. 7 shows a perspective view of a safety device secured to a fitted mattress with straps penetrating passages in the fitted sheet;
FIG. 8 shows a bottom view of the fitted sheet with the safety device mounted to the fitted sheet as in FIG. 7 ;
FIG. 9 shows a perspective view of an alternative arrangement for securing a safety device to a fitted mattress at the sides of the mattress;
FIG. 10 is a side view showing a method in which a blanket is slid over the bottom end of a mattress with a cover sheet;
FIG. 11 is a perspective view showing insertion of a harness on top of the mattress, in the method of FIG. 10 ;
FIG. 12 is a perspective view showing insertion of an infant between the harness and upper blanket, in the method of FIG. 10 ;
FIG. 13 is a perspective view showing the opposing securing straps of the harness pulled through mating strap passages in the blanket providing for strap locations on opposing sides of the infant's torso, in the method of FIG. 10 ;
FIG. 14 is a perspective view showing a first securing strap secured to a mating hook and pile fastener section on the upper surface of the blanket above the infant's torso, in the method of FIG. 10 ; and
FIG. 15 is a perspective view showing a second securing strap secured to a mating hook and pile fastener section on the upper surface of the first secured strap above the infant's torso, completing the method of FIG. 10 .
In the following Detailed Description section various specially orienting terms are used such as “upper” and “lower.” It is to be understood that such terms are used for convenience in association with the drawings but are not be themselves limiting or requiring of any absolute orientation in space.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 , a safety device 102 comprises cover means in the form of a rectangular sheet 104 , and a harness 106 . The sheet 104 and the harness 106 are formed of a flexible, soft, and breathable material, such as fleece. It should be appreciated that the sheet 104 and the harness 106 may be made from any suitable material. Factors to consider when choosing a suitable material include the softness of the material, possible irritation to the infant's skin, climate in which the device will be used (i.e., cooling fabrics for warmer climates, etc.) fabrics which will not react to an infant's bodily excretions such as saliva, vomit and urine, etc.
The harness 106 comprises a gusset strap 108 as displayed in FIG. 2 and a securing strap 110 extending perpendicularly away from each side of a first end thereof. The gusset strap 108 of the harness 106 is attached at a second end thereof to a rear face 112 of the sheet 104 . The attachment may be accomplished in a wide variety of ways, such as by stitching or with buttons in mating button holes in the harness, or via other fastening techniques.
The opposing ends of the securing strap 110 pass from the rear face 112 of the sheet 104 to a front face 114 of the sheet 104 via two laterally spaced elongate apertures 116 in the sheet 104 . Therefore, as shown in FIG. 2 , the harness 106 forms a T shape, but other shapes may be utilized.
An alternative embodiment of a harness 206 is shown in FIG. 6 . In this embodiment, the harness 206 has a seat 208 of a shape that an infant can sit in, for example, in the shape of a seat of a pair of briefs. A bottom edge 210 of the seat 208 is secured to the rear face 112 of the sheet 104 . Attached at opposing sides toward the top of the seat 208 are securing straps (not shown) which extend through the apertures 116 and function in the same manner as will be described below. The front face 114 of the sheet 104 fitted with the preferred harness 206 is as described with reference to FIG. 1 below.
The front face 114 of the sheet 104 (as shown in FIG. 1 ) has a securing pad 118 approximately centrally disposed between the two apertures 116 . The securing pad 118 is attached to the sheet 104 by stitching and has female hook and pile fastener on its outer surface, e.g., the pile portion of the hook and pile fastener.
Toward a first end 120 of the securing strap 110 there is attached a portion of hook and pile fastener on each face thereof (not shown), one portion being male hook and pile fastener, the other portion being female hook and pile fastener. Toward a second end 122 of the securing strap there is attached a portion of male hook and pile fastener (not shown).
It is preferred that the male hook and pile fastener (i.e., the hook portion) be attached on the surfaces which are least likely to come into contact with an infant, in use. This is because the texture of the male hook and pile fastener is coarse and may irritate an infant, whereas the female hook and pile fastener (the pile) has a softer texture. This is exemplified by providing the female hock and pile fastener on the securing pad 118 which faces upwards, away from the infant, in use.
The device 102 may be attached to or form part of a mattress or cushion upon which an infant sleeps.
Alternatively, as shown in FIGS. 4 and 5 , the device 102 may be attached to or form part of a fitted bed sheet 126 . In this embodiment, a fitted bed sheet has an upper face 128 and side faces 130 of an appropriate size to fit an infant's mattress 132 . The device 102 may be attached to the upper face 128 of the fitted bed sheet 126 .
The attachment or incorporation of the device 202 onto or into a bed sheet, mattress, cushion etc. should incorporate a pocket 124 as shown in FIGS. 3 , 4 and 5 into which an infant may be placed.
A further alternative (shown in FIG. 3 ) is to form the sheet 104 into a pocket which may be fitted over one end of a mattress already fitted with a bed sheet. The device 102 would therefore be held in place by the weight of the mattress.
The sheet 104 is shown in a preferred rectangular shape, however it should be appreciated that many shapes of sheet could perform the same function in a similar manner.
In use, an infant (not shown) is placed under the sheet 104 such that the gusset strap 108 of the harness 106 sits between the infant's legs and the securing strap 110 around the infant's waist or torso. The ends of the securing strap 110 are then pulled through the apertures 116 so that the infant is pulled toward the rear face 112 of the sheet 104 . The first end 120 of the securing strap 110 is then attached to the securing pad 118 by the hook and pile fastener thereon. The second end 122 of the securing strap 110 is then attached to the first end 120 of the securing strap 110 by the hook and pile fastener between them.
As shown in FIG. 7 , yet another embodiment of the safety or securing device has a harness 200 that is mountable to fitted or other sheet 202 , which is in turn mounted to a bed mattress (not shown). In this embodiment, the harness 200 has a generally semi-triangular or T-shape with three securing straps 204 , 206 , 208 extending from the central body 210 of the harness 200 . Two collinear but opposing securing straps 206 , 208 penetrate mating securing strap passages, 212 , 214 respectively, in the sheet 202 . The mating securing strap passages 212 , 214 are equidistant from the axial center A of the bed mattress, in order to center a body secured by the harness 200 in the axial center of the bed mattress and equally spaced from the opposing lateral sides 216 , 218 and top and bottom sides 220 , 222 of the sheet on the bed mattress.
A center, axially extending securing strap 204 extends from the central body 210 transverse to the opposing securing straps 206 , 208 toward the bottom or foot of the bed 222 . The remote end 224 of the axially extending strap 204 is secured to the bed sheet 220 such as by stitching or other fastening means.
Each of the opposing securing straps, e.g., 204 , extends from its mating securing strap passage, e.g., 212 , between the sheet 202 and underlying mattress (not shown) to then protrude outwardly from mating side strap passage, e.g., 226 , in the associated side 216 of the sheet 202 and underlying bed mattress. The distal, protruding end 228 of the securing strap 204 is then secured to side 216 of the sheet 202 such as by a hook and pile fastener sections matingly mounted between the protruding end 228 and the side 216 of the sheet 202 . Other types of fasteners may also be used. Alternatively, the protruding end 228 may be lengthened and tied to adjacent structure (not shown) such a as a crib gate.
As shown in a somewhat alternative construction in FIG. 8 , the axially extending strap 204 may be adjustable and/or removable rather than fixed to the bed sheet 202 as in FIG. 7 and, for example, extend through a mating strap passage 230 in the bed sheet 202 . The fastening end 232 of the axially extending strap 204 may similarly be secured to the bed sheet 202 by hook and pile or other fasteners (not shown). Alternatively, the axially extending strap 204 may extend through yet an additional passage (not shown), such as in the bottom side 222 of the bed sheet 202 to be secured in the fashion of the opposing securing straps 206 , 208 as shown in FIG. 7 . Numerous other harness securing structures and techniques may be utilized.
For example, in yet another embodiment, the mating side strap passage 226 of FIG. 7 may be enlarged 240 as shown in FIG. 8 . Further, the hook and pile fastener portion 242 secured to the bed sheet 202 may be widened to cover a greater lateral area on the side 216 of the bed sheet 202 . This configuration can allow for lateral adjustment of the mounting or fastening position of the associated opposing or sidewardly extending securing strap 244 . In this manner, the securing strap 244 may be mounted in various locations along the side 216 of the bed 202 and avoid interfering structure such as a crib gate or side bed post (not shown).
The securing harnesses shown in FIGS. 8 and 9 may thus be relatively easily removed from the associated bed sheet and replaced, washed, or repaired as desired. Further, they can be secured in position, to maintain an associated body in position, in a fashion that can be difficult or impossible for an infant, or perhaps other body, to undo the orientation of the harness when secured to the associated bed street or other structure.
In the embodiments of FIGS. 7-9 , the harness is shown unattached to a sheet or blanket. A sheet (meaning herein any other desired cover, such as a blanket as noted above) may be either attached to the harness before or after installation of the harness and in any number of ways. For example, a sheet might be secured in position with respect the harness and associated infant or other body by securing corners of the sheet to a crib gate or other structure. The corners of the sheet may have any number of fastening devices attached to such or other locations. Examples can include straps secured to the sheet location, mating hook and pile fasteners mounted on the straps of mating structures, or button and mating passage fastening structures.
The sheet can be further secured in position in many other ways. One example is to secure the sheet to the harness above the infant or other body by means of mating hook and pile fastener sections mounted to the harness and the mating section of the sheet.
Alternatively, the sheet can include included pocket structure with the harness of FIGS. 7-9 mounted within the pocket to secure an infant or other body within the pocket. The pocket may be created by slip-over sheeting on a mattress, or it may be formed of a section of sheet stitched or otherwise fastened to another sheet.
With reference now to FIGS. 10-15 , one method of utilizing a harness and associated sheet with an infant comprises:
A. sliding a pre-constructed or arranged pocket sheet 300 (such as, as one example, a stretchable fleece blanket in the embodiment of FIGS. 10-15 ) over the bottom or lower end 302 of a mattress pre-covered with an underlying fitted sheet 304 ; B. inserting a somewhat triangularly shaped securing harness 306 between the fitted sheet 304 and mating upper section 308 of the pocket sheet 300 ; C. placing an infant 310 on the upper face 312 of the harness 306 and below the mating upper section 308 of the pocket sheet 300 , with the upper edge 314 of the mating upper section 308 of the pocket sheet 300 extending across the infant's torso 316 spaced from the infant's head 318 and, in this particular embodiment, shoulders 320 ; D. pulling the two opposing securing straps 322 , 324 of the harness 306 through mating strap passages, e.g., 326 , in the sheet 300 providing for strap passage locations on opposing sides 328 , 330 of the infant's torso 316 ; E. securing a first securing strap 322 to a mating hook and pile fastener section 332 on the upper surface 334 of the sheet 300 above the infant's torso; and F. securing the opposing second securing strap 324 to a mating hook and pile fastener section 336 on the upper surface 338 of the first secured strap 322 above the infant's torso 316 .
The infant 310 is thereby secured safely in position on the lower end 302 of the bed mattress generally equidistant from the opposing lateral sides 340 , 342 of the bed mattress.
It can thus be seen that the applicants have provided body orienting device that may, depending on the embodiment utilized, relatively comfortably orient a body, such as a human body, with respect to other objects, particularly when the body is intended to be at rest. In this regard, the embodiments shown herein have shown particular structures for a harness. As noted above, other harness structures or configurations may be used to secure a body in position. For example, the harness may be enlarged to secure larger bodies, such as older children, infirm adults, or certain animals undergoing care.
In the embodiments such as those in which the securing element or harness is used in conjunction with a flexible, relatively thin, fleece sheet secured to a fitted or otherwise relatively secured bed sheet, such as in FIGS. 4 , 5 , and 10 - 15 for example:
reduces the risk of being kicked off or over the infant's head, thereby also reducing the risk of suffocation or breathing of oxygen reduced or depleted air; reduces the risk that the baby may slip down under the blanket, further reducing the risk of overheating or suffocation; reduces the need for excessive heating in the baby's room and further reducing the chance of overheating the baby; allows comforting airflow around the baby as it kicks to maintain a desired body temperature; positions the baby at the foot of the bed and away from the sides, thereby reducing danger of suffocation or breathing of oxygen reduced or depleted air; maintains the baby in the correct sleeping position, comfortably, while reducing the danger sudden infant death syndrome; maintains swaddling of the baby in the a soft harness, promoting increased sleep duration.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
For example, the harness may be configured to consist of a central body with three corners, and each corner may have extending sections that may wrap around a separate mounting strap and secure to the strap or to themselves by mating hook and pile fastening sections or other fastener devices. In turn, the harness may be mounted to one or more separate, removable, and adjustable mounting straps secured around or to a mounting structure, such as a bed. For example, two corners of the harness might be mounted to one strap extending across a bed, and another corner mounted to another strap extending across the bed.
It is to be understood that the foregoing is a detailed description of preferred and alternative embodiments. It would be apparent to those skilled in the art that many more modifications than mentioned above are possible without departing from the invention or while implementing it. The disclosure, therefore, is not to be restricted by the foregoing detailed descriptions, and the scope of the invention is to be determined by reference to the claims as issued. | Body orienting harnesses and associated structures are disclosed, along with methods of use. The body orienting harness can position a body, such an infant, with respect to the associated structure, such as a bed, bed frame or crib, a sheet, or a blanket for example. The harness may be integrated with a sheet or blanket in order to secure not only a body in position but also secure the sheet or blanket in position with respect to the body. The sheet, blanket, or other cover, can provide a slip cover for an underlying support surface, such as a mattress for example. Alternatively, the cover can be secured in other ways to form a pocket in association with other structure, such as a bed sheet for example. The harness can be mounted in association with the pocket to secure a body in position with the respect to the pocket and associated structure, such as a mattress, crib, etc. When used to secure an infant during sleep, certain embodiments of the harness and associated structure can help significantly reduce the chance of overheating, suffocating, or otherwise harming the infant. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to plasmin. More particularly, this invention relates to a synthetic substrate for the colorimetric or fluorometric assay of plasmin.
In man, fibrinolysis is controlled and regulated by the activity of the plasminogen-plasmin proteolytic enzyme system. Plasminogen, the naturally occurring precursor, is converted to plasmin by naturally occurring plasminogen activators or by kinases, such as streptokinase, urokinase, and staphylokinase. Plasminogen, normally present in all body fluids and secretions, has its highest concentration in plasma.
In the prior art, plasmin assays typically involved protein digestion systems, with casein being the most commonly used protein. Although such systems were satisfactory to a limited extent, a number of disadvantages are inherent in such systems. In general, protein digestion systems require at least about 15 minutes per assay; during this period of time, it is not possible to measure kinetic changes (e.g., the instantaneous formation of plasmin). Furthermore, it is not possible to evaluate the presence of plasminogen activators. Additionally, at high plasmin levels, turbid solutions often result. More importantly, protein digestion systems are not entirely reproducible from one source of protein to another (hence, from one laboratory to another). Protein digestion systems require the use of an ultraviolet spectrophotometer, which poses problems in determining the appropriate blank since digestion of serum proteins in the blank contributes to ultraviolet absorption. Furthermore, plasmin content cannot be defined in the traditional manner of micromoles of substrate hydrolyzed per unit of time. That is, the hydrolysis is not linear with enzymatic activity; an arbitrary curve is obtained which must be defined by a standard enzyme solution of limited availability.
Attempts to overcome the disadvantages of protein digestion systems in the assay of plasmin have led to the preparation of a number of synthetic substrates. Examples of such synthetic substrates include, among others, the following: ethyl p-guanidinobenzoate hydrochloride and p-nitrophenyl p'-guanidinobenzoate hydrochloride [T. Chase, Jr. and E. Shaw, Biochemistry, 8, 2212 (1969)]; N-(p-carboxybenzyl)pyridinium bromide p-nitrophenyl ester [J. M. Sodetz and F. J. Castellino, Biochemistry, 11, 3167 (1972)]; N.sup.α -tosyl-L-arginine methyl, ethyl, and butyl esters, ethyl esters of glycine, L-lysine, DL-valine, L-leucine, L-isoleucine, DL-methionine, L-tyrosine, and DL-tryptophan, N.sup.α -benzoyl-L-arginine ethyl ester, N.sup.α -acetyl-L-tyrosine ethyl ester, N.sup.α -acetyl-DL-tryptophan ethyl ester, and N.sup.α -acetyl-DL-methionine ethyl ester [W. Troll, et al., J. Biol. Chem., 208, 85 (1954)]; L-arginine methyl ester, L-lysine methyl ester, N.sup.α -acetyl-L-lysine methyl ester, N.sup.α -benzoyl-L-arginine methyl ester, N.sup.α -carbobenzoxy-L-lysine methyl ester, N.sup.α -tosyl-L-lysine methyl ester, N.sup.α -carbobenzoxy-L-arginine methyl ester, and N.sup.α -acetyl-L-arginine methyl ester [S. Sherry, et al., Thromb. Diath. Haemorrh., 34, 20 (1975)]; N.sup.α -benzyloxycarbonyl-L-lysine p-nitrophenyl ester [R. M. Silverstein, Thrombos. Res., 3, 729 (1973)]; N.sup.α -methyl-N.sup.α -tosyl-L-lysine β-naphthol ester [P. H. Bell, et al., Anal. Biochem., 61, 200 (1974)]; and N.sup.α -benzoylphenylalanine-valine-arginine-p-nitroanilide [P. Friberger, et al., Thromb. Diath. Haemorrh., 34, 321 (1975)]. The usual problems with most such synthetic substrates include, among others, a slow rate of reaction, rapid spontaneous hydrolysis, and difficulty in measuring the hydrolysis products.
It should be noted that some tripeptides are known which have the same amino acid sequences as the tripeptidyl portion of some of the substrates of the present invention. Examples of such known tripeptides include the following: N.sup.α -trityl-glycine-glycine-N.sup.ε -benzyloxycarbonyl-L-lysine benzyl ester, glycine-glycine-L-lysine, glycine-glycine-N.sup.ε -benzyloxycarbonyl-L-lysine benzyl ester hydrochloride, and N.sup.α -benzyloxycarbonyl-glycine-glycine-N.sup.ε -benzyloxycarbonyl-L-lysine benzyl ester and hydrazide [O. Abe, et al., Bull. Chem. Soc. Japan, 40, 1945 (1967)]; N.sup.α -formyl-L-phenylalanine-L-leucine-N.sup.ε -t-butyloxycarbonyl-L-lysine and methyl ester thereof [L. V. Ionova and E. A. Morozova, J. Gen. Chem. USSR, 34, 407 (1964)]; N.sup.α -benzyloxycarbonyl-glycine-glycine-L-lysine and diacetate monohydrate thereof [K. Suzuki and T. Abiko, Chem. Pharm. Bull. (Tokyo), 16, 1997 (1968)]; and O-benzyl-N.sup.α -benzyloxycarbonyl-L-tyrosine-L-serine-N.sup.ε -t-butyloxycarbonyl-L-lysine methyl ester, N.sup.α,O-bis(benzyloxycarbonyl)-L-tyrosine-L-serine-N.sup.ε -t-butyloxycarbonyl-L-lysine methyl ester, N.sup.α -benzyloxycarbonyl-L-tyrosine-L-serine-N.sup.ε -t-butyloxycarbonyl-L-lysine methyl ester, and L-tyrosine-L-serine-N.sup.ε -t-butyloxycarbonyl-L-lysine methyl ester [A. A. Costopanagiotis, et al., J. Org. Chem., 33, 1261 (1968)].
The assay of plasmin by the plasmin-catalyzed hydrolysis of a given substrate to give one or more identifiable and measurable products is, of course, known in the art. The substrates of the present invention, however, can be used in such known procedure or procedures related thereto without the disadvantages attending the known, prior art substrates.
SUMMARY OF THE INVENTION
It therefore is an object of the present invention to provide a substrate for the assay of plasmin which eliminates or minimizes many of the problems associated with prior art protein digestion systems.
A further object of the present invention is to provide a substrate for the assay of plasmin which eliminates or minimizes many of the problems associated with prior art synthetic plasmin substrates.
Yet another object is to provide a sensitive, stable, versatile, substrate for the assay of plasmin which can be used with either colorimetric or fluorometric techniques. These and other objects will be apparent to those skilled in the art from a consideration of the specification and claims which follow.
In accordance with the present invention, a plasmin assay substrate is provided, which substrate is a tripeptidyl-4-methoxy-2-naphthylamide having the formula, ##STR2## in which R 1 and R 2 independently are hydrogen, alkyl, hydroxyalkyl, mercaptoalkyl, methylthioalkyl, benzyl, or hydroxybenzyl, with the proviso that at least one of R 1 and R 2 must be other than benzyl or hydroxybenzyl; and the acid addition salts thereof in which the acid is inorganic or C 1 -C 2 carboxylic.
It will be understood by those skilled in the art that reference to the assay of plasmin also includes the assay of plasminogen, since plasminogen is readily converted to plasmin by a small amount of activator, such as streptokinase, urokinase, and the like.
The substrates of the present invention are useful for either routine clinical plasmin or plasminogen assays or kinetic studies.
DETAILED DESCRIPTION OF THE INVENTION
As is well known in the art, all of the naturally-occurring amino acids, with the exception of glycine, are in the L form. To indicate this in the above-described general formula, the amino group (as a carboxylic acid amide) of each amino acid is placed above the carbon chain when the carbon chain is written horizontally with the carboxylic acid group (as the carboxylic acid amide) at the right. When reference is made herein to a specific tripeptidyl-4-methoxy-2-naphthylamide, the Tentative Rules of IUPAC-IUB Commission on Biochemical Nomenclature, Abbreviated Designation of Amino Acid Derivatives and Peptides, will be followed [see, e.g., J. Biol. Chem., 241, 2491 (1966)]; the 4-methoxy-2-naphthylamide portion will be indicated by the abbreviation, --MNA, and the N-blocking group, benzyloxycarbonyl, will be indicated by the abbreviation, Z-. In accordance with nomenclature already established by those skilled in the art, the peptidyl amides of 4-methoxy-naphthyl amine disclosed herein are named as tripeptidyl-4-methoxy-2-naphthylamides.
As already stated, R 1 and R 2 independently are hydrogen, alkyl, hydroxyalkyl, mercaptoalkyl, methylthioalkyl, benzyl, or hydroxybenzyl, with the proviso that at least one of R 1 and R 2 must be other than benzyl or hydroxybenzyl. Preferably, R 1 and R 2 independently are hydrogen or alkyl. More preferably, R 1 and R 2 both are either hydrogen or alkyl, and most preferably are alkyl. Examples of amino acids, other than lysine, which can be employed include, among others, glycine, alanine, valine, leucine, isoleucine, serine, threonine, cysteine, methionine, phenylalanine, and tyrosine.
Examples of specific tripeptidyl-4-methoxy-2-naphthylamides coming within the general formula described hereinabove include, among others, the following:
Z-gly-Gly-L-Lys-MNA,
Z-l-ala-L-Ala-L-Lys-MNA,
Z-l-val-L-Val-L-Lys-MNA,
Z-l-leu-L-Leu-L-Lys-MNA,
Z-l-ile-L-Ile-L-Lys-MNA,
Z-l-ser-L-Ser-L-Lys-MNA,
Z-l-thr-L-Thr-L-Lys-MNA,
Z-l-cys-L-Cys-L-Lys-MNA,
Z-l-met-L-Met-L-Lys-MNA,
Z-gly-L-Ala-L-Lys-MNA,
Z-gly-L-Cys-L-Lys-MNA,
Z-l-ala-Gly-L-Lys-MNA,
Z-l-ala-L-Tyr-L-Lys-MNA,
Z-l-val-L-Ser-L-Lys-MNA,
Z-l-leu-L-Met-L-Lys-MNA,
Z-l-ile-L-Ala-L-Lys-MNA,
Z-l-ile-L-Thr-L-Lys-MNA,
Z-l-ser-L-Ala-L-Lys-MNA,
Z-l-ser-L-Phe-L-Lys-MNA,
Z-l-thr-L-Ile-L-Lys-MNA,
Z-l-cys-L-Val-L-Lys-MNA,
Z-l-met-L-Cys-L-Lys-MNA,
Z-l-met-L-Tyr-L-Lys-MNA,
Z-l-phe-l-Thr-L-Lys-MNA,
Z-l-tyr-Gly-L-Lys-MNA,
Z-l-tyr-L-Met-L-Lys-MNA,
and the like.
Examples of the preferred compounds include, among others, Z-L-Ala-L-Ala-L-Lys-MNA, Z-L-Val-L-Val-L-Lys-MNA, Z-L-Leu-L-Leu-L-Lys-MNA, Z-L-Ile-L-Ile-L-Lys-MNA, Z-Gly-Gly-L-Lys-MNA, Z-Gly-L-Ala-L-Lys-MNA, Z-Gly-L-Ile-L-Lys-MNA, Z-L-Ala-Gly-L-Lys-MNA, Z-L-Ala-L-Leu-L-Lys-MNA, Z-L-Val-L-Ala-L-Lys-MNA, Z-L-Val-L-Ile-L-Lys-MNA, Z-L-Leu-Gly-L-Lys-MNA, Z-L-Leu-L-Val-L-Lys-MNA, Z-L-Leu-L-Ile-l-Lys-MNA, Z-L-Ile-L-Ala-L-Lys-MNA, Z-L-Ile-L-Leu-L-Lys-MNA, and the like. Examples of the more preferred compounds include, among others, Z-L-Ala-L-Ala-L-Lys-MNA, Z-L-Val-L-Val-L-Lys-MNA, Z-L-Leu-L-Leu-L-Lys-MNA, Z-L-Ile-L-Ile-L-Lys-MNA, Z-Gly-Gly-L-Lys-MNA, and the like. Examples of the most preferred compounds include, among others, Z-L-Ala-L-Ala-L-Lys-MNA, Z-L-Val-L-Val-L-Lys-MNA, Z-L-Leu-L-Leu-L-Lys-MNA, Z-L-Ile-L-Ile-L-Lys-MNA, and the like.
The tripeptidyl-4-methoxy-2-naphthylamide substrates provided by the present invention are prepared according to standard peptide chemistry procedures. The following examples are representative of such procedures:
EXAMPLE 1
Preparation of N.sup.α -Z-N.sup.ε -BOC-L-LYS-MNA
A mixture of 28.1 g. (50 mmol) of N.sup.α -Z-N.sup.ε -Boc-L-Lys as the N,N-dicyclohexylamine salt [prepared by the method of L. Zervas and C. Hamalidis, J. Amer. Chem. Soc., 87, 99 (1965)] and 17.25 g. (50 mmol) of 4-methoxy-2-naphthylamine p-toluenesulfonate [prepared by the procedure of E. L. Smithwick, Jr. and R. T. Shuman, synthesis, 8, 581 (1974)] in 100 ml. of N,N-dimethylformamide was agitated under a nitrogen atmosphere for 30 minutes. To the reaction mixture, cooled to 0° C., were added 6.75 g. (50 mmol) of 1-hydroxybenzotriazole and 10.3 g. (50 mmol) of N,N'-dicyclohexylcarbodiimide. After agitating for 2 hours at 0° C., the reaction mixture then was stirred at ambient temperature for 24 hours. The reaction mixture was cooled to 0° C. and the precipitated N,N'-dicyclohexylurea was removed by filtration. The filtrate was distilled under reduced pressure; the residue was triturated with 1 N aqueous sodium bicarbonate solution, then recrystallized three times from hot ethanol, giving 15.3 g. (58 percent) of N.sup.α -Z-N.sup.ε -Boc-L-Lys-MNA, m.p. 157°-159° C. The following elemental microanalysis was obtained:
Calculated for C 30 H 37 N 3 O 6 : C, 67.27; H, 6.96; N, 7.84
Found: C, 67.25; H, 6.74; N, 7.62.
EXAMPLE 2
Preparation of N.sup.α -Z-L-Ala-L-Ala-N.sup.ε -Boc-L-Lys-MNA
N.sup.α -Z-N.sup.ε -Boc-L-Lys-MNA (4.7 g., 8.8 mmol) was dissolved in 20 ml. of N,N-dimethylformamide and 50 ml. of ethanol, and subjected to hydrogenolysis over 1 g. of palladium on carbon at 1 atmosphere hydrogen pressure for 4 hours. The reaction mixture was filtered. The filtrate was concentrated under reduced pressure and the residue was dissolved in 30 ml. of N,N-dimethylformamide. To the resulting solution were added 8.8 mmol of N.sup.α -Z-L-Ala-L-Ala [prepared by the procedure of M. Goodman, et al., Bioorg. Chem., 1, 294 (1971)], 1.19 g. (8.8 mmol) of 1-hydroxybenzotriazole, and 1.81 g. (8.8 mmol) of N,N'-dicyclohexylcarbodiimide. After standing 48 hours at 4° C., the reaction mixture was filtered to remove precipitated N,N'-dicyclohexylurea, and the filtrate was evaporated under reduced pressure. Trituration of the residue with 1 N sodium bicarbonate, followed by two recrystallizations from N,N-dimethylformamide/ethanol gave 3.5 g. (60 percent) of N.sup.α -Z-L-Ala-L-Ala-N.sup.ε -Boc-L-Lys-MNA, m.p. 213°-214° C. The following elemental microanalysis was obtained:
Calculated for C 36 H 47 N 5 O 8 : C, 63.79; H, 6.99; N, 10.33
Found: C, 64.05; H, 6.51; N, 10.63.
EXAMPLE 3
Preparation of N.sup.α -Z-L-Ala-L-Ala-L-Lys-MNA Acetate
A mixture of 3.0 g. (4.43 mmol) of N.sup.α -Z-L-Ala-L-Ala-N.sup.ε -Boc-L-Lys-MNA and 2.5 g. (3 meq) of p-toluene-sulfonic acid monohydrate in 100 ml. of acetonitrile containing 10 percent triethylsilane was agitated at ambient temperature for 8 hours. The reaction mixture was diluted with diethyl ether and the resulting precipitate was isolated by filtration. The precipitate was redissolved in N,N-dimethylformamide and extracted into chloroform after neutralization of the N,N-dimethylformamide solution with aqueous base. The chloroform was dried over anhydrous magnesium sulfate and evaporated in vacuo to give a residue which was lyophilized from acetic acid. The resulting residue then was dissolved in ethanol, treated with activated charcoal, and the product precipitated with diethyl ether, giving 1.5 g. (53 percent) of N.sup.α -Z-L-Ala-L-Ala-L-Lys-MNA acetate. The following amino acid analysis was obtained:
Ala, 2.03; Lys, 0.97 (92 percent recovery).
EXAMPLE 4
Preparation of N.sup.α -Z-Gly-Gly-N.sup.ε -Boc-L-Lys-MNA
N.sup.α -Z-Gly-Gly-N.sup.ε -Boc-L-Lys-MNA was prepared from Z-Gly-Gly and N.sup.ε -Boc-L-Lys-MNA by the procedure of Example 2, then recrystallized from ethanol; m.p. 145°-147° C. The following elemental microanalysis was obtained:
Calculated for C 34 H 43 N 5 O 8 : C, 62.85; H, 6.67; N, 10.78
Found: C, 62.62; H, 6.42; N, 10.56
EXAMPLE 5
Preparation of N.sup.α -Z-Gly-Gly-L-Lys-MNA Acetate
N.sup.α -Z-Gly-Gly-L-Lys-MNA acetate was prepared from the compound of Example 4 by the procedure of Example 3. The following amino acid analysis was obtained:
Gly, 1.98; Lys, 1.02 (74 percent recovery).
As already stated, the substrates of the present invention are useful for the determination of plasmin. Plasminogen, the plasmin precursor, normally has its highest concentration in plasma, which concentration depends upon the physical well-being of the individual. Since plasminogen concentration, and, consequently, plasmin concentration, are altered by various fibrinolytic disorders, the monitoring of plasmin concentration in plasma provides a means for the detection of fibrinolytic disorders and for monitoring the clinical treatment of such disorders as is well known in the art.
In general, the plasmin assay employing the substrates of the present invention is carried out in accordance with known procedures. Briefly, from about 0.1 ml. to about 0.5 ml., preferably from about 0.1 to about 0.2 ml., of blood plasma is diluted to a volume of 1.5 ml. with 0.05 molar tris(hydroxymethyl)aminomethane (Tris) buffer at pH 8.0. If plasminogen is to be determined, 500-1000 International Units of streptokinase is added to the blood plasma sample before diluting with the Tris buffer. To the diluted blood plasma solution is added 1.0 ml. of an aqueous substrate solution containing 1.2 mg. (2 mM) of substrate per ml. of water. The resulting reaction mixture then is incubated, typically for 15 minutes at 37° C. For a fluorometric assay, the reaction solution is transferred immediately after incubation to a fluorometer and light of 360 nm wavelength is used for excitation; the relative intensity of fluorescence at 420 nm is measured. For colorimetric assay, the reaction is stopped after incubation by the addition of 0.1 ml. 1.0 N aqueous hydrochloric acid solution. To the reaction solution then is added 1 ml. of fast blue B dye solution containing 1 mg. of dye. Color is allowed to develop, typically for 5 minutes at ambient temperature, and absorbance then is measured at 520 nm. If desired, instantaneous measurements of plasmin activity can be made by transferring the reaction mixture, without incubation, immediately to a fluorometer and recording the increase of fluorescence with time.
The results obtained from either the colorimetric or fluorometric assay are compared with plasmin standard curves which are prepared in accordance with known procedures. The plasmin standard curves employed to obtain the data reported herein were made with "First British Standard for Plasmin, Human, 72/739," obtained from the National Institute for Biological Standards and Control, Holly Hill, Hampstead, London. Fast blue B dye was purchased from K and K Laboratories, Plainview, N.Y.
Colorimetric measurements were made with Gilford Spectrophotometers, either Model 300-N or Model 240 with a digital absorbance meter (Model 410) and recorder (Model 6040). Absorption spectra were determined with a Cary 14 Recording Spectrophotometer. Fluorescence measurements were made with an Aminco-Bowman Spectrophotofluorometer with a Xenon lamp ratio photometer and a Shimadzu recorder, Model R-101.
The use of the above-described procedure to assay plasmin and plasminogen is ilustrated by the data in Table 1. Such data were obtained by the preferred 15-minute colorimetric assay, using as substrate Z-L-Ala-L-Ala-L-Lys-MNA. The streptokinase, when used, was added to the blood plasma sample, prepared in the usual way, prior to dilution with Tris buffer. While any plasmin already present will be measured along with plasmin derived from plasminogen, it usually is not necessary to correct the plasminogen value for plasmin when normal subjects are used, since the blood plasma of such subjects typically contains negligible amounts of plasmin.
Table 1______________________________________Colorimetric Plasminogen and Plasmin Assays of Blood Plasmafrom Normal Subjects, Using Z-L-Ala-L-Ala-L-Lys-MNAAs Substrate______________________________________ Plas- Plasma Units minogen, Plasmin,Sample Vol., ml. SK.sup.a A.sub.520 Units/ml. Units/ml.______________________________________A. Human Plasma Patient 1 0.1 1000 0.12 1.2 -- Patient 2 0.1 1000 0.18 1.8 -- Patient 3 0.2 1000 0.36 1.8 --B. Dog Plasma Sample 1 0.1 500 0.096 1.0 -- Sample 2 0.1 500 0.085 0.8 -- Sample 2 0.1 0 0.005 -- <0.05______________________________________ .sup.a SK=Streptokinase
All enzyme contents are expressed in the internationally defined units which are well known to those skilled in the art. It may be noted from Table 1 that the approximate lower limit of detection of plasmin is 0.05 unit/ml. The limit is to a large extent the result of instrumental error at low absorbance values. Thus, when plasmin content is known to be low, larger plasma samples should be employed.
The colored compound formed by the reaction of 4-methoxy-2-naphthylamine with fast blue B dye has a strong absorption band at 520 nm. The molar absorption coefficient, ε, decreases with time and exposure to light, and concentrated solutions, i,e., solutions giving an absorbance through a 1 cm. cell greater than about 1.0, fade and frequently form a precipitate. Fading and precipitation are accelerated by exposure to light. The maximum value for ε obtained by using a dilute solution and development of color in the dark, is about 33,000 M -1 cm -1 . Although maximum color is not achieved in light, it is more convenient to let the color develop under ordinary room illumination and to read absorption values consistently five minutes after adding dye to the assay sample. Under such conditions, the value for ε is about 27,000 M -1 cm -1 . Except as discussed above, the value for ε in either case in constant for any given amine-dye coupling product and is independent of the tripeptidyl moiety.
In general, the assay can be carried out at a pH of from about 7 to about 10. The optimum pH, however, is from about 8 to about 8.5, with pH 8.0 being most preferred.
The relationship of absorbance or intensity of fluorescence to plasmin concentration typically is linear, provided that plasmin concentration is less than about 1.0 unit of plasmin per assay volume (typically about 3.5 ml.) and the incubation time is no greater than about 15 minutes. The linearity of such relationship is preserved, however, at longer incubation times, e.g., up to about 60 minutes, when plasmin concentration is less than about 0.2 unit plasmin per assay volume. Accordingly, it is preferred to use sample sizes which will provide less than about 1 unit of plasmin per assay volume and incubation periods of 15 minutes.
In order to study the effectiveness of the substrates provided by the present invention, colorimetric plasmin assays were run using solutions containing known quantities of plasmin in place of blood plasma samples. Plasmin was obtained by converting plasminogen to plasmin by the addition of either streptokinase or urokinase to a plasminogen-containing solution. The plasminogen was prepared from outdated human plasma by batch absorption on lysine-Sepharose, entirely under cold conditions; see R. J. Walther, et al., J. Biol. Chem., 249 1173 (1974), and D. K. McClintock, et al., Biochemistry, 13, 5334 (1974). Steptokinase was obtained as Varidase from Lederle, Pearl River, N.Y., and urokinase was obtained from Leo Pharmaceutical Products, Denmark. The colorimetric assay results obtained with such known plasmin solutions are summarized in Table 2.
TABLE 2______________________________________Hydrolysis of Plasmin Substrates Units nmoles HydrolyzedSubstrate Plasmin .sup.A 520 /unit plasmin______________________________________Z-Gly-Gly-L-Lys-MNA 10 1.2 16Z-L-Ala-L-Ala-L-Lys-MNA 2 1.8 120______________________________________
Plasmin content is expressed in the internationally defined units which are well known to those skilled in the art. From the last or right-hand column of Table 2, it is seen that of the two substrates tested, Z-L-Ala-L-Ala-L-Lys-MNA is the more sensitive toward hydrolysis by plasmin. Thus, such substrate will be the more effective for determinations involving low plasmin concentrations.
While the substrates of the present invention are not specific for plasmin, such substrates do possess a sufficient degree of specificity for plasmin that the plasmin assay can be carried out in the presence of small amounts of other, related enzymes. Such specificity is shown in Table 3, which summarizes the hydrolysis, determined by the colorimetric procedure, of Z-L-Ala-L-Ala-L-Lys-MNA by plasmin and several other proteinases. Trypsin was obtained from Worthington Biochemical Corporation, Freehold, New Jersey; thrombin was purchased from Parke, Davis, and Company, Detroit, Michigan; and procine acrosin was obtained from Dr. P. J. Burck of the Lilly Research Laboratories, Indianapolis, Ind. Except as footnoted in Table 2, all amounts of enzymes are expressed in internationally defined units.
TABLE 3______________________________________Hydrolysis of Z-L-Ala-L-Ala-L-Lys-MNA by Proteinases mole Units Units Per Hydrolyzed Per nmoles mole of per mole ofEnzyme Test Hydrolyzed Enzyme Enzyme______________________________________Thrombin 100 74 8.5 × 10.sup.10 63Acrosin 400 23 1.2 × 10.sup.12 69Urokinase 400 9 3.8 × 10.sup.12 86Plasmin 1 120 3.4 × 10.sup.9 340Trypsin 2.sup.a 290 24 × 10.sup.9 3500______________________________________ .sup.a 1 unit - 1 μg
The data in both Tables 2 and 3 were obtained in accordance with the preferred 15-minute colorimetric plasmin assay described hereinbefore. As already stated, Table 3 is an illustration of the relative order of specificity of several proteinases toward Z-L-Ala-L-Ala-L-Lys-MNA, one of the substrates of the present invention. The data in Table 3 were obtained by subjecting the substrate to hydrolysis by each enzyme. The nmoles of substrate hydrolyzed in each case were determined from the absorbance value in the usual manner. The nmoles of substrate hydrolyzed then were converted to moles of substrate hydrolyzed per mole of enzyme, using the generally accepted value, taken from the literature, for the number of units per mole of each enzyme. The relatively low values for moles of substrate hydrolyzed per mole of enzyme for thrombin, acrosin, and urokinase demonstrate that the presence of small amounts of such enzymes will not significantly interfer with the plasmin assay. The enzyme trypsin, however, is known to be both potent and of a broad specificity, requiring only the presence of a basic amino acid. Therefore, the rapid hydrolysis of trypsin of the substrate of Table 2 was expected. Trypsin, however, normally is not present in the blood and hence presents no problem in the plasmin assay.
The substrates of the present invention provide the means for plasmin assays which are reproducible, sensitive, and convenient. The sensitivity of the assay results more from the sensitivity in detecting hydrolysis than from the kinetics of the reaction; hence, blank corrections for the substrates of the present invention are negligible. The high molar absorptivity of the dye complex and the intensity of the fluorescence facilitate detection of small amounts of hydrolysis product.
It should be pointed out that substrate solubility must be taken into consideration when carrying out plasmin assays with such substrates. The assay as described uses a substrate concentration of about 2 mM. This does not cause problems so long as the substrate concentration is consistent and assays are restricted to the linear part of the rate curve. If necessary, the concentration of such substrate can be doubled, thereby approaching the limits of solubility of the substrate, to obtain a slight increase in sensitivity and an extension of the range of the linearity. Beyond that, substrate insolubility becomes a problem. The substrate also is less soluble in buffer of ionic strength greater than 0.1. Protein also precipitates the substrate, but the assay has been used to measure serum plasma levels without difficulty.
Since substrate solubility can be important, it often is desirable to employ an acid addition salt of the substrate in order to improve substrate solubility. The term "acid addition salt" is well known to those skilled in the art. In general, such a salt is formed by reacting in a mutual solvent a stoichiometric amount of a suitable acid with a substrate of the present invention, although an excess of the acid can be used where the acid is sufficiently volatile. Normally, the choice of salt-forming acid is not critical. Representative and suitable acids include, among others, the following: hydrochloric, hydrobromic, hydriodic, sulfuric, nitric, phosphoric, formic, acetic, and the like.
The chief advantage of the substrates of the present invention are in the versatility of the plasmin assay employing such substrates. A large number of routine assays are easily handled by the colorimetric procedure. Very sensitive measurements can be made by fluorometry. Kinetic analyses of plasmin activity can be made to avoid problems of enzyme stability. The substrates of the present invention also are useful in the identification of enzyme activity on electropherograms, using either fluorometric or colorimetric techniques. | The proteinase plasmin is assayed either colorimetrically or fluorometrically with a tripeptidyl-4-methoxy-2-naphthylamide substrate having the following general formula: ##STR1## The substrate is useful for either routine clinical assays or kinetic studies. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a continuation of currently U.S. patent application Ser. No. 11/472,616, filed Jun. 22, 2006 now U.S. Pat. No. 7,437,235, which claims the benefit of U.S. Provisional Patent Application No. 60/693,177, filed Jun. 23, 2005.
FIELD OF THE INVENTION
This invention relates to ignition timing devices, more particularly to ignition timing devices with timing correction.
BACKGROUND OF THE INVENTION
Sensors are used in many automobile applications. One application is to use a sensor to measure the timing in ignition systems. This sensor can be a Hall Effect sensor, a magnetic pickup sensor, an optical sensor, or other sensors known in the art. These sensors can be used to detect the position of the crankshaft and camshaft and to monitor engine RPM. The signal generated by these sensors are used to ensure that proper engine timing is maintained.
In electronic ignition systems, sensors are used to ensure that spark plugs ignite a compressed air-fuel mixture within the engine at an optimum position. By way of example, for a system that utilizes a Hall Effect sensor, at least one ferrous target is mounted or integrated into a rotating engine component, such as the crank shaft. As the target approaches the Hall Effect sensor, containing a magnet, the sensor detects the flux field changes and produces an electric signal. The electric signal in turn is processed and used to trigger an ignition box. The electric signal can be a signal that is either 12 volts or ground and depends on the relative position of the target to the sensor. As the ferrous target approaches a sensor the field flux increases through the sensor. At a critical field flux density the sensor switches from 5 volts, the peak, to ground, the low. The minimum distance position represents the moment when the engine is at peak power, such as optimum compression in a combustion chamber. The passing of the target past the sensor creates a pulse with a width. The pulse has a leading edge that transitions from 5 volts to ground and a trailing edge that transitions from ground to 5 volts. The pulse is modified to a 12 volt high and the ignition box triggers the spark plugs as it detects a 0 to 12 volt edge rise in the pulse. The intention is for the spark plugs to ignite when the engine can produce peak power.
FIG. 1 depicts a Hall Effect Pickup incorporated into an engine component 100 . Engine component 100 comprises a rotating shaft 111 , which is coupled to oscillating piston elements (not shown) in the engine. Coupled to shaft 111 is reluctor 112 . Reluctor 112 comprises 8 ferrous blades 113 . The position of the blades 113 on Reluctor 112 corresponds to the compression positions of the piston elements. Engine component 100 also comprises a bell distributor housing 114 that partially encompasses shaft 111 . A Hall Effect sensor 115 is coupled to the inner wall of housing 114 . As the shaft 111 rotates, the blades 113 of reluctor 112 also rotate. As a first blade 113 approaches sensor 115 the sensor 115 detects the increasing flux field strength. The field strength will be at its maximum when the spacing between sensor 115 and blade 113 is at a minimum. At a critical flux field strength, the sensor 115 will trigger and switch from 5 volts to ground. The rotation of blades 113 past sensor 115 decreases the field strength about sensor 115 . The field increases once again as a second blade approaches the sensor 115 . The rotation of blades 113 means that sensor 115 is producing a signal with a period that will correspond to the time between each blade reaching a minimum separation from the sensor 115 . Thus, the frequency of the resulting Hall Effect signal reflects the revolutions per minute of the reluctor 112 , and consequently the engine. At low RPMs, the frequency of the Hall Effect signal will be low, and consequently long periods. At high RPMs, the frequency of the Hall Effect signal will be high, and consequently short periods.
In order to have engine peak power the trigger of the Hall Effect signal should occur at the same moment in time as a blade being at a minimum separation from the sensor. However, there is an inherent delay between the position of a blade and the trigger of the Hall Effect signal in time. As a result, the leading edge of a pulse will be off by a time t 1 from the moment when the blade 113 is first in detection proximity to the sensor 115 and off by a time t 3 from the moment when the blade 113 moves away from the detection proximity of sensor 115 . The time t 1 should correspond or be equal to time t 3 . As a result, the triggering edge of the pulse is displaced to a moment that does not correspond to the minimum spacing of the blade 113 to the sensor 115 or the optimum power position of the engine. The time span between the leading edge of the pulse and the moment that the blade moves away from the detection proximity is considered time t 2 . Thus, the phase of the Hall Effect signal will not accurately represent the position of the blade in time. This can be due to the delay in the Hall Effect sensor detecting the position of a rotating blade and the time it takes for the Hall Effect sensor to process a signal. By the time that the triggering edge of the Hall Effect signal reaches a spark plug the engine is no longer in a position of peak power, such as optimum piston compression. This results in a loss of engine efficiency. When an engine operates at low revolutions per minute the period of a Hall Effect signal is relatively long. As a result, the relationship between degree of displacement from peak power and ignition, i.e. the degree in which the signal and piston are out of phase may only be slight. However, when an engine is operating at high revolutions per minute the period of a Hall Effect signal is much shorter. This means that the degree to which peak power and the signal are out of phase is much more pronounced and significant. As a result, there is a greater loss of efficiency at higher RPMs.
While the above example is discussed by way of an ignition timing system that utilizes a Hall Effect sensor, ignition timing systems can alternatively incorporate other sensors such as a magnetic pickup sensor or an optical sensor. An alternative ignition timing system provides sensor 115 as a magnetic pickup sensor that detects the movement of reluctor 112 . Another ignition timing system provides sensor 115 as an optical sensor that also detects the movement of reluctor 112 . As with the Hall Effect sensor, the magnetic pickup sensor and the optical sensor produce a signal with a period that will correspond to the time between each blade reaching a minimum separation from either sensor. Also like the Hall Effect sensor, the signal produced by either sensor also has an inherent delay between the position of a blade and the trigger of either sensor.
What is needed is a method and device that achieves maximum precision of engine timing. It would be beneficial if such a method could correct the timing of a sensor, such as a Hall Effect sensor, a magnetic pickup sensor or an optical sensor. It would also be beneficial if the method could be achieved by a circuit that is coupled to a sensor.
SUMMARY OF THE INVENTION
This objective is achieved by a method that includes the steps of generating a first signal with a first phase that is out of phase with a periodic object; generating a voltage signal that corresponds to the frequency of the first signal; and generating a second signal based on the first signal and the voltage signal, the second signal having a second phase that is substantially in phase with the periodic object.
Another aspect of the method is to supply the first signal and the voltage signal to a timing circuit and to supply the first signal to a frequency to voltage converter.
A further aspect of the method is for the frequency to voltage converter to generate the voltage signal in linear relation to the frequency of the first signal and for the timing circuit to generate the second signal based on the voltage signal and the first signal.
The objective is also achieved by a circuit comprising a first signal circuit that generates a first signal with a first phase that is out of phase with a periodic object; a voltage signal circuit that produces a voltage signal that corresponds to the frequency of the first signal; and a timing circuit that receives the first signal and the voltage signal and produces a second signal with a second phase that is substantially in phase with the periodic object.
The first signal circuit can include a sensor, such as a Hall Effect sensor, magnetic pickup sensor, or optical sensor, that is positioned to detect the motion of the periodic object and generates a signal. The voltage signal circuit can include a frequency to voltage converter that produces a voltage level that is linearly related to the frequency of the first signal.
The circuit can be incorporated in a system that includes a periodic object such as a rotating shaft or at least one oscillating piston. The second signal can be supplied to an ignition box through a buffer circuit at the moment when an engine is in a state of optimum power.
Other objects of the invention and its particular features and advantages will become more apparent from consideration of the following drawings and accompanying detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a depiction of an example of an electronic ignition timing system that incorporates a Hall Effect sensor incorporated into an engine system.
FIG. 2 is a flow diagram of an embodiment of the present invention that illustrates the processing of a signal from a Hall Effect sensor with correction of the signal.
FIG. 3 is a depiction of an embodiment of the present invention that illustrates a circuit that corrects a signal from a Hall Effect Sensor.
DETAILED DESCRIPTION OF THE INVENTION
There are various embodiments of systems for correcting the timing of a sensor of an ignition system which would be encompassed by the instant description and following claims. A preferred embodiment is described in more detail below. In addition to the described system that corrects the ignition timing of a Hall Effect sensor, other systems within the scope of the present invention can correct the ignition timing of a signal generated by other sensors, such as a magnetic pickup sensor or an optical sensor.
FIG. 2 is a depiction of an arrangement 200 of elements and steps for correcting the signal timing produced by a sensor. A voltage regulator circuit 210 generates a regulated voltage from a battery supply to circuits 220 , 230 , 250 , and 270 . Hall Effect circuit 220 produces a Hall Effect signal that is supplied to a voltage signal circuit 250 . The voltage signal circuit 250 converts the Hall Effect signal to a constant voltage signal level that depends upon the frequency of the Hall Effect signal. If the frequency were to change, the voltage level produced would be altered accordingly. This voltage signal level and the Hall Effect signal are supplied to a timing circuit 230 . The timing circuit 230 applies the voltage signal from circuit 250 to the Hall Effect signal. This alters the period or phase of the Hall Effect signal such that a corrected signal is produced by timing circuit 230 . The corrected signal is supplied to buffer circuit 270 which inverts the corrected signal and transfers the corrected signal to an ignition box 290 .
FIG. 3 depicts a circuit 300 that incorporates the elements and sequence of steps identified in FIG. 2 . A list of parts for circuit 300 are as follows:
FIG. 3 depicts a circuit 300 that incorporates the elements and sequence of steps identified in FIG. 2 . A list of parts for circuit 300 are as follows:
311 D 4 (1N4002) 312 R 2 (10 OHM 1/4 WATT) 313 C 1 (33UFD @ 35WVDC) 314 C 2 (0.01 UFD) 315 U 1 (78L05A) (VOLTAGE REGULTAOR) 321 C 3 (1UFD) 322 U 5 (ATS672LSB-LN) (HALL EFFECT SENSOR) 323 C 13 (0.01 UFD) 324 R 1 (560 OHM) 331 R 5 (1K OHM) 332 R 13 (1K OHM) 333 R 4 (100K OHM) 334 C 4 (0.47 UFD) 335 A U 5 (COMPARITOR-LMV331) 335 B U 5 (COMPARITOR-LMV331) 336 C 5 (0.022 UFD) 337 R 8 (22K OHM) 338 R 7 (1.5K OHM) 339 R 6 (10K OHM) 340 R 3 (10K OHM) 341 R 22 (12K OHM) 342 D 1 (1N4448 DIODE) 343 R 9 (10K OHM) 344 D 3 (1N4448 DIODE) 345 A U 3 (14001, CMOS OR GATE) 345 B U 3 (14001, CMOS OR GATE) 351 C 1 (1UFD) 352 R 5 (10K OHM) R 11 (470 OHM) 354 C 9 (22 UFD) 355 U 2 (LM2917) C 8 (0.01 UFD) C 7 (1 UFD) R 21 (33K OHM) R 14 (1K OHM) R 18 (10K OHM) R 17 (100K OHM) R 16 (15K OHM) U 4 (OPAMP OPA364A) 371 D 2 (1N4448 DIODE) C 6 (150 PF) 373 R 10 (10 MEG OHM) 374 A U 3 (14001, CMOS OR GATE) 374 B U 3 (14001, CMOS OR GATE) 375 C 10 (0.01 UFD) 376 R 12 (100K OHM) 377 R 20 (5.6 K OHM) 378 R 19 (S60 OHM) 379 Q 1 (NSB7002A FET) 380 C 13 (0.01 UFD) 381 Q 2 (NSB7002A FET)
The circuit 300 incorporates a voltage regulator circuit 310 , a Hall Effect circuit 320 , a timing circuit 330 , a voltage signal circuit 350 , and a buffer circuit 370 . The dashed lines in FIG. 3 indicate the different regions of circuit 300 that correspond to circuits 310 , 320 , 330 , 350 and 370 . The voltage regulator circuit 310 regulates the voltage from a battery 311 to 5 volts. This ensures that any voltage fluctuation from battery 311 does not effect the correction of the signal from Hall Effect sensor 322 . The voltage regulator circuit 310 supplies a voltage to circuits 320 , 330 , 350 , and 370 .
Hall Effect circuit 320 comprises a Hall Effect sensor 322 , such as an Allegro ATS672LSB-LN Hall effect sensor. The Hall Effect sensor 322 produces a signal that represents the rotation of reluctor 112 and the relative position of blades 113 to sensor 322 . The signal comprises a low, or trough, that represents the blade in close proximity to the sensor 322 and a high, or peak, that represents the blade at a position away from the sensor 322 . Due to the delay in detection and processing by sensor 322 the leading edge of a pulse will be off by a time t 1 from the moment when the blade 113 is first in detection proximity to the sensor 115 and off by a time t 3 from the moment when the blade 113 moves away from the detection proximity of sensor 115 . The time t 1 should be equal to time t 3 . The time span between the leading edge of the pulse and the moment that the blade moves away from the detection proximity is considered time t 2 . The signal generated from Hall Effect circuit 320 is fed into timing circuit 330 and voltage signal circuit 350 .
Voltage signal circuit 350 comprises a frequency to voltage converter 355 . Converter 355 converts the signal from Hall Effect circuit 320 to a single converted voltage. The level of this converted voltage depends on the frequency of the voltage signal. Converter 355 incorporates a linear relationship in this conversion. As a result, a higher frequency Hall Effect signal results in a higher converted voltage produced by converter 355 . A low frequency Hall Effect signal results in a low converted voltage produced by converter 355 . The voltage from converter 355 is then supplied to timing circuit 330 .
Timing circuit 330 comprises a comparator circuit and a logic circuit. The comparator circuit comprises a first 335 A and second 335 b comparators. The logic circuit comprises a first 345 A and second 345 B logic gates. The signals from the Hall Effect circuit 320 and the voltage signal circuit 350 are fed into the first 335 A and second 335 B comparators. The comparators 335 A and 335 B apply the voltage signal generated by circuit 350 to the Hall Effect signal generated by Hall Effect circuit 320 . The comparators 335 A and 335 B output a partially corrected signal that has undergone a phase period shift. The degree of the phase/period shift depends upon the frequency of the Hall Effect signal and the voltage supplied by the voltage signal circuit 350 . This partially corrected signal is fed into logic gates 345 A and 345 B. The logic gates 345 A and 345 B further shift the phase/period of the partially corrected signal to generate a corrected signal. The phase/period shift of the corrected signal is characterized by a pulse width that is increased. The corrected signal can also be characterized by a pulse with a leading edge that is aligned in time with the location of the position of blade 113 , i.e. the position of the optimum power state of the engine such as the compression position of a piston.
The corrected signal from timing circuit 330 is fed into buffer circuit 370 . Buffer circuit 370 comprises logic gates 74 A and 74 B. Buffer circuit 370 inverts the pulse of the corrected signal from a low, or trough, to a high, or peak. As a result, a leading edge of the pulse is formed from ground to 5 volts and a trailing edge of the pulse is formed from 5 volts to ground. Buffer circuit 370 intern supplies the inverted corrected signal to an ignition box to trigger the spark plugs. Thus, the leading edge of the corrected pulse, which is aligned with the optimum power state of the engine, will trigger the ignition box. The result of this processing of the Hall Effect signal into a corrected signal and intern to invert that signal, is to produce a signal that is in phase with the phase of the optimum power state of the engine, such as the phase of the pistons.
The operation of circuit 300 will now be discussed by way of example. Hall Effect Sensor 322 is mounted in a position so as to detect the relative position of blades mounted on a rotating shaft. The position of these blades correspond to the optimum power state of an engine, such as the compression position of oscillating piston elements. A first blade approaches Hall Effect sensor 322 , comes within a minimum distance of Hall Effect sensor 322 , and moves beyond Hall Effect sensor 322 , generating a Hall Effect signal. The Hall Effect signal has a first low or trough that corresponds with the minimum distance between the first blade and the sensor 322 . The first low is out of phase with the position of the first blade by a time amount t. The signal also has a high or peak that corresponds to the moment when the sensor 322 moves away from the triggering position of the sensor 322 . The resulting signal is a pulse with a leading edge and a trailing edge. As the second blade approaches the sensor 322 , this forms a second low. The Hall Effect signal is fed into a voltage signal circuit 350 . The voltage signal circuit creates a voltage signal at a single (or constant) voltage level that linearly corresponds to the frequency of the Hall Effect signal. The Hall Effect signal and the voltage signal are fed into timing circuit 330 . The timing circuit 330 uses the voltage signal to delay the Hall Effect signal, or shift the phase/period of the Hall Effect signal. Thus, the degree of phase/period shift of the Hall Effect signal is in proportion to the frequency of the Hall Effect signal. The timing circuit 330 outputs a corrected signal that has undergone a phase/period shift. As a result, the corrected signal has a phase that is either in phase or out of phase by a time less than t with the position of the blades on the rotating shaft. Thus, the corrected signal is substantially in phase with the rotation of the blades and consequently the optimum power state of the engine. The timing circuit feeds this corrected signal to a buffer circuit 370 . Buffer circuit 370 inverts the corrected signal such that the leading edge of the inverted signal will trigger the ignition box when the engine is in an optimum power state. Buffer circuit 370 applies the corrected signal to the ignition box. Due to circuit 300 the signal applied to the ignition box is now in phase with the optimum power state of the engine. This improves the efficiency of the engine at higher RPM levels.
While the above embodiment describes a circuit that corrects the timing of a Hall Effect signal, the present invention can be used to correct the timing of a signal generated by other types of sensors, such as magnetic pickup sensors or optical sensors. In the context of a system that utilizes a different type of sensor, such as a magnetic pickup sensor or optical sensor, the system can incorporate a voltage regulator circuit 210 , 310 , a sensor circuit, a timing circuit 230 , 330 , a voltage signal circuit 250 , 350 , a buffer circuit 270 , 370 and an ignition box 290 , as described above. The sensor circuit would replace Hall Effect circuit 220 , 320 . In these systems, the sensor circuit produces a sensor signal that is supplied to the voltage signal circuit. The voltage signal circuit converts the sensor signal to a constant voltage signal level that corresponds to the frequency of the sensor signal. This voltage signal level and the sensor signal are supplied to the timing circuit. The timing circuit applies the voltage signal from the voltage signal circuit to the sensor signal, altering the period or phase of the sensor signal such that a corrected signal is produced by the timing circuit. The corrected signal is supplied to the buffer circuit, which inverts the corrected signal and transfers the corrected signal to the ignition box.
It should be noted that, while various functions and methods have been described and presented in a sequence of steps, the sequence has been provided merely as an illustration of one advantageous embodiment, and that it is not necessary to perform these functions in the specific order illustrated. It is further contemplated that any of these steps may be moved and/or combined relative to any of the other steps. In addition, it is still further contemplated that it may be advantageous, depending upon the application, to utilize all or any portion of the functions described herein.
Further, although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art. | A circuit and method for correcting signal timing. The circuit and method generate a first signal with a first phase that is out of phase with a periodic object, generate a voltage signal that corresponds to the frequency of the first signal and generate a second signal based on the first signal and the voltage signal, the second signal having a second phase that is substantially in phase with the periodic object. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 09/320,431, filed May 26, 1999, now abandoned, which is a divisional of application Ser. No. 09/177,738, filed Oct. 23, 1998, now U.S. Pat. No. 6,194,783 B1, issued Feb. 27, 2001, which is a divisional of application Ser. No. 08/892,930, filed Jul. 15, 1997, now U.S. Pat. No. 6,222,271 B1, issued Apr. 24, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a method of sputter deposition of an aluminum-containing film onto a semiconductor substrate, such as a silicon wafer. More particularly, the invention relates to using hydrogen gas with argon during the deposition of aluminum or aluminum alloys to form an aluminum-containing film that is resistant to hillock formation.
2. State of the Art
Thin film structures are becoming prominent in the circuitry components used in integrated circuits (“ICs”) and in active matrix liquid crystal displays (“AMLCDs”). In many applications utilizing thin film structures, low resistivity of metal lines (gate lines and data lines) within those structures is important for high performance. For example, with AMLCDs, low resistivity metal lines minimize RC delay, which results in faster screen refresh rates. Refractory metals, such as chromium (Cr), molybdenum (Mo), tantalum (Ta), and tungsten (W), have resistances that are too high for use in high performance AMLCDs or ICs. Additionally, the cost of refractory metals is greater than non-refractory metals. From the standpoint of low resistance and cost, aluminum (Al) is a desirable metal. Furthermore, aluminum is advantageous because it forms an oxidized film on its outer surfaces, which protects the aluminum from environmental attack, and aluminum has good adhesion to silicon and silicon compounds.
An aluminum film is usually applied to a semiconductor substrate using sputter deposition. Sputter deposition is generally performed inside the vacuum chamber where a solid slab (called the “target”) of the desired film material, such as aluminum, is mounted and a substrate is located. Argon gas is introduced into the vacuum chamber and an electrical field is applied between the target and the substrate, which strikes a plasma. In the plasma, gases are ionized and accelerated, according to their charge and the applied electrical field, toward the target. As the argon atoms accelerate toward the target, they gain sufficient momentum to knock off or “sputter” atoms and/or molecules from the target's surface upon impact with the target. After sputtering the atoms and/or molecules from the target, the argon ions, the sputtered atoms/molecules, argon atoms and electrons generated by the sputtering process form a plasma region in front of the target before coming to rest on the semiconductor substrate, which is usually positioned below or parallel to the target within the vacuum chamber. However, the sputtered atoms and/or molecules may scatter within the vacuum chamber without contributing to the establishment of the plasma region and thus not deposit on the semiconductor substrate. This problem is at least partly resolved with a “magnetron sputtering system,” which utilizes magnets behind and around the target. These magnets help confine the sputtered material in the plasma region. The magnetron sputtering system also has the advantage of requiring lower pressures in the vacuum chamber than other sputtering systems. Lower pressure within the vacuum chamber contributes to a cleaner deposited film. The magnetron sputtering system also results in a lower target temperature, which is conducive to sputtering of low melt temperature materials, such as aluminum and aluminum alloys.
Although aluminum films have great advantages for use in thin film structures, aluminum has an unfortunate tendency to form defects, called “hillocks.” Hillocks are projections that erupt in response to a state of compressive stress in a metal film and consequently protrude from the metal film surface.
There are two reasons why hillocks are an especially severe problem in aluminum thin films. First, the coefficient of thermal expansion of aluminum (approximately 23.5×10 −6 /° C.) is almost ten times as large as that of a typical silicon semiconductor substrate (approximately 2.5×10 −6 /° C.). When the semiconductor substrate is heated during different stages of processing of a semiconductor device, the thin aluminum film, which is strongly adhered to the semiconductor substrate, attempts to expand more than is allowed by the expansion of the semiconductor substrate. The inability of the aluminum film to expand results in the formation of the hillocks to relieve the expansion stresses. The second factor involves the low melting point of aluminum (approximately 660° C.), and the consequent high rate of vacancy diffusion in aluminum films. Hillock growth takes place as a result of a vacancy-diffusion mechanism. Vacancy diffusion occurs as a result of the vacancy-concentration gradient arising from the expansion stresses. Additionally, the rate of diffusion of the aluminum increases very rapidly with increasing temperature. Thus, hillock growth can be described as a mechanism that relieves the compressive stress in the aluminum film through the process of vacancy diffusion away from the hillock site, both through the aluminum grains and along grain boundaries. This mechanism often drives up resistance and may cause open circuits.
A hillock-related problem in thin film structure manufacturing occurs in multilevel thin film structures. In such structures, hillocks cause interlevel shorting when they penetrate or punch through a dielectric layer separating overlying metal lines. This interlevel shorting can result in a failure of the IC or the AMLCD. Such a shorted structure is illustrated in FIG. 11 .
FIG. 11 illustrates a hillock 202 in a thin film structure 200 . The thin film structure 200 comprises a semiconductor substrate 204 , such as a silicon wafer, with a patterned aluminum layer 206 thereon. A lower dielectric layer 208 , such as a layer of silicon dioxide or silicon nitride, is deposited over the semiconductor substrate 204 and the patterned aluminum layer 206 . The lower dielectric layer 208 acts as an insulative layer between the patterned aluminum layer 206 and an active layer 210 deposited over the lower dielectric layer 208 . A metal line 212 is patterned on the active layer 210 and an upper dielectric layer 214 is deposited over the metal line 212 and the active layer 210 . The hillock 202 is shown penetrating through the lower dielectric layer 208 and the active layer 210 to short with the metal line 212 .
Numerous techniques have been tried to alleviate the problem of hillock formation, including: adding elements, such as tantalum, cobalt, nickel, or the like, that have a limited solubility in aluminum (however, this generally only reduces but not eliminates hillock formation); depositing a layer of tungsten or titanium on top or below the aluminum film (however, this requires additional processing steps); layering the aluminum films with one or more titanium layers (however, this increases the resistivity of the films); and using hillocks resistant refractory metal films such as tungsten or molybdenum, rather than aluminum (however, as previously mentioned, these refractory metals are not cost effective and have excessive resistivities for use in high performance ICs and AMLCDs).
In particular with AMLCDs, and more particularly with thin film transistor-liquid crystal displays (“TFT-LCDs”), consumer demand is requiring larger screens, higher resolution, and higher contrast. As TFT-LCDs are developed in response to these consumer demands, the need for metal lines that have low resistivity and high resistance to hillock formation becomes critical.
Therefore, it would be advantageous to develop an aluminum-containing material that is resistant to the formation of hillocks and a technique for forming an aluminum-containing film on a semiconductor substrate that is substantially free from hillocks, while using inexpensive, commercially available, widely practiced semiconductor device fabrication techniques and apparatus and without requiring complex processing steps.
SUMMARY OF THE INVENTION
The present invention relates to a method of introducing hydrogen gas along with argon gas into a sputter deposition vacuum chamber during the sputter deposition of aluminum or aluminum alloys onto a semiconductor substrate including, but not limited to, glass, quartz, aluminum oxide, silicon, oxides, plastics, or the like, and to the aluminum-containing films resulting therefrom.
The method of the present invention involves using a standard sputter deposition chamber, preferably a magnetron sputter deposition chamber, at a power level of between about 1 and 4 kilowatts (KW) of direct current power applied between a cathode (in this case the aluminum target) and an anode (flat panel display substrate—i.e., soda-lime glass) to create the plasma (after vacuum evacuation of the chamber). The chamber is maintained at a pressure of between about 1.0 and 2.5 millitorr with appropriate amounts of argon gas and hydrogen gas flowing into the chamber. The argon gas is preferably fed at a rate between about 50 and 90 standard cubic centimeters per minute (“sccm”). The hydrogen gas is preferably fed at a rate between about 90 and 600 sccm. The ratio of argon gas to hydrogen gas is preferably between about 1:1 and about 1:6. The films with higher hydrogen/argon ratios exhibited smoother texture. The deposition process is conducted at room temperature (i.e., about 22° C.).
The aluminum-containing films resulting from this method have an average oxygen content between about 1 and 5% (atomic) oxygen in the form of aluminum oxide (Al 2 O 3 ) with the remainder being aluminum. The aluminum-containing films formed under the process parameters described exhibit a color similar to, but slightly darker than, pure aluminum metal. The most compelling attribute of the aluminum-containing films resulting from this method is that they are hillock-free, even after being subjected to thermal stresses.
Although the precise mechanical and/or chemical mechanism for forming these aluminum-containing films is not completely understood, it appears that the hydrogen gas functions in the manner of a catalyst for delivering oxygen into the aluminum-containing films. The oxygen gas comes from residual air within the vacuum chamber remaining after the vacuum chamber has been evacuated. Although the amount of residual oxygen in the air of the evacuated vacuum chamber is small, there is a relatively large percentage of oxygen present in the deposited aluminum-containing films. In experiments by the inventors, oxygen gas was introduced into the vacuum chamber, without any hydrogen gas being introduced (i.e., only oxygen gas and argon gas were introduced). The resulting films deposited on the substrate did not have a measurable amount (by x-ray photoelectron spectroscopy) of oxygen present.
As stated previously, oxygen is present in the deposited aluminum-containing film in the form of aluminum oxide. However, aluminum oxide is an insulator. It is counter-intuitive to form an insulative compound (which should increase the resistivity of the film) in a film that requires very low resistivity. However, it has been found that the formation of the aluminum oxide does not interrupt the conducting matrix of aluminum grains within the aluminum-containing film. Thus, the resistivity of the aluminum-containing film is surprisingly low.
Aside from being substantially hillock-free and having a low resistivity (i.e., high conductivity), the resultant aluminum-containing films have additional desirable properties including low roughness, low residual stress, and good mechanical strength (as determined by a simple scratch test compared to pure aluminum or by the low compressive stress (between about −5×10 8 and −1×10 9 dyne/cm 2 ), which is considered to be an indication of high scratch resistance). Measurements of the aluminum-containing films have shown that the roughness before and after annealing is low compared to pure aluminum (about 600–1300 Å before annealing and 400–1000 Å after annealing). Low roughness prevents stress migration, prevents stress-induced voids, and, consequently, prevents hillock formation. Additionally, low roughness allows for better contact to other thin films and widens the latitude of subsequent processing steps, since less rough films result in less translation of crests and valleys in the film layers deposited thereover, less diffuse reflectivity, which makes photolithography easier, no need to clad the aluminum in the production of AMLCDs (rough aluminum traps charge, which effects electronic performance, that is to say, high or variable capacitance), and more uniform etching.
The mechanical strength of the aluminum-containing films resulting from the process of the present invention is higher than conventionally sputtered thin films of aluminum and some of its alloys. A high mechanical strength results in the resulting aluminum-containing films being resistant to both electromigration and stress induced voiding.
This combination of such properties is superior to that of thin films of aluminum and its alloys that are presently known. These properties make the aluminum-containing films of the present invention desirable for electronic device interconnects. These properties are also desirable in thin films for optics, electro-optics, protective coatings, and ornamental applications.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming that which is regarded as the present invention, the advantages of this invention can be more readily ascertained from the following description of the invention when read in conjunction with the accompanying drawings in which:
FIGS. 1 and 2 are illustrations of scanning electron micrographs of an aluminum thin film produced by a prior art method before annealing and after annealing, respectively;
FIGS. 3 and 4 are illustrations of scanning electron micrographs of an aluminum thin film (Test Sample 1) produced by a method of the present invention before annealing and after annealing, respectively;
FIGS. 5 and 6 are illustrations of scanning electron micrographs of an aluminum thin film (Test Sample 2) produced by a method of the present invention before annealing and after annealing, respectively;
FIG. 7 is an x-ray photoelectron spectroscopy graph showing the oxygen content through the depth of an aluminum-containing film produced by a method of the present invention;
FIG. 8 is a graph of roughness measurements (by atomic force microscopy) of various aluminum-containing films made in accordance with methods of the present invention;
FIG. 9 is a cross-sectional side view illustration of a thin film transistor utilizing a gate electrode and source/drain electrodes formed from an aluminum-containing film produced by a method of the present invention;
FIG. 10 is a schematic of a standard active matrix liquid crystal display layout utilizing column buses and row buses formed from an aluminum-containing film produced by a method of the present invention; and
FIG. 11 is a cross-sectional side view illustration of interlevel shorting resulting from hillock formation.
DETAILED DESCRIPTION OF THE INVENTION
The method of the present invention preferably involves using a conventional magnetron sputter deposition chamber within the following process parameters:
Power (DC): between about 1 and 4 KW Pressure: between about 1.0 and 2.5 millitorr Argon Gas Flow Rate: between about 50 and 90 sccm Hydrogen Gas Flow Rate: between about 90 and 600 sccm Argon:Hydrogen Gas Ratio: between about 1:1 and 1:6
The operation of the magnetron sputter deposition chamber generally involves applying the direct current power between the cathode (in this case the aluminum target) and the anode (substrate) to create the plasma. The chamber is maintained within the above pressure range and with an appropriate mixture of argon gas and hydrogen gas. The aluminum-containing films resulting from this method have between about a trace amount and 12% (atomic) oxygen in the form of aluminum oxide (Al 2 O 3 ) with the remainder being aluminum.
It is believed that the primary hillock prevention mechanism is the presence of the hydrogen in the system, since it has been found that even using the system with no oxygen or virtually no oxygen present (trace amounts that are unmeasurable by present equipment and techniques) results in a hillock-free aluminum-containing film. It is also believed that the presence of oxygen in the film is primarily responsible for a smooth (less rough) aluminum-containing film, since roughness generally decreases with an increase in oxygen content in the film.
It is understood that the sputter deposition system of the present invention will usually always have a trace amount of oxygen. This trace amount of oxygen will be incorporated into the aluminum containing film in the presence of hydrogen, even though the very low amount of oxygen within the aluminum film cannot be detected by present analysis equipment. This trace amount of oxygen may come from two potential sources: incomplete chamber evacuation and/or inherent trace oxygen contamination in the argon or hydrogen gas feeds. The first source, incomplete chamber evacuation, comes from the fact that no vacuum is a perfect vacuum. There will also be some residual gas in the system, whether a purge gas or atmospheric gas, no matter how extreme the vacuum evacuation. The second source is a result of inherent trace gas contamination in industrial grade gases, such as the argon and hydrogen used in the present invention. The oxygen impurity content specification for the argon gas used is 1 ppm and the hydrogen gas is 3 ppm. Thus, a high flow rate of the argon and hydrogen into the system will present more trace oxygen to be scavenged from the gas streams and integrated into the aluminum-containing film. Therefore, even though present equipment cannot measure the content of the oxygen in the aluminum-containing film when it exists below 0.1%, a trace amount below 0.1% may be incorporated into the aluminum-containing film.
EXAMPLE 1
A control sample of an aluminum film coating on a semiconductor substrate was formed in a manner exemplary of prior art processes (i.e., no hydrogen gas present) using a Kurdex-DC sputtering system to deposit aluminum from an aluminum target onto a soda-lime glass substrate.
The substrate was loaded in a load lock chamber of the sputtering system and evacuated to about 5×10 −3 torr. The load lock was opened and a main deposition chamber was evacuated to about 10 −7 torr before the substrate was moved into the main deposition chamber for the sputtering process. The evacuation was throttled and specific gases were delivered into the main deposition chamber. In the control deposition, argon gas alone was used for the sputtering process. Once a predetermined amount of argon gas stabilized (about 5 minutes) in the main deposition chamber, about 2 kilowatts of direct current power was applied between a cathode (in this case the aluminum target) and the anode (substrate) to create the plasma, as discussed above. The substrate was moved in front of the plasma from between about 8 and 10 minutes to form an aluminum-containing film having a thickness of about 1800 angstroms.
Table 1 discloses the operating parameters of the sputtering equipment and the characteristics of the aluminum film formed by this process.
TABLE 1
Control Sample
Sputtering Process Parameters
Power (KW)
2
Pressure (mtorr)
2.05
Gas Flow (sccm)
Argon = 90
Characterization Parameters and Properties
Thickness (Å)
1800
Stress (dyne/cm 2 ) (compressive)
−4.94 × 10 8 (C)
Roughness (Å)
1480
(unannealed)
2040
(annealed)
Resistivity (μΩ-cm)
approx. 2.7
Grain Size (Å)
1000–1200
Hillock Density
approx. 2 to 5 × 10 9 /m 2
The measurements for the characterization parameters and properties were taken as follows: thickness—Stylus Profilometer and scanning electron microscopy; stress—Tencor FLX using laser scanning; roughness—atomic force microscopy; resistivity—two point probe; grain size—scanning electron microscopy; and hillock density—scanning electron microscopy.
FIG. 1 is an illustration of a scanning electron micrograph of the surface of the aluminum film produced under the process parameters before annealing. FIG. 2 is an illustration of a scanning electron micrograph of the surface of the aluminum-containing film produced under the process parameters after annealing. Both FIGS. 1 and 2 show substantial hillock formation (discrete bumps on the aluminum film surface) both before and after annealing.
EXAMPLE 2
Two test samples (test sample 1 and test sample 2) of an aluminum film coating on a semiconductor substrate were fabricated using the method of the present invention. These two test samples were also formed using the Kurdex-DC sputtering system with an aluminum target depositing on a soda-lime glass substrate.
The operating procedures of the sputtering system were essentially the same as the control sample, as discussed above, with the exception that the gas content vented into the main deposition chamber included argon and hydrogen. Additionally, the pressure in the main deposition chamber during the deposition and the thickness of the aluminum-containing film was varied from the control sample pressure for each of the test samples.
Table 2 discloses the operating parameters of the sputtering equipment and the characteristics of the two aluminum films formed by the process of the present invention.
TABLE 2
Test Sample 1
Test Sample 2
Sputtering Process Parameters
Power (KW)
2
2
Pressure (mtorr)
2.4
2.5
Gas Flow (sccm)
Argon =
90
Argon =
90
Hydrogen =
200
Hydrogen =
400
Characterization Parameters
and Properties
Thickness (Å)
1600
1500
Stress (dyne/cm 2 )
−1.12 × 10 8 (C)
−5.6 × 10 8 (C)
(compressive)
Roughness (Å) (after
800
540
annealing)
Resistivity (μΩ-cm)
5.5
6.0
Grain Size (Å)
1000–1200
1000–1200
Hillock Density
no hillocks present
no hillocks present
FIG. 3 is an illustration of a scanning electron micrograph of the surface of the Test Sample 1 before annealing. FIG. 4 is an illustration of a scanning electron micrograph of the surface of the Test Sample 1 after annealing. FIG. 5 is an illustration of a scanning electron micrograph of the surface of the Test Sample 2 before annealing. FIG. 6 is an illustration of a scanning electron micrograph of the surface of the Test Sample 2 after annealing. As it can be seen from FIGS. 3–6 , no hillocks formed on either sample whether annealed or not.
EXAMPLE 3
A number of aluminum-containing films were made at different ratios of Ar/H 2 and various system pressures were measured for oxygen content within the films. The power at 2 KW. The oxygen content was measured by XPS (x-ray photoelectron spectroscopy). The results of the measurements are shown in Table 3.
TABLE 3
TABLE 3
Sample
Ar/H 2
Pressure
Oxygen Content
Number
(sccm)
Ar/H 2 Ratio
(millitorr)
Range (atomic %)
1
90/200
0.450
2.40
5–10
2
90/400
0.225
2.50
5–10
3
50/90
0.556
1.27
3
4
90/90
1.000
2.15
<1%
An XPS depth profile for sample 3 (Ar/H 2 (sccm)=50/90, pressure=1.27) is illustrated in FIG. 7 , which shows the oxygen content to be on average about 3% (atomic) through the depth of the film.
FIG. 8 illustrates the roughness of the two aluminum-containing film samples. As FIG. 8 generally illustrates, the higher the amount of hydrogen gas delivered to the sputter deposition chamber (i.e., the lower the Ar/H 2 ratio—x-axis), the smoother the aluminum-containing film (i.e., lower roughness—y-axis). It is noted that the “jog” in the graph could be experimental error or could be a result of the difference in the amount of argon introduced into the system or by the difference in the system pressure for sample number 3.
FIG. 9 illustrates a thin film transistor 120 utilizing a gate electrode and source/drain electrodes that may be formed from an aluminum-containing film produced by a method of the present invention. The thin film transistor 120 comprises a substrate 122 having an aluminum-containing gate electrode 124 thereon that may be produced by a method of the present invention. The aluminum-containing gate electrode 124 is covered by an insulating layer 126 . A channel 128 is formed on the insulating layer 126 over the aluminum-containing gate electrode 124 with an etch stop 130 and contact 132 formed atop the channel 128 . An aluminum-containing source/drain electrode 134 , which may be produced by a method of the present invention, is formed atop the contact 132 and the insulating layer 126 , and contacts a picture cell electrode 136 . The aluminum-containing source/drain electrode 134 is covered and the picture cell electrode 136 is partially covered by a passivation layer 138 .
FIG. 10 is a schematic of a standard active matrix liquid crystal display layout 150 utilizing column buses 152 and row buses 154 formed from an aluminum-containing film produced by a method of the present invention. The column buses 152 and row buses 154 are in electrical communication with pixel areas 156 (known in the art) to form the active matrix liquid crystal display layout 150 .
Having thus described in detail preferred embodiments of the present invention, it is to be understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description, as many apparent variations are possible without departing from the spirit or scope thereof. | Aluminum-containing films having an oxygen content within the films. The aluminum-containing film is formed by introducing hydrogen gas along with argon gas into a sputter deposition vacuum chamber during the sputter deposition of aluminum or aluminum alloys onto a semiconductor substrate. The aluminum-containing film so formed is hillock-free and has low resistivity, relatively low roughness compared to pure aluminum, good mechanical strength, and low residual stress. | 8 |
The Government has rights in this invention pursuant to Contract No. F19628-80-C0002, awarded by the U.S. Air Force.
CROSS REFERENCE TO RELATED APPLICATION
The present application is related to the copending application of Hwang, Chen and Ragonese entitled A DIGITALLY CONTROLLED WIDEBAND PHASE SHIFTER, Ser. No. 735,990 filed May 20, 1985, now U.S. Pat. No. 4,638,190 assigned to the Assignee of the present invention, and filed concurrently herewith.
BACKGROUND OF THE INVENTlON
1. Field of the lnvention
The invention relates to stepped signal scaling and more particularly to a metal semiconductor field effect transistor (MESFET) designed for operation at frequencies ranging from a fraction of a gigahertz to many gigahertz, the signal transfer (gain and/or attenuation) being stepped in discrete steps over a given range of transfer values. Signal scaling finds major application to antenna arrays.
2. Description of the Prior Art
Monolithic microwave integrated circuit (MMIC) technology has proven useful in electronic circuitry operating at frequencies in the gigahertz range. The technology relies largely on the definition of the active and passive components and their interconnections by a precise, and repeatable photolithographic technique on a monolithic substrate. A preferred substrate material is gallium arsenide. Application of the technology results in a compact and electrically efficient design. The circuits and devices fabricated from this material function well at these frequencies and are capable of precise engineering characterization.
Typically, signal gain in the transmission or reception of signals involving antenna arrays must be adjusted either row by row or element by element. The adjusting means depending upon the number of rows or elements of the array, must be of such accuracy as to preserve the accuracy inherent in focusing or the steering of the array. The adjusting means should be sufficiently broadband as not to distort the signal, often broadband, which is being processed.
It has been proposed that a dual gate MESFET be used for signal gain control. In this application, the signal is applied to the number 1 gate, the gate closest to the source, and a gain control voltage is applied to the number 2 gate, the gate closest to the drain. The control effected by this means is highly non-linear in the conventional device. In addition, because there are many variables effecting the signal transfer value, this approach has lacked precision and repeatability.
An inherent problem in the referenced design is that when the voltage applied to the control gate is changed, both the gain and the phase of the output signal also change. The complex transfer value is additionally dependent upon the biasing, upon the geometry, and upon process dependent characteristics of the device. The result is that the device is difficult to characterize in practice, and when characterized, difficult to employ without compensation. Thus, it has become desirable to find an approach to signal scaling in which the signal gain or attenuation may be adjusted largely independently of phase, and in which the transfer function is precise and repeatable.
SUMMARY OF THE INVENTION
An object of the invention is to provide an improved signal scaling MESFET in which the small AC signal transfer is adjustable in selected discrete steps.
It is another object of the invention to provide an improved signal scaling MESFET for use at frequencies ranging from tenths of a gigahertz to tens of gigahertz.
It is a further object of the invention to provide a stepwise signal scaling MESFET for use at gigahertz frequencies wherein changes in amplitude may be achieved without a substantial change in phase.
It is an additional object of the invention to provide an accurate signal scaling MESFET for use at gigahertz frequencies applicable to signals of wide bandwidth.
It is still another object of the invention to provide a stepwise adjusted, signal scaling MESFET for use at gigahertz frequencies, which has a substantially constant input impedance at each setting to reduce reflective signal loss due to impedance mismatching.
It is another object of the invention to provide a small AC signal scaling MESFET for use at gigahertz frequencies having improved input/output isolation.
These and other objects are achieved in accordance with the invention in a monolithically integrated MESFET having a small AC signal transfer which is adjustable in discrete steps. The MESFET is an active MESFET, subdivided into an n-fold plurality of selectively activated MESFET segments, each of a predetermined width, with dual gates for each segment.
The MESFET is provided with a single terminal for application of an AC input signal to the first gates of all n segments, a drain terminal for application of drain potentials and derivation of an AC output signal (from all n segments), a source terminal for application of source potentials, and an n-fold plurality of segment activating terminals for selective application of DC control potentials to the second, activating gate of each of the n segments.
The MESFET segments each include an electroded source region, an electroded drain region, and a gate region. The gate region of each segment is provided with a signal gate, connected in common with the signal gates of all the other segments, and disposed between the source and the second, activating gate electrode. The signal gate electrode is designed to modify the output signal current of the MESFET segment as a function of its transconductance, the transconductance being substantially proportional to the width of the segment. The gate region has a second, activating gate electrode individually connected to a segment activating terminal, and disposed between the signal gate and the drain. The activating gate electrode is designed to turn current flow in the individual segment "ON" and "OFF". These conditions correspond respectively to substantial cut-off and substantial saturation of the segment.
The n-fold MESFET segment transconductances are weighted such that when the segments are activated in successive combinations, a desired series of MESFET transfer values is achieved. The MESFET transfer values are each substantially constant in a small AC signal sense and successive values are stepped at intervals depending upon the application. For instance, in the event that it is desired to provide a linearly scaled output, in which the gain is stepped in proportion to a series of consecutive integers, one may use binary scaling in which successive segments are of twice the transconductance of the preceeding segment (i.e. 1, 2, 4, etc. achieved by doubling the width of succeeding segments). In this manner, consecutive transconductances proportional to 0, 1, 2, 3, 4, 5, 6, 7, etc. may be achieved, under the control of a conventional binary coded signal of three bits (or more). The transconductance of successive combinations may also be scaled for logarithmically or arbitrarily stepped values.
In accordance with a further aspect of the invention, vernier or trimming steps may be achieved, either to extend the range or to increase the resolution, by using a voltage divider for applying the signal to the segments representing the smaller steps. This allows the width of the smaller width segment to be increased in proportion to the division ratio while not increasing the equivalent transconductance, a practice which restores the signal transfer to the desired value, while avoiding the disadvantages of unduly narrow gates.
The segmented dual MESFET is fabricated ussing monolithic microwave integrated circuit (MMIC) techniques on a semi-insulating substrate having locally active semiconductor regions. A preferred substrate material is gallium arsenide. The MESFET (including segment electrodes and segment interconnections), and the electrical connections and signal paths to the MESFET, the essential passive components connected to the MESFET for signal coupling and filtering are formed on the substrate and defined by a photolithographic process.
The technique permits very compact minimum reactance segment interconnections reducing deleterious parasitics, facilitating virtual unitary MESFET operation to very high frequencies, and broadband scaling.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel and distinctive features of the invention are set forth in the claims. The invention itself, however, together with further objects and advantages thereof may best be understood by reference to the following description and accompanying drawings in which:
FIGS. 1A and 1B are plan views of a novel monolithically integrated segmented dual gate MESFET designed for accurate signal scaling;
FIG. 1A is a plan view of the MESFET at an intermediate stage in the assembly illustrating the electrodes of individual segments of the MESFET and the pads at the perimeter of the semiconductor substrate; and
FIG. 1B is a plan view of the MESFET of FIG. 1A at a later stage in the assembly, after connections between electrodes and pads are complete;
FIG. 2 is a circuit diagram of the MESFET illustrated in FIG. 1; and
FIGS. 3A and 3B are simplified equivalent circuit models of a segment of the signal scaling MESFET illustrated in FIGS. 1A and 1B corresponding to operation in the "ON" and "OFF" states, respectively;
FIGS. 4A and 4B are graphs illustrating the performance of the embodiment illustrated in FIGS. 1A and 1B;
FIG. 4A illustrates the constancy of the output signal magnitude with frequency and the constancy of the scaling ratios; and
FIG. 4B illustrates the constancy of phase with frequency and more particularly the independance of the phase, at a given frequency, with respect to scaling ratios;
FIG. 5 is a circuit diagram of an attenuator suitable for use from UHF to X-band wherein a second segmented dual gate MESFET is provided in series with a first device for providing additional vernier steps to supplement the coarser steps provided by the initial device; and
FIG. 6 is a plan view of the MESFET illustrated in FIG. 5, at an intermediate stage in the assembly at which electrodes and pads are in place, but before bridges have been added.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A novel monolithically integrated signal scaling MESFET embodying the invention is shown in FIGS. 1A, 1B and 2. The MESFET is of a segmented dual gate design having a first gate (G1) for signal input and a second gate (G2) for activation of each segment into which the total MESFET is divided. The individual segments, which are fully functional active MESFET devices, have the widths noted in the circuit diagram of FIG. 2. The metallizations of the individual source, drain and gate segments of the MESFET and of the pads for external connection are as shown in FIG. 1A. Afterwards, air bridges and serial resistances are added, as shown in FIG. 1B, to complete the connections between segments and between segments and the external pads.
The signal scaling MESFET provides an accurately stepped voltage transfer function to an applied small AC signal over broad microwave bandwidths. The stepped transfer function, which consists of a series of constant transfer values, is achieved by dividing the MESFET into a plurality of individual segments and by activating or inactivating individual segments to achieve a desired active gate width. In the first embodiment, the control is achieved in sixteen steps by selective activation of four individual segments (A, B, C, D) having respective gate widths of 50, 100, 200, and 400 microns. Selective activation of the segments allows the MESFET to exhibit sixteen active gate widths from 0 to 750 microns in 50 micron increments. The equivalent transconductances, which may be obtained approximately by multiplying the active gate widths by a constant, is thus also available in sixteen steps.
The signal scaling MESFET, since it is an active MESFET device, may be designed to provide a signal transfer of moderate gain or attenuation. Larger devices provide higher gain and better accuracy, but do so at the cost of larger substrate areas and greater DC power consumption. In typical designs, the signal transfer value (gain) is one, or a few decibels below one, at the highest transconductance setting.
The metallizations and a principal portion of the substrate of the MESFET are shown in FIGS. 1A and 1B. For high frequency operation (up to at least 10 gHz), the substrate is preferably of gallium arsenide, a semi-insulating material capable of being modified to form semiconducting regions suitable for transistor formation. The two most prevalent methods of transistor formation are direct ion implantation or the provision of an expitaxial layer which is semiconducting and which is etched away to form localized mesas suitable for semiconductor activity. The MESFET is formed on a square GaAs substrate approximately 800 microns by 800 microns, with pads P1-P7 for external connection being provided around the periphery of the substrate. The semiconducting region of the substrate is generally rectangular in shape, being approximately 200 by 260 microns, and may be identified by five relatively broad, mutually parallel rectangular metallizations 17, 18, 19, 20, and 21-22 (the lowermost metallizations having two parts). The remainder of the substrate (beyond the 200 by 260 micron region) is semi-insulating permitting conductor runs, transmission lines, capacitors and resistors to be formed on the substrate without significant loss. The MESFET and the circuitry leading to and including the pads at the perimeter of the substrate are formed on the substrate and defined by a lithographic process.
The metallizations 17-31, which are parts of the source, drain and gate electrodes of the FET, are arranged in an interdigitated design. The three broad metalizations 17, 19 and 21-22, at the top, middle and bottom respectively of the electrode set, are part of the drain electrodes for all of the individual segments. The remaining broad metallizations 18 and 20 are a part of the source electrodes for all of the individual segments. The very narrow line-like metallizations which run in parallel between adjoining source and drain metallizations [e.g. (17-18); (18-19); etc.] and which occur in pairs, are the first and second gate electrodes shown in the circuit diagram of FIG. 2. Numbered in pairs from top to bottom, the gate metallizations are (23,24), (25,26), (27,28) and in the bottom most set (29, (30, 31)) where 29 is the continuous upper gate metallization and 30 is the lower gate metallization to the left and 31 for the lower gate metallization to the right.
The pads P1 to P7 are connected to the metallizations 17 to 31 as follows. The pad P1 is the signal input pad. As seen in FIG. 2, the signal input pad is connected to the input signal gate of all four segments of the segmented MESFET. The input signal gate (per FIG. 2) is the gate nearest the source and for that reason may be referred to as the number 1 gate. The pad P1 is provided with two Y-shaped metallizations 32 and 33 respectively at the left edge. The bases of the Y-shaped metallizations 32, 33 abut the pad P1 and the branched ends lead to the full length line-like input signal gate metallizations 24, 25, 28, 29. More particularly, the upper branch of the upper Y metallization 32 is connected to the input signal gate metallization 24 and the lower branch of 32 is connected to the input signal gate metallization 25. The upper branch of the lower Y metallization 33 is connected to the input signal gate metallization 28 and the lower branch is connected to the input signal gate metallization 29.
The pad P2 (per FIG. 2) is the signal output connection for the drains of all four segments of the segmented MESFET. As best seen in FIG. 1B, the drain pad P2 leads upwards toward a connection to the lowermost right drain metallization 22. An air bridge 34 connects the drain metallization 22 to the other lowermost drain metallization 21. An air bridge 35, connects the centrally disposed drain metallization 19 via 22 to the drain pad P2. Finally, an air bridge 36 connects the uppermost drain metallization 17 via 19, via 22 to the drain pad P2.
The pad P3 is the source pad and makes connection (per FIG. 2) to the sources of all four segments of the segmented MESFET. As best seen in FIG. 1B, the source pad P3 leads downwards toward an air bridge 37 spanning the uppermost metallization 17 (a drain) and making contact to the upper source metallization 18. A second air bridge 38 leading downward from metallization 18 spans the metallization 19 and makes contact with the lower source metallization 20, completing the path between pad P3 and metallization 20.
The remaining pads P4, P5, P6, P7 provide independent connections to the line-like metallizations (23, 26, 27, 31, 30) of the activating gates of each MESFET segment via individual 2000 ohm resistors. (The activating gate is furthest from the source and may be referred to as the number two gate.) The activating gates provide a visual means of identifying on FIGS. 1A and 1B the individual A, B, C, and D segments of the MESFET.
As shown in FIG. 1A, the pad P4, which is associated with the A segment, leads upwardly via a 2000 ohm resistance 40, which has short pads at either end. The short line-like activating gate metallization 30 which extends to the right from the upper resistance pad has a "width" of approximately one-quarter the length of the source and drain metallization (17-20) and is of the least width. Activating gate 30 is coextensive in width with and defines the 50 micron wide A segment of the MESFET.
The pad P5 in the lower right corner of FIG. 1A is associated with the B segment and is connected via a 2000 ohm resistance 41, which has pads at either end, to the line-like activating gate metallization 31. The gate metallization 31 which extends to the left from the upper resistance pad has a "width" of approximately one-half the length of the source and drain metallizations (17-20). Activating gate 31 is coextensive in width with and defines the 100 micron wide B segment of the MESFET.
The pad P6 at the left center of FIG. 1A is associated with the C segment and is connected via a 2000 ohm resistance 42, which has pads at either end, to the line-like activating gate metalization 27. The gate metallization 27, which is disposed to the right of the rightmost resistance pad, is approximately the length of the principal source and drain metallizations (17-20). Activating gate 27 is coextensive in width with and defines the 200 micron wide C segment of the MESFET.
The pad P7 in the upper left corner of FIG. 1A is associated with the D segment and is connected via a 2000 ohm resistance 43 and via a U-shaped metallization 44 to the two part line-like activating gate metallizations 23, 26. In particular, the "base" of the U-shaped metallization 44, abuts the right pad of the resistance 43. The upper branch of the "U" is connected to the gate metallization 23 and the lower branch of the "U" is connected to the gate metallization 26. The two metallizations 23 and 26 each extend for the length of the principal source and drain metallizations and by virtue of being connected together have a combined width of 400 microns. They define the width of the D segment of the MESFET as being 400 microns and equal to twice the length of the source and drain metallizations (17-20).
The individual segments (A, B, C, and D) are fully electroded, fully functional MESFET devices which may be activated selectively to determine the transfer value (scaling factor) applied to the input signal as it progresses to the signal output terminal (drain) of the MESFET. The transfer value is attributable to the transconductance of the MESFET, which is the parameter controlling the scaling of the signal, and which is in turn controlled by the width of individual segments. FIGS. 3A and 3B are simplified equivalent circuit models of a dual gate MESFET segment; FIG. 3A representing the "ON" state and FIG. 3B the "OFF" state. The equivalent circuit model is applicable to the transmission of small AC signals in the operating frequency range and is applicable to the segments individually and in combinations.
The MESFET segment is represented in both FIGS. 3A and 3B as a device with four external terminals (not including ground). The pad P1 is the ungrounded signal input terminal leading to the first gate of the segment. The pad P2 is the signal output terminal leading from the segment drain. The pad P3 is the terminal for connection to the segment source and the pad Pn is the terminal to the activating gate of the (nth) segment combination. The equivalent circuit representations are applicable over two or three decades of frequency (i.e. from hundreds of megahertz to tens or perhaps hundreds of gHz). The diagram includes a substantial number of parasitic resistances and capacitances whose value remains substantially the same in the "ON" and "OFF" states of the segment; and a transconductance (Gm) and a drain-source conductance (Gds) which vary between the "ON" and "OFF" states.
More particularly, the equivalent circuit of the MESFET segment combination in FIGS. 3A, 3B includes a gate resistance Rg, a gate to drain capacitance Cgd and a drain resistance Rd in the series path between pads P1 and P2. A first shunt path interconnected between the Rg-Cgd terminal and source pad P3 comprises the gate to source capacitance Cgs, an intrinsic resistance Ri and source resistance Rs. The active region of the MESFET segment is further represented in FIG. 3A by three elements including the transconductance Gm "ON", the drain to source conductance Gds "ON" and the drain to source capacitance Cds, each mutually connected in shunt between the Cgd-Rd terminal and the Ri-Rs terminal. The active region of the MESFET segment is further depicted in FIGS. 3A and 3B by the notations "ON" and "OFF" applicable to the transconductance, (Gm) and to the drain to source conductance (Gds), which are different for the "ON" and "OFF" states. The second gate region is depicted as the drain to G2 resistance Rdg2 shunted by the drain to G2 capacitance Cdg2, the combination being connected between the Cgd-Rd terminal and the activating pad Pn (n denoting the nth segment combination). An external capacitance Ce, which appears at the pad Pn, is useful to explaining device operation.
The equivalent circuit representations of FIGS. 3A and 3B are designed to illustrate the MESFET segment in the "ON" state wherein the device is operated between saturation and "pinch-off". The MESFET devices may be operated in principle in either the depletion mode or enhancement mode, but those herein illustrated are designed for depletion mode operation.
The model and in particular the Gm prediction can be scaled with substantial accuracy with gate width provided that the geometry, terminal voltage and external impedances remain the same. The MESFET is operated with practical loads and accordingly a given Gm will produce a signal transfer (gain or attenuation) in that load which reflects the Gm, but which may not be exactly proportional to Gm as the Gm is scaled. If exact signal scaling ratios are desired, then the Gm values must be tailored to fit the practical application. The tailoring may be regarded as being attributable to the loading effect from parallelled devices exhibiting finite output impedances, the back-gating effect from the non-ideal nature of the substrate, and fringing fields at the smaller gate widths. The scaling may approach the ideal by using good material, good design rules and accurate simulating software. The scaling, when under binary digital control, is readily applied with 4, 5, or 6 bit accuracy. Certain procedures such as the one illustrated in FIGS. 5 and 6 may be used to extend the range up to 10 bit accuracy.
The performance of the segmented dual gate MESFET so far described is illustrated in FIGS. 4A and 4B. FIG. 4A illustrates the magnitude of the output signal under test conditions over the band of 1,000 to 1,500 megahertz at each of the five settings of the activating control (0000,0001, 0010, 0100, and 1000). The illustrated magnitudes are constant and in constant relative proportions (i.e. scaling) to one part in a hundred. FIG. 4B illustrates the phase versus frequency performance of the first embodiment. In particular, the phase is examined over the frequency range of 1,000 to 1,500 megahertz at each of the active settings of the scaler. It may be seen that the phase, which is at approximately 144.2° at 1,000 megahertz is substantially the same (within 1%) at each setting of the activating gates within the illustrated frequency ranges and drifts less than 10% (16°) over the illustrated frequency range.
The embodiment illustrated in FIGS. 1A and 1B provides a step wise linear count of relative transconductance values in integers from zero to seven. One may also implement non-linear steps such as that required for trigonometric functions. A particularly simple approximation of trigonometric scaling may be provided by a three segment gate controlled by a four bit signal. The gate width ratios of the three channels are one to four to eight which by suitable combinations achieves a divide by 13 scheme (i.e. 0/13, 5/13, 9/13, 12/13, 13/13) to provide sine or cosine values at 22.5° intervals between 0° and 90°. For 111/4° intervals between 0° to 90°, a divide by 50 approximation controlled by a 5-bit signal may be employed in which the successive effective segment widths have the values of 0/50, 10/50, 19/50, 29/50, 35/50, 41/50, 46/50, 49/50 and 50/50. In both examples, the error of the approximation is never greater than 2%. The same two approximations may be computer optimized. If the weights of the three segment MESFET for the 221/2° intervals are in the proportions of 1:3.613:7.524, an error of less than 1/2% is to be expected. If the weights of the five segment MESFET for 111/4° intervals are in the proportions of 1:1.45535:2.14035:5.25838:10.95002 then an error of less than 0.8% is to be expected. The application of the scaler and the choice of scaling weights for phase shifting is the subject of the above cited patent application to Messrs Hwang and Chen.
An attenuator having logarithmic scaling suitable for use from UHF to X-band is illustrated in FIGS. 5 and 6. The attenuation varies from zero to greater than 10 db under digital control utilizing 6 coarse (greater than 1 db) settings and four fine (0.2 db) settings. The coarse settings are produced by a first relatively large, four segment MESFET 51 while the fine settings are produced by a three segment MESFET 56 having a first segment width of 169 microns followed by a voltage divider coupling the signal to two smaller segments of 20 and 40 microns width respectivly. The circuit associated with the three segment device 56, illustrates the provision of high resolution attenuation steps.
FIG. 5 in particular provides an electrical circuit diagram of both the coarse and trimmer sections of the attenuator. The drawing indicates the circuit values and the gate widths utilized in the trimmer section. FIG. 6 illustrates the layout of the trimmer section.
As shown in FIG. 5, the input signal to the attenuator is coupled to the signal input pad 50 which is coupled via a 4 picofarad capacitor to the number 1 signal input gates of the segments T1, T2, T3, T4 of the first MESFET 51. The signal input gates are returned via a 2000 ohm resistance to the pad 63 connected to the negative gate supply voltage. The sources of the MESFET segments T1, T2, T3, T4 are connected to substrate ground and the number 2 activating gates are connected through 2K resistances to activating control terminals 52, 53, 54, 55 respectively. The drains of the segments T1, T2, T3 and T4 are connected together and lead via a first load resistance RL1 of 50 ohms to a positive drain source terminal 62, which is bypassed by a 10 picofarad capacity C10, to ground.
The signal from the drain of the MESFET 51 (continuing to trace the circuit diagram of FIG. 5) is then coupled via a 4 picofarad capacitor C2 to the signal gate, common to the three segments of the MESFET 56 in the vernier section of the attenuator. The capacitor-terminal connected to the T5 signal gate, is connected via a 200 ohm resistance to the number 1 signal gates of the T6 and T7 segments and via a 2000 ohm resistance to the pad 63 connected to the negative source supply voltage. A second resistance of 50 ohms connects the signal gates of T6-T7 to the negative source, and forms a voltage division (having a ratio of 5 to 1) of the signal coupled to the attenuator segments T6-T7. The sources of the segments T5, T6, and T7 are connected together and to substrate ground. The three number 2 activating gates of T5, T6, T7 are connected to activating control terminals 57, 58, 59 respectively. The drains of the three segments T5, T6, T7 are connected via a 50 ohm load resistance RL2 to the B+ supply terminal 61 which is bypassed to ground with a 10 picofarad capacitor C12. The signal output appears at the common drain connection of T5, T6, T7 and is coupled via a four picofarad capacitor C3 to the signal output terminal 60.
The logarithmic attenuator of FIG. 5 was fabricated using monolithic microwave circuit fabrication techniques on a gallium arsenide substrate having overall dimensions of approximately 1400 microns by 1600 microns. The MESFETS of the FIG. 5, 6 embodiment have a linear non-interdigitated layout. In the trimmer section, the set of segments T5, T6, and T7 of MESFET 56 are in line, and have the same azimuthal orientation. In the "in line" design, the source, number 1 gate, number 2 gate and drain metallizations occur in the same order along the same coordinate (i.e. from top of the drawing to the bottom).
In the orientations of FIG. 6, the three MESFET segments T5, T6, and T7 of the trimmer section of the attenuator are shown in the center of the substrate with pads for external connection being shown along the top edge, right edge and bottom edge of the illustrated portion of the substrate. Each of the segments is oriented with the drain being uppermost, the number 2 activating gate being next below, the number 1 signal gate being below that, and the drains being lowermost. Each segment of the MESFET 56 is formed on a localized semiconducting region formed on the semi-insulating gallium arsenide substrate. The surrounding semi-insulating region supports inter-segmental connections, DC and signal connections to the MESFET, and passive components such as the signal coupling capacitors (C2, C2 and voltage divider (R1 R2); and filtering and power supply components (RL1, C12). Each feature is formed on the gallium arsenide substrate and defined by a photolithographic process.
The path of the signal proceeds generally from left to right in the FIG. 6 illustration being introduced at the left edge of the substrate via the metallization 66 which leads to the capacitor C2. The capacitor C2 is then connected via a short metallization to the number one signal gate of T5 and then via the voltage divider R1, R2 to the number one signal gates of segments T6 and T7. The attenuator output signal is derived from a metallization 67 coupled to the drains of T5, T6 and T7, which is coupled upward via a filter network consisting of load resistance RL2 and bypass capacitor C12 to the pad 61 for application to a source of positive drain potentials. The signal from metallization 67 is coupled via the capacitor C3 via a downward extending metallization 68 to the signal output pad 60. The sources of the devices T5, T6, and T7 are illustrated connected together to substrate ground. The number 1 signal gates of MESFET T5, are coupled via the resistance R3 to the pad 63 at the lower left corner of the substrate. The segment activating gates are each coupled via a 2000 ohm resistance to the pads 57, 58 and 59 at the top edge of the substrate.
The "in line" design has a process advantage with devices of smaller geometries. For instance, an error in mask positioning, which offsets all of the gates along a coordinate perpendicular to the gate, will produce the same effect on all MESFET segments. In the interdigitated structure, assuming that the order of the source and drain are interchanged in half of the segments, the same mask displacement will place one set of gates closer to the source and the alternate set of gates closer to the drain. The result is that alternate devices will have differing operating characteristics. This problem is most severe at the higher resolutions, but at lower resolutions is only one of many factors which must be taken into account when establishing a satisfactory MMIC layout.
The present invention provides a method of scaling the gain of a MESFET by partitioning the MESFET into segments of differing width dimensions, and selectively activating different combinations of segments. The scaling therefor becomes proportional to the transconductances of the activated segments, which in turn are dependent on the respective widths of the segments. Since the segments are operated in an "ON/OFF" mode (i.e. "activated"), the scaling retains its accuracy irrespective of changes in bias, in temperature and in many process variations. These changes, which affect each segment proportionately, do not--to a first order at least--affect the scaling which the dual gate segmented MESFET produces.
The scaling range or the finess of the resolution may be increased by the use of the voltage divider illustrated in the FIGS. 5, 6 embodiment. Without the use of the 5 to 1 step down voltage divider, the gates subject to the step down ratio would have had to be one-fifth the gate width finally employed. Because of fringing effects and inaccuracies, gate width scaling down to gate widths of a few microns (normally less than 10 microns) is often impractical. With the voltage divider having a division ratio of 5 to 1, the gate widths may be multiplied by a factor of approximately 5, which increases the transconductance by a factor of five to achieve approximately the same overall gain. Thus with the use of a supplemental voltage divider, the voltage scaling can assume a wider scaling range or finer resolution when fixed input and output impedances are assumed.
As earlier noted, with binary segment scaling, 4, 5, and 6 bit signal scaling is quite practical, while with the use of the voltage division technique, the scaling may be extended several more bits, depending on application.
The vernier principle may be applied within a MESFET to apply to the finer segments or it may be applied between two MESFETS, one designed for coarse steps and the other designed for the finer steps.
The signal transfer of the segmented dual gate MESFET may provide either a stepped attenuation, a stepped gain, or stepped signal scaling in which the range incompasses both attenuation and gain. At a signal at a given frequency within the range of application of the invention, whether narrow band or broad band, a change in signal amplitude is not accompanied by a substantial change in phase.
In principle, the scaling property is dependent upon scaling the transconductance of the individual segments, which is achieved by adjusting the widths of the individual segments. The signal gain may be calculated as a function of the input signal voltage, the transconductance which produces a corresponding output signal current, and a load resistance in which the output signal current flows and produces an output signal voltage. In practical applications, exact gate width dimensions are obtained by taking into account those parameters significantly impacting the signal transfer calculation.
The use of a dual gate design for the individual MESFET segments has two further advantages in most practical applications. The presence of the second, activating gate acts as a shield between the signal input gate and the signal output drain and greatly enhances the input-output isolation. The isolation gives greater accuracy in scaling by reducing the feedthrough capacity. In addition, the dual gate design tends to retain a substantially constant input impedance due to the fixed nature of the parasitics in the equivalent circuit at the first gate which change very little between the active and inactive states. Thus the segmental dual gate MESFET devices, when inserted in a circuit, may be designed to match the characteristic impedances of the connecting transmission lines (e.g. 50 ohms), and will preserve the match throughout the range of settings of the attenuator. Thus signal losses due to reflections of the attenuator will remain quite low.
The segmented dual gate MESFET herein described is a broad band device often operable over an octave of the frequency spectrum in practical realizations. In principle, there is no lower frequency limit. However, in practice the VHF frequencies may represent the lower limit at which the design has practical advantages over competing techniques. The upper frequency limit is established by the gain and parasitics of a given device viewed as an amplifier. A current upper limit using gallium arsenide devices with 1 micron gates is approximately 10 gigahertz. The bandwidth of the device is ordinarily measured in terms of the tolerable change in relative phase at different settings of the scaler. Accordingly, assuming a system application in which a 5 degree error in relative phase is tolerable, a bandwidth of 10% can be achieved at 5 gigahertz. Since the phase error increases at the upper limits of operation and decreases at the lower limits, a full octave of operation below these frequencies is ordinarily available without a significant increase in the phase error.
As previously stated, the scaler herein described makes use of the extraordinary characteristics of a method of circuit fabrication currently known as "MMIC" (monolithic microwave integrated circuit) technology. In current usage, the term "MMIC" implies a circuit fabrication technique in which active and passive components are formed by a photolithographic process on an insulating substrate having both electrically active regions, in which transistors may be formed, and electrically passive regions, in which conductive runs, transmission lines, inductors, capacitors and resistors may be formed. The fabrication technique, except for external connections to the pads made at the perimeter of the MMIC component, is throughout a photolithographic process controlled by large scale masks which may be generated by computer aided methods and which lend themselves to an automated mode of fabrication.
The word "monolithic" in the term "MMIC" implies the use of a single crystal, insulating, semi-insulating or semiconductor substrate upon which passive and active circuit elements may be fabricated and interconnected in accordance with one of several competing semiconductor technologies. At higher frequencies, the substrate material currently preferred for its semiconducting properties is gallium arsenide which has a high carrier (electron) mobility. In addition, gallium arsenide classified as a semi-insulator is available with the high bulk resistivity required to support low loss transmission lines and low loss conductive paths and required to provide good isolation between components. Gallium arsenide has a high dielectric instant (13.0) which is a factor, not always beneficial, influencing the transmission path design.
The word "microwave" in the term "MMIC" generally expresses the frequencies at which integrated circuits incorporating this technology are functional. Commonly the word implies circuit functionality at frequencies of 300 megahertz to 300,000 megahertz (Webster's New World Dictionary, p. 898). While some definitions may recognize no upper limit (e.g. "from about 1000 megahertz upwards" IEEE Standard Dictionary of Electronic and Electrical Terms, 3rd Edition, 1984), the word is also used to imply suitability for applications at much lower operating frequencies where high frequency response (at microwave frequencies) can improve circuit performance.
Functionality of an integrated circuit over the "microwave" portion of the radio frequency spectrum requires both good transistors in the active regions of the substrate as well as good passive devices and good point to point connections in the passive regions. In respect to the latter, the microwave transmission paths should be of reasonable efficiency and the conductive runs should be of low loss and good crossover techniques essential to any general circuit strategy such as "air bridges" should be present.
The term "integrated circuit" in the term "MMIC" implies that circuit components are formed integrally with the substrate by the photolithographic techniques discussed earlier, and that the circuit comprises pluralities of interconnected components, at least some of which are active.
MMIC technology is to be distinguished from "hybrid" monolithic integrated circuit technology. The dimensions of MMIC components, whether passive or active, are orders of magnitude smaller than lumped discrete components characteristic of the "hybrid" monolithic integrated circuit technology. In hybrid MIC technology, IC chips, transistor chips, capacitors, and resistors, etc. are treated as discrete components to be interconnected by wire bonds or similar non photolithographic techniques. Wire bond interconnections pose both the problem of creating electrical discontinuities at high frequencies by unwanted parasitic reactances and of introducing a variability in electrical characterization not present in a photolithographically defined interconnection technique.
The smaller dimensions characteristic of MMIC technology often reduces the phase delays in conductive paths and transmission lines to near negligibility. For instance, a differential signal path length of 200 microns, reasonable for the devices herein described, corresponds to a phase aberration of less than 2° at 10 gigahertz, where 10° would be tolerable. The smaller sizes and shorter distances between components characteristic of MMIC technology also reduce the parasitic capacitances and inductances within the active devices and in the interconnections between passive and active devices. These factors permit operation at frequencies as high as C-band (5-6 gigahertz) and often beyond with little difficulty.
Finally, both passive and active components can be matched with precision more economically with MMIC technology than with discrete technology. Large area metallizations, such as are used for capacitor plates or high current transmission lines are of course, highly accurate in an absolute sense. While absolute values may be somewhat more variable in small area devices, "tracking" or "matching" is often present. The symmetry attributable to common design rules in computer assisted layouts used in forming comparable devices contributes to this high degree of matching. In addition, the technology, which uses methods such as mask defined conductor runs and air bridges provides accuracy in conductor layouts with a repeatability which is not present in any other process.
In practical terms, MMIC technology has made possible the fabrication of the scaler herein described which is functional at frequencies as high as 5 gigahertz. In the embodiment of the scaler illustrated in FIG. 6, multiple active MESFET segments cooperate as parts of a unitary active MESFET with accurately formed resistive and capacitive elements and with efficient signal paths in close association with the MESFET to achieve a high frequency performance that cannot be matched by the discrete MIC technology.
While the monolithically integrated active MESFET herein described has particular advantage at very high frequencies, it is inherently a broadband device capable of working from DC to the very high microwave regions. At low frequencies, the segmented MESFET exhibits high input and output impedances due to low device capacitances and a very low feedback capacitance. This permits the device to be used at lower frequencies for high precision applications because of its low circuit loading and low internal feedback. For example, at lower frequencies attenuators having up to 60 db of attenuation or five bit phase shifters with less than five degrees of phase error can be built using MMIC technology. | A novel signal scaling MESFET of a segmented dual gate design is disclosed. The MESFET, which is monolithically integrated on a semi-insulating substrate capable of localized surface modification to form active semiconductor regions using MMIC (monolithic microwave integrated circuit) techniques, has a small AC signal transfer which is adjustable in selected discrete steps. For operation in the gigahertz range, the substrate is preferably of gallium arsenide.
In applying the MMIC technique, the MESFET, including segment electrodes and segment interconnections, and the electrical connections, signal paths, and passive components connected to the MESFET are formed on the substrate and defined by a photolithographic process. The technique permits reproducable feature definition and very compact minimum reactance segment interconnections, reducing deleterious parasitics and facilitating virtual unitary MESFET operation to very high frequencies.
The signal scaling MESFET is an active MESFET subdivided into an n-fold plurality of selectively activated MESFET segments, each of a predetermined width, with dual gates for each segment. The AC input signal is applied to the first gates of all n segments and a DC control potential is selectively applied to the second activating gate of each of the n segments to turn current flow "ON" or "OFF" in selected segments. The MESFET transfer values so formed are each substantially constant in a small AC signal sense and successive values are stepped at intervals suitable for linear, trigonometric, logarithmic or arbitrary scaling functions. | 7 |
RELATED APPLICATION
[0001] This application is based upon and claims the benefit of Provisional Application 60/240,198, filed Oct. 13, 2001.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a new and improved way of attaching a welded wire soil-reinforcing grid to a facing system for use in mechanically stabilized earth (MSE) retaining structures. The invention is an improvement over the prior art in that it places even stress on the tension elements, defined herein as the longitudinal wires of the soil-reinforcing grid. Further, the present invention allows a welded wire grid to translate in a horizontal plane with respect to the facing panel.
[0003] One form of prior art relies on attaching welded wire reinforcing grid by forming a loop or special crimp in individual longitudinal wires of the grid. The loops are formed by bending the wire 180° and welding the bent end to the longitudinal wire. This forms an integrated loop. This apparatus appears in U.S. Pat. No. 4,725,170-Davis. The loop of the welded wire grid is then placed through a coiled anchor that is cast into the back of a concrete face panel. The loop of the soil reinforcing grid and anchor are in a vertical plane which is perpendicular to the back face of the panel.
[0004] In another prior art MSE system the longitudinal wire is bent 90° and attached with a plate and bolt to the back of the facing unit. In another system the longitudinal wire is crimped and joined to an anchor with a connection pin. These can be seen in U.S. Pat. No. 5,749,680-Hilfiker and U.S. Pat. No. 4,324,508-Hilfiker, respectively. The arrangement of patent U.S. Pat. No. 5,749,680 allows the reinforcing grids to translate in a horizontal plane with respect to the facing panel.
[0005] Other prior art places the transverse wire of the welded wire grid work behind a loop that is formed in a panel anchor. The welded wire grid is attached to the panel anchor with a connection pin. This appears in U.S. Pat. No. 5,259,704-Orgorchock.
[0006] Still other prior art bends a single longitudinal wire 180° to form a paired longitudinal wire hairpin configuration. Welded to the paired longitudinal wires are transverse wires, which form a welded wire grid work. This combination forms an integral loop at the lead end of the soil-reinforcing element. The anchoring element protruding from the back of a panel is a formed loop. The soil-reinforcing element and loop are joined with the aid of a snap together mechanism. This can be seen in the prior art Alviterra connection shown in FIG. 1.
[0007] One block system utilizes a reinforcing element having parallel longitudinal wires with loops formed in each end. Each longitudinal wire is placed in counter bores formed in the top surface of a block. Rods are inserted through the counter bores and loops to secure the reinforcing element in the block. This arrangement can be found in U.S. Pat. No. 5,487,623-Anderson.
[0008] A second block system utilizes a flat polymeric soil reinforcing mat that is placed between blocks. The soil reinforcing mat is sandwiched between the blocks. The blocks are secured together by a pin that anchors the grid. This can be seen in U.S. Pat. No. 4,914,876-Forsberg.
[0009] U.S. Pat. No. 6,050,748 -Anderson, discloses a variety of loop connectors on the ends of the longitudinal wires of soil reinforcing mats to secure these mats to face elements. Of particular interest are the connections seen in FIGS. 47 to 52 of this patent which include overlapping loops which are engaged between or over connecting elements embedded in the face panels.
SUMMARY OF THE INVENTION
[0010] A principal object of the present invention is to provide an apparatus and method for attaching the face of an earthen retaining structure to a soil-reinforcing element through means of loops formed by parallel longitudinal wires of the element. The loops are overlapped on top of one another. The loops can be formed in numerous fashions. The use of separate wires makes manufacturing of the loops easier. The loops are attached to the face so that the soil-reinforcing element is free to rotate about the axis of the loops. This allows the soil-reinforcing element to be skewed at an angle to the back face of the structure. An advantage of the overlapping loops is that when a force is applied to the longitudinal wires each loop tightens upon itself. This tightening increases the connection capacity. In addition, the connection is mechanical and does not rely on the weld shear of a transverse wire. Further, the soil-reinforcing element can be rotated to pass obstructions. Additionally, since two longitudinal wires are utilized in lieu of one there is twice the strength available.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a plan view showing the prior art Alviterra mat;
[0012] [0012]FIG. 2 is a top plan view of a first embodiment of the connection of the present invention;
[0013] [0013]FIG. 3 is a side elevational view of the first embodiment connection;
[0014] [0014]FIG. 4 is an end elevational view of the first embodiment connection, shown connected to an anchor element;
[0015] [0015]FIG. 5 is a side elevational view of the first embodiment connection, shown connected to a generally U-shaped anchor element embedded in a concrete face panel;
[0016] [0016]FIG. 6 is an elevational cross-sectional view of first modification of the first embodiment connection wherein a flanged sleeve is inserted through the coils of the connection;
[0017] [0017]FIG. 7 is a top plan of a second modification of the first embodiment connection, wherein the looped wires of the connection are bent 180° about themselves and welded together at their lead ends;
[0018] [0018]FIG. 8 is a side elevational view of the connection of FIG. 7;
[0019] [0019]FIG. 9 is a top plan view of a third modification of the first embodiment connection wherein the looped wires of the connection are bent 180° about themselves and twisted together;
[0020] [0020]FIG. 10 is a top plan view of a second embodiment of the connection of the present invention;
[0021] [0021]FIG. 11 is a top plan view of a third embodiment of the connection of the present invention;
[0022] [0022]FIG. 12 is an end elevational view of the third embodiment connection;
[0023] [0023]FIG. 13 is a side elevational view of the third embodiment connection;
[0024] [0024]FIG. 14 is a first modified version of the third embodiment connection wherein the loops are kinked;
[0025] [0025]FIG. 15 is a side elevational view of the first embodiment connection, shown connected to concrete block face elements;
[0026] [0026]FIG. 16 is a side elevational view of the first embodiment connection, shown attached to a cast concrete face element having a bifurcated shelf for receiving the connection;
[0027] [0027]FIG. 17 is a side elevational view of the first embodiment connection, shown attached to a cast concrete face element having an open shelf for receiving the connection;
[0028] [0028]FIG. 18 is a side elevational view of the first embodiment connection, shown attached to a welded wire face element;
[0029] [0029]FIG. 19 is a side elevational view of the first embodiment connection, shown secured between two concrete facing elements;
[0030] [0030]FIG. 20 is a top plan view of the FIG. 19 arrangement, showing the connection to the lower face panel shown in FIG. 19, with the upper panel removed;
[0031] [0031]FIG. 21 is a top plan view showing a modified version of the arrangement wherein the connection is held between segmental concrete panels, and the panels are made up of block-like elements;
[0032] FIGS. 22 is a side elevational view of the arrangement shown in FIG. 21;
[0033] [0033]FIG. 23 is a top plan view of an arrangement wherein the connection is between block elements and the pin securing the connection to the elements does not tie successive rows of block elements together; and
[0034] FIGS. 24 to 26 are top plan views illustrating how the connection of the present invention allows the soil reinforcing grids attached to various forms of face elements to translate in a horizontal plane relative to the face elements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
[0035] The first embodiment of the present invention consists of a welded wire grid 1 containing paired longitudinal wires 2 A, 2 B that are substantially parallel to one another. Cross members 3 are joined to the longitudinal wires in a perpendicular fashion by welds at their intersections 4 . The lead ends of the longitudinal wires are manufactured into a coil-loop 5 by wrapping the longitudinal wire around a pin. This forms a through-hole 6 in the end of the wire. The paired longitudinal wires are deflected inward toward one another so the through-holes overlap. The welded wire grid is attached to the back of a concrete element C by placing the coiled-loop between the legs of anchor elements 8 (see FIG. 5). The anchor elements 8 are C-shaped and each consist of a top leg 9 and a bottom leg 10 , each leg having a hole 11 extending therethrough of approximately the same diameter as the opening in the coil-loop. A rebar 7 extends within the concrete element C and through the bight portion of the anchor element 8 . Through the intersecting holes in the anchor and the coil-loop, a bolt or a pin 12 is placed. This ties the grid to the concrete panel 13 (see FIG. 5).
[0036] To prevent the longitudinal wires from separating, until such time that a pin is passed through the anchor and the coil, the coils can be welded together or a hollow tube 14 can be placed through the coil-loop opening and the ends 15 flared outward as shown in the modification of FIG. 6. This tube will keep the holes from each coiled longitudinal 2 A, 2 B wire in line. The coiled assembly is then fastened to the anchor.
[0037] The modification of the first embodiment connection shown in FIGS. 7 and 8 embodies a welded wire grid 1 having paired longitudinal wires 2 A, 2 B that are substantially parallel to one another and cross members 3 welded to the longitudinal wires at the intersections 4 . The lead ends of the longitudinal wires are laid over one another, with their ends bent 180° upon themselves, as may best be seen from FIG. 7. The loops are resistance welded to one another by “W” at their lead ends and where the distal portions of the loops cross (see FIG. 7).
[0038] The third modified version of the first embodiment shown in FIG. 9 is similar to the second modification of FIGS. 7 and 8, except that in the FIG. 9 modification no welds are provided between the loops and the distal portions of the loops are twisted about themselves at “T.” This twisted connection prevents the loops from straightening and releasing under the application of tension forces to the wires 2 A and 2 B.
Second Embodiment
[0039] The second embodiment of the present invention is shown in FIG. 10 and comprises welded wire grid 16 having paired longitudinal wires 2 A, 2 B that are substantially parallel to one another. Cross members 3 are joined to the longitudinal wires in a perpendicular fashion by a welds at their intersections 4 . The lead longitudinal wires are manufactured into a loop by bending the longitudinal wire 180° around a pin and welding the ends 17 of the wires to the longitudinal wires. This forms a loop 18 in the end of each longitudinal wire. The looped longitudinal wires are deflected inward toward one another so the through-holes 19 formed therein intersect. The wires are connected with a weld 20 , or a flared tube as previously described. The welded wire grid is then attached to the back of a concrete element by placing the loops between the legs of an anchor element. The anchor element corresponds to previously described element 8 and comprises a top leg and a bottom leg, each leg having a through-hole of approximately the same diameter as the opening in the coil loop. Through the intersecting holes in the anchor and the loops, a bolt or a pin is placed, similarly to what is seen in FIG. 5. This ties the grid to the concrete panel.
Third Embodiment
[0040] A third embodiment of the present invention, as shown in FIGS. 11 to 13 , comprises a welded wire grid 1 having paired longitudinal wires 2 A, 2 B that are substantially parallel to one another. Cross members 3 are joined to the longitudinal wires in perpendicular fashion by welds at their intersections 4 . The lead longitudinal wires are deflected toward one another. The ends of the longitudinal wires are bent around one another in an over-lapping fashion and welded together, forming a closed loop 7 .
[0041] The wires are placed in anchor as previously described (see FIG. 4). In order to make movement of the closed loop more restrictive, it can be formed with a kink, as shown in the modified version of the third embodiment shown in the modification of FIG. 14.
Use of the Connection
[0042] Each of the embodiments can be attached to concrete panels as shown in FIGS. 16, 17, 19 and 20 , blocks as shown in FIG. 15, or a welded wire-facing element as shown in FIG. 18. Attachment can be made with an anchor 8 that is attached to the facing and captures the loops between the protruding top and bottom portions 9 , 10 . In the block arrangement of FIG. 15, the element 8 is connected to the blocks B with a bolt or pin 22 that is “L” shaped.
[0043] The panel arrangements can be made of cast concrete that is manufactured into a face panel D (FIG. 16) to provide bifurcated shelf having a slot 22 providing an opening that the loops are placed through, or as a simple shelf 24 (FIG. 17) upon which the loops rest. The soil-reinforcing elements are joined to the panels P with a pin 25 .
[0044] The wire face arrangement (FIG. 18) employs a C-shaped anchor element 8 A similar to the element 8 previously described. The C-shaped element is placed to the front of the facing element, designated 26 , and captures two transverse wires of the facing element. The soil-reinforcing element is attached by placing a bolt or pin 12 through the opening in the anchor and the coil loops.
[0045] The coil loops can also be attached by capturing the loops between two concrete facing elements 29 A, segmental concrete panels or segmental concrete blocks 29 B, as shown in FIGS. 19 to 22 . In these arrangements, the loops are placed in a void that is cast into the top surface of the concrete element. A segmental concrete element is placed on the soil-reinforcing element. Cast into the void is a hole 30 that will allow a pin 32 to be set in the panel and passed through the soil-reinforcing loop opening securing it from removal. The pin can pass into the segmental element above.
[0046] [0046]FIG. 23 shows a connection to a block arrangement in which the pin 34 for connecting the loop of the invention does not tie into the block 29 C row above, but is between successive paired blocks of above. The block 29 C is shaped in such a manner that the pin does not tie the second row of blocks together. It would be possible to pass the pin into the third row of blocks. This would tie every other row of blocks together.
[0047] FIGS. 24 - 26 illustrates how the connection of the present invention allows a welded wire soil reinforcing grid to translate in a horizontal plane with respect to the facing member to which it is attached.
[0048] While specific embodiments of the invention have been illustrated and described, it should be understood that the invention is not intended to be limited to these embodiments, but rather as defined by the claims. | A connection for securing the longitudinal wires of a soil reinforcing mat to a face element for an earthen formation is provided by converging the lead ends of the wires toward one another and forming aligned coils distally on the lead ends. A pin extending through the coils secures the soil-reinforcing mat to the face element for pivotal movement relative thereto in a horizontal plane. A variety of means are provided to secure the coils against unwinding in response to tension force applied to the wires. | 4 |
TECHNICAL FIELD
The present invention relates to pressure equalization in a proportionally regulated fluid system and more particularly, to the equalization of pressure between distinct channels of a split fluid system that operates with independent proportional valve pressure control.
BACKGROUND OF THE INVENTION
Proportional regulation in a fluid system is the action of a mechanism to vary fluid output pressure relative to the fluid input pressure in response to one or more varying control factors. The output pressure is generally controlled to effect a desired response from a fluid actuated element. This type of a control mechanism has useful application in the control of automotive braking systems.
It is typical for an automotive braking system to operate in a traditional base brake mode wherein manual actuation of a master cylinder effects a desired application of the wheel brakes. In addition to the base brake mode, braking systems are often capable of controlling vehicle deceleration through anti-lock operation, controlling vehicle acceleration through traction control operation and improving lateral and longitudinal vehicle stability through stability enhancement systems which provide a level of dynamic handling augmentation. Such multi-functional brake systems are becoming increasingly more common and therefore, providing an effective and economical multi-functional system is desirable.
Brake apply system designs are known wherein the pressure applied to a vehicle's wheel brakes is controlled by an electronic unit that evaluates several parameters and delivers a control signal to a hydraulic modulator that sets the wheel brake pressure. A key parameter used to determine the appropriate braking pressure is the driver's command, delivered as an input on the brake pedal. Braking systems that provide several distinct operating modes require a mechanism to "modulate" the braking pressure at the wheel brakes based on parameters other than, or in addition to, the driver's application of force to the brake pedal. A modulator typically includes a pressure generation mechanism and a means of controlling delivery of the generated pressure to the wheel brakes. This may take the form of a pump and proportional hydraulic valve, a pump with a pair of two way valves or a movable-piston variable pressure chamber device. The number and arrangement of these elements included in a braking system is determined by the system layout and selected control scheme.
There are many operating conditions to consider in designing a multi-functional braking system. During braking operation on a uniform road surface for a vehicle moving in a substantially straight line, the friction characteristic at the tire to road interface is similar for all four wheels. If the brakes are applied to slow the vehicle, it is preferable for the application rate to be consistent between the left and the right sides of the vehicle, to inhibit the introduction of brake induced yaw. If brakes are applied according to an automatic control mechanism for target path correction of the vehicle in maneuvering situations, then the application rates are selected to purposely introduce a yaw moment. Additionally, anti-lock and traction control braking operation often varies braking pressure between the individual wheel brakes of a vehicle. Therefore, it is preferable to have the ability to provide consistent braking pressure across the sides of a vehicle and also to have the ability to vary the braking pressure across the sides of a vehicle. The operating conditions are complicated by friction coefficient variances between wheels of the vehicle and other operational conditions.
SUMMARY OF THE INVENTION
In accordance with an aspect of the present invention, a braking system generally provides pressure equalization between the sides of a split braking circuit. The amount of equalization provided is limited to enable the introduction of purposely induced pressure variances. A result is that pressure variations are moderated and intentional target pressure variations are easily obtainable. The braking system provides power braking operation in response to a manually actuated master cylinder and in response to a motor driven pump.
A preferred embodiment of the present invention includes a manually actuated and power boosted master cylinder that operates to pressurize dual braking circuits. Fluid pressure is transmitted through isolation valves directly to the wheel brakes. A check valve feature preferably prevents the transmission of pressure to those parts of the braking circuits that include the pressure equalization effecting devices. This isolates the compliancy introduced by the devices from the master cylinder and the wheel brakes during base brake operation.
In automatic power braking operation of the braking system to slow the associated vehicle, a powered pump delivers pressurized fluid through a controllable supply valve. When the supply valve is open, the isolation valve(s) are shifted to provide open fluid communication paths between proportional pressure control valves and the wheel brakes. The check valve features prevent the transmission of fluid pressure to the master cylinder during automatic power braking operation.
Providing fluid pressure to actuate the wheel brakes is achieved by actuating the proportional valves which are controlled to effect a target braking pressure. The target braking pressure is set by a programmable electronic controller which utilizes various data. Any side to side pressure variation that could result by independent operation of the proportional valves is avoided by operation of the pressure equalization effecting devices. Therefore, during automatic power braking operation to slow the vehicle, the fluid pressure applied to the front wheel brakes is substantially equal. Similarly, the fluid pressure applied to the rear wheel brakes is substantially equal.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a diagrammatic illustration of a vehicle braking system in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the Figure, illustrated is a fluid pressure regulation system embodied as brake system 10. Brake system 10 is capable of conventional manual base brake operation and is also capable of electrically controlled brake operation in response to manual actuation or various sensed vehicle operational parameters for traditional braking, anti-lock braking, traction control operation, vehicle handling augmentation through a stability enhancement system, and automatic power braking operation.
The braking system 10 includes a conventional master cylinder 12 with an associated fluid reservoir 14. The master cylinder 12 is manually actuated in response to the application of force to the brake pedal 15 through the push rod 17. A hydraulic power booster 11 is associated with the master cylinder 12 to intensify the force applied by the brake pedal 15 and apply the intensified force to the master cylinder 12. The master cylinder 12 includes two output ports 16 and 18. Through the output ports 16 and 18, the master cylinder 12 is capable of actuating two braking channels through the master cylinder pressure input lines 21 and 22.
The braking system 10 is arranged in a diagonally split manner so that the master cylinder pressure input line 21 supplies left front wheel brake 25 and right rear wheel brake 27. Similarly, master cylinder pressure input line 22 supplies right front wheel brake 24 and left rear wheel brake 26. Although the system is arranged in a diagonally split manner, a plurality of other braking supply arrangements are possible and the present embodiment is intended merely to demonstrate the manner of fluid pressure regulation provided by the present invention.
The master cylinder pressure input lines 21 and 22 do not extend directly to the wheel brakes 24-27 themselves, but rather are routed through isolation valves 30, 31, 32 and 33. The isolation valves 30-33 are spring biased to a normal position wherein the master cylinder pressure input line 21 is in communication, through isolation valve 31 and pressure output line 36, with wheel brake 25, and through isolation valve 33 and pressure output line 38, with wheel brake 27. Similarly, the master cylinder pressure input line 22 is normally in communication, through isolation valve 30 and pressure output line 35, with wheel brake 24, and through isolation valve 32 and pressure output line 37, with wheel brake 26. In the "three way" isolation valves 30-33, pressure is certain to be directed to the wheel brakes 24-27 because of the integral check feature 61-64. In this base brake mode, which is the default mode, a normally open connection to the wheel brakes 24-27 through the isolation valves 30-33 is provided so that manual actuation of the master cylinder 12 through the application of force to brake pedal 15 as intensified by hydraulic power booster 11 is certain to provide vehicle braking.
The hydraulic power booster 11 includes an open fluid line 8 that communicates with the fluid reservoir 14 for fluid make-up and return requirements. The power supply for the hydraulic power booster 11 includes an accumulator 42 which maintains fluid pressure generated by pump assembly 40. When the brake pedal is actuated, fluid pressure is transmitted through line 23 and applied to an internal piston (not illustrated), of the hydraulic power booster 11 for power operation of the master cylinder 12.
In addition to the capability of manually actuating the braking system 10 through the master cylinder 12 and hydraulic power booster 11, a system of power operation exists which is capable of automatic control. Powered brake actuation is provided through the motor driven pump assembly 40. The input of the pump assembly 40 is connected to the reservoir 14 through line 71 to provide necessary fluid make-up and return requirements. The outlet of the pump assembly 40 is connected to port 80 of accumulator 42.
Accumulator 42 comprises a gas chamber 81 and a fluid chamber 82 separated by a slidable piston 83. In addition to the port 80, the accumulator includes a second port 84 that serves as an outlet downstream of the port 80 in the pump pressure input line 41. Providing a two-port accumulator 42 results in pump noise attenuation at the accumulator 42. This is accomplished by means of routing all output fluid from the pump assembly 40 into the fluid chamber 82 which permits volumetric expansion by movement of the piston 83 to compress the gas chamber 81. Noise damping occurs in the fluid chamber 82. Therefore, the accumulator 42 provides the dual functions of attenuating pump noise and providing a fluid pressure reservoir for the pressure input line 41.
Fluid pressure in the pump pressure input line 41 is monitored by pressure transducer 86 for use in establishing a desired level of pressure charge in the fluid chamber 82 of accumulator 42. The pressure charge is maintained by a positive shut-off feature of the supply valve 47 which is positioned in pump pressure input line 41 downstream of accumulator 42. The supply valve 47 separates the pressure rail side 88 of pump pressure input line 41 from the charged side 87 of pump pressure input line 41. A pressure regulation line (not illustrated), may extend between the charged side 87 of pump pressure input line 41 and the system return 89.
In the deenergized position, supply valve 47 ensures that the charged side 87 of pump pressure input line 41 is securely sealed off from the pressure rail side 88. The pressure rail side 88 distributes the pump pressure input line 41 to proportional valves 51, 52, 53 and 54. The pump pressure input line 41 extends through its pressure rail side 88 to the proportional valves 51-54 resulting in control of the fluid pressure reaching the isolation valves 30-33. Pressure in the modulated pump pressure input line segments 56, 57, 58 and 59 is controlled by operation of the proportional valves 51-54. Pressure balancing lines 67 and 68 extend between the modulated segments 56,57 and 58,59 respectively, of pump pressure input line 41. A spring centered piston unit 70 ensures fluid separation in the pressure balancing line 67. Similarly, a spring centered piston unit 71 ensures fluid separation in the pressure balancing line 68.
The spring centered piston unit 70 includes a body 72 having a main bore 73. A spool shaped piston 74 is slidably and sealingly carried in the bore 73. The segment 75 of pressure balancing line 67 communicates between modulated segment 56 and chamber 76 defined in bore 73. The segment 69 of pressure balancing line 67 communicates between modulated segment 57 and chamber 77 defined in bore 73. A third chamber 78 is defined by the piston 74 in bore 73. The chamber 78 continuously communicates with the reservoir 14 through the return 89 and vent line 91. Any fluid pressure inadvertently passing the seals (not shown), of piston 74 from chambers 76 or 77 to chamber 78 is vented to the reservoir 14.
Piston 74 is normally held in a centered position in bore 73, relative to the stops 92,93 by springs 94 and 95. When a pressure differential exists between modulated segments 56 and 57 the piston 74 slides, compressing the spring 94 or 95 to balance the pressure. When the pressure differential exceeds a predetermined value, the piston 74 engages the stop 92 or 94 so that an intended target pressure differential is achievable.
The spring centered piston unit 71 is substantially the same as the spring centered piston unit 70. A piston 101 separates out three chambers 102-104 within the spring centered piston unit 71. The segment 105 of pressure balancing line 68 communicates between modulated segment 58 and chamber 102. The segment 106 of pressure balancing line 67 communicates between modulated segment 59 and chamber 103. Chamber 104 continuously communicates with the reservoir 14 through the return 89 and the vent line 79.
Piston 101 is normally held in a centered position, relative to the stops 107,108 by a pair of springs. When a pressure differential exists between modulated segments 58 and 59 the piston 101 slides to balance the pressure. When the pressure differential exceeds a predetermined value, the piston 101 engages the stop 107 or 108 so that an intended target pressure differential is achievable.
In normal base brake operation of the braking system 10, the manual application of force on the brake pedal 15 results in actuation of the wheel brakes 24-27. The manual force is transmitted through the push rod 17 to the hydraulic power booster 11. The hydraulic power booster 11 utilizes the fluid pressure maintained by accumulator 42 to intensify the manually applied force for power actuation of the master cylinder 12. The manually actuated and power boosted operation of master cylinder 12 results in pressurization of the master cylinder pressure input lines 21 and 22 through the output ports 16 and 18. Fluid pressure is transmitted through the isolation valves 30-33 directly to the wheel brakes 24-27. The integral checks 61-64, prevent the transmission of pressure to the modulated segments 56-59. This isolates the spring centered piston units 70 and 71 from the master cylinder 12 and the wheel brakes 24-27. Therefore, movement of the pistons 74 and 101 does not affect the base brake design and operation.
In automatic power braking operation of the braking system 10, to slow the associated vehicle, the motor 40 is powered into operation and the supply valve 47 is energized and shifted to its open position. This pressurizes the pressure rail side 88 of the pump pressure input line 41. The isolation valves 30-33 are energized and shifted to provide open fluid communication between the modulated segments 56-59 and the pressure output lines 35-38. The integral check features 61-64 prevent the transmission of fluid pressure to the master cylinder 12 and the master cylinder pressure input lines 21 and 22.
Providing fluid pressure to actuate the wheel brakes 24-27 is achieved by operating the proportional valves 51-54 which are actuated to effect a target braking pressure. The target braking pressure is set by a programmable electronic controller (not illustrated), which utilizes various data. Open communication is provided through the isolation valves 30-33 since they have been shifted to an actuated position. Any side to side pressure variation that could result by independent operation of the proportional valves 51-54 is avoided by operation of the spring centered piston units 70 and 71. Therefore, during automatic power braking operation to slow the vehicle, the fluid pressure applied to the front wheel brakes 24 and 25 is substantially equal. Similarly, the fluid pressure applied to the rear wheel brakes 26 and 27 is substantially equal.
The accumulator 42, which is provided to cooperate with the pump 40 in maintaining a consistent minimum pressure in charged side 87 of pump pressure input line 41, ensures that upon the immediate actuation of supply valve 47, pressure exists to charge the pressure rail side 88 and is available for braking needs to the wheel brakes 24-27 without waiting for pressure to build in response to the operation of pump 40. The securely closing supply valve 47 ensures that the pressure maintained on charged side 87 is not lost during braking inactivity.
In addition to normal base brake operation, the braking system 10 is capable of providing anti-lock braking, traction control, vehicle handling augmentation through stability enhancement control, and automatic power braking operation to slow the vehicle. For anti-lock braking functions during base brake applies, the proportional valves 51-54 are independently shiftable to control pressure release from the wheel brakes 24-27. This is effected while the necessary isolation valve(s) 30-33 are energized to provide an open flow path between the involved pressure supply line(s) 35-38 and the respective modulated segment(s) 56-59.
For traction control operation, automatic response to various vehicular sensors (not illustrated) independent of actuation of the brake pedal 15 the pump 40 is provided. The braking system 10 is pressurized through the supply valve 47 which is shifted to its actuated position charging the pressure rail side 88 of pump pressure input line 41. Braking pressure is available at the proportional valves 51-54, each of which is independently actuated to effect braking pressure at any selected wheel brake 24-27 through its associated isolation valve 30-33 which is shifted to its actuated position by the electronic controller.
Essentially the same actuation of the wheel brakes 24-27 is effected in response to various sensor inputs to enhance vehicle stability and maneuverability. The traction control and stability enhancement control operation is enhanced by the rapid response time of the system wherein the charged side 87 of the pump pressure input line 41 remains available to effect braking response at any of the wheel brakes 24-27 without waiting for pressure build to occur as a result of operation of pump 40.
In operation, the proportional valves 51-54, provide braking pressure to the wheel brakes 24-27 in response to the electronic controller which receives various sensor input data including that from the pressure transducer 19. Operation of the isolation valves 30-33, helps provide an effective and low cost method of isolating the master cylinder 12 from the wheel brakes 24-27, automatic power braking function operation in a relatively simple manner. The positive shut-off feature provided by the discharge valve 47 ensures that the braking system 10 is capable of responding quickly to any brake actuation requirements. During ABS release operation, any apply pressure feed from the master cylinder 12, through the integral check feature of the isolation valves 30-33 is released to the system return 89 through the corresponding proportional valve(s) 51-54. | A braking system generally provides pressure equalization between the sides of a split braking circuit. The amount of equalization provided is limited to enable the introduction of purposely induced pressure variances. A result is that unintentional pressure variations are moderated and intentional target pressure variations are easily obtainable. The braking system provides power braking operation in response to a manually actuated master cylinder. Fluid pressure is transmitted through isolation valves directly to the wheel brakes. The braking system also provides power operation in response to a powered pump. The pump delivers pressurized fluid through a controllable supply valve. When the supply valve is open, the isolation valve(s) are shifted to provide open fluid communication path between proportional pressure control valves and the wheel brakes. The pressure equalization effecting device is isolated from the master cylinder pressurized circuit during base brake operation. | 1 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to the production of coated abrasives engineered to have patterned surfaces with properties specific to the desired application.
[0002] The proposal to deposit isolated structures such as islands of a mixture of a binder and abrasive material on a backing material has been known for many years. If the islands have very similar heights above the backing and are adequately separated then, (perhaps after a minor dressing operation), use of the product will result in reduced surface scratching and improved surface smoothness. In addition the spaces between the islands provide a route by which swarf generated by the abrasion can be dispersed from the work area.
[0003] In a conventional coated abrasive, investigation of the grinding surface reveals that a comparatively small number of the surface abrasive grits in an active abrading zone are in contact with the workpiece at the same time. As the surface wears, this number increases but equally the utility of some of those abrasive grits may be reduced by dulling. The use of abrasive surfaces comprising a uniform array of isolated islands has the advantage that the uniform islands wear at essentially the same rate such that a uniform rate of abrasion can be maintained for longer periods. In a sense the abrading work is more evenly shared among a larger number of grinding points. Moreover since the islands comprise many smaller particles of abrasive, erosion of an island uncovers new, unused abrasive particles which are as yet undulled.
[0004] One technique for forming such an array of isolated islands or dots that has been described is that of the rotogravure printing. The technique of rotogravure printing employs a roll into the surface of which a pattern of cells has been engraved. The cells are filled with the formulation and the roll is pressed against a surface and the formulation in the cells is transferred to the surface. Normally the formulation would then flow until there was no separation between the formulations deposited from any individual cell. Ultimately a layer of essentially uniform thickness would be obtained. By way of illustration, comparative Examples C and D of U.S. Pat. No. 5,152,917 describe a process in which the pattern obtained by a rotogravure process quickly lost all separation of the individual amounts deposited from the cells.
[0005] In U.S. Pat. No. 5,014,468 a binder/abrasive formulation was deposited from rotogravure cells on a roller in such a way that the formulation was laid down in a series of structures surrounding an area devoid of abrasive. This is believed to be the result of depositing less than the full volume of the cell and only from the perimeter of each cell, which would leave the ring formations described.
[0006] The problem with the rotogravure approach has therefore always been the retention of a useful shape to the island. To formulate an abrasive/binder mixture that is sufficiently flowable to be deposited and yet sufficiently non-flowable such that it does not slump to an essentially uniform layer coating when deposited on a substrate has proved very difficult.
[0007] Chasman et al., in U.S. Pat. No. 4,773,920 disclosed that using a rotogravure coater, it is possible to apply a uniform pattern of ridges and valleys to the binder composition which, when cured, can serve as channels for the removal of lubricant and swarf. However beyond the bare statement of possibility, no details are given that might teach how this might be carried out.
[0008] In U.S. Pat. No. 4,644,703 Kaczmarek et al. used a rotogravure roll in a more conventional fashion to deposit an abrasive/binder formulation to deposit a layer that is then smoothed out before a second layer is deposited by a rotogravure process on top of the smoothed-out first layer. There is no teaching of the nature of the final cured surface.
[0009] Another approach has been to deposit the abrasive/binder mixture on a substrate surface and then impose a pattern comprising an array of isolated islands on the mixture by curing the binder while in contact with a mold having the inverse of the desired patterned surface. This approach is described in U.S. Pat. Nos. 5,437,754; 5,378,251; 5,304,223 and 5,152,917. There are several variations on this theme but all have the common feature that each island in the pattern is set by curing the binder in contact with a molding surface.
[0010] Yet another approach is described in U.S. Pat. No. 5,863,306 in which a pattern is embossed on a surface of a layer comprising a radiation-curable binder having abrasive particles dispersed therein after the surface of the layer has been modified to increase its viscosity but before curing of the binder has been initiated.
[0011] The present invention presents a technique for tailoring the formulation formed into patterns to generate grinding properties that vary with the degree of wear the coated abrasive has experienced.
[0012] The present invention therefore provides a flexible and effective route for the production of products uniquely suited to a specific task such that multiple abrading/fining/polishing operations can be avoided.
General Description of the Invention
[0013] The present invention provides a coated abrasive having a patterned surface comprising a plurality of shaped structures wherein each such structure comprises a curable binder with abrasive particles dispersed therein wherein the improvement comprises providing that the structures are layered such that, as the structure is eroded during use, different properties are revealed.
[0014] The term “shaped structure” is intended to convey a structure having a defined contoured shape that is raised above a backing surface upon which the structure is located. A “patterned surface” is a surface comprising a plurality of such shaped structures disposed on a backing surface in a repeating pattern with each shaped structure having a height dimension above the backing surface such that an initial contact plane is defined parallel to the backing surface and passing through only the tops of shaped structures. In preferred patterned surfaces at least 50% of the tops of the shaped structures lie in the initial contact plane. The shape of each “shaped structure” can be exactly replicated either across the whole of the patterned surface or in a number of groups of different repeating shaped structures, each structure within a group being identical, in defined or randomized patterns. Alternatively the shapes may be less exactly replicated as would be the case if an instrumentality imposing the shape were to be removed before the material shaped had completely lost the ability to flow.
[0015] The layers which make up the shaped structures comprise a curable binder and, dispersed therein, a particulate material. The nature and/or the amount of the particulate material varies within the shaped structure so as to achieve different properties at different layers of the structure as indicated above.
[0016] U.S. Pat. No. 5,863,306 shows a form of this approach in which the structures comprise abrasive particles dispersed in a UV-curable binder and the concentration of the abrasive in the surface layers of an abrasive structure is increased by comparison with the rest of the structure by for example application to the uncured binder/abrasive formulation surface a layer of a functional powder which, during an embossing process to form the shaped structures becomes at least partially incorporated into the surface layer of the structure. The functional powder can be, for example, abrasive particles or particles of a grinding aid or a mixture of both. This approach is described generically in U.S. Pat. No. 5,833,724. In each case the size of the powder particles laid on the surface was the same as or finer than or coarser than the abrasive particles within the shaped structure.
[0017] It is also known to deposit layers of grinding adjuvants on the surface of a patterned abrasive in the form of a supersize layer or even a “diamond-like” layer. These are however layers deposited on top of shaped structures rather than forming part of the structures themselves as is the case in the present invention.
[0018] The layers from which the shaped structures are built up need not be separately identifiable in a cross-section but can in fact merge into one another to give a gradual transition from one to the next. This is in fact to be expected if the layers are laid down sequentially while the layers below are still fluid. Each layer preferably comprises a curable resin binder in which an active component is dispersed. In this context an “active component” is a component that fulfils a function such as an abrasive, a grinding aid, a wear indicator, a filler, a cure agent or an anti-static additive.
[0019] A major component of formulations from which the layers are formed is the binder. This is a curable resin formulation preferably selected from radiation curable resins, such as those curable using electron beam, UV radiation or visible light, such as acrylated oligomers of acrylated epoxy resins, acrylated urethanes and polyester acrylates and acrylated monomers including monoacrylated, multiacrylated monomers, and thermally curable resins such as phenolic resins, urea/formaldehyde resins and epoxy resins, moisture curable resins, as well as mixtures of such resins. The preferred curing mechanism is through UV light with or without the assistance of an additional thermal cure mechanism.
[0020] It is often convenient to have a radiation curable component present in the formulation that can be cured relatively quickly after the formulation has been shaped so as to add to the stability of the shape. In the context of this application it is understood that the term “radiation curable” embraces the use of visible light, ultraviolet (UV) light and electron beam radiation as the agent bringing about the cure. In some cases the thermal cure functions and the radiation cure functions can be provided by different functionalities in the same molecule. This is often a desirable expedient.
[0021] The resin binder formulation can also comprise a non-reactive thermoplastic resin which can enhance the self-sharpening characteristics of the deposited abrasive composites by enhancing the erodability. Examples of such thermoplastic resin include polypropylene glycol, polyethylene glycol, and polyoxypropylene-polyoxyethylene block copolymer, etc.
[0022] Fillers can be incorporated into the abrasive formulation to modify the rheology of formulation and the hardness and toughness of the cured binders. Examples of useful fillers include: metal carbonates such as calcium carbonate, sodium carbonate; silicas such as quartz, glass beads, glass bubbles; silicates such as talc, clays, calcium metasilicate; metal sulfate such as barium sulfate, calcium sulfate, aluminum sulfate; metal oxides such as calcium oxide and alumina bubbles; and aluminum trihydrate.
[0023] The abrasive particles can be selected from those typically used is such products including fused alumina, sintered alumina, alumina-zirconia, silicon carbide, diamond, CBN and for applications such as polishing or buffing or the finishing of optical or electronic surfaces, gamma alumina, silica or ceria. Other additives that might be added included grinding aids which usually contain components that, under grinding conditions, liberate chemicals that render the surface more susceptible to abrading. Typical compounds liberate halogens or halogen acids or sulfur oxides. Other possible components include: 1) fillers—calcium carbonate, clay, silica, wollastonite, aluminum trihydrate, etc.; 2) grinding aids—KBF 4 , cryolite, halide salt, halogenated hydrocarbons, etc.; 3) anti-loading agents—zinc stearate, calcium stearate, etc., 4) anti-static agents—carbon black, graphite, etc., 5) lubricants—waxes, PTFE powder, polyethylene glycol, polypropylene glycol, polysiloxanes etc.
[0024] The shaped structures preferably used in the coated abrasives forming part of this invention typically are widest at the base and decrease in cross-section with distance from the substrate upon which they are deposited. Thus as the structure erodes, a larger grinding surface is exposed. In products according to the prior art the size of the abrasive grits remains unchanged and this means that the grits in the lower portion of the structures will not work quite so efficiently as the individual pressure on each grit will be reduced. This is inefficient and can lead to variations in cut rate during use. The present invention avoids this result by tailoring the composition of the lower levels to ensure that the desired cut rate and the desired finish can be obtained efficiently in a single operation.
[0025] The pattern in which the shaped structures are arranged can comprise isolated islands of formulation, or a pattern of ridges separated by valleys or a plurality of connected ridges. The patterns are generally designed to provide an abrasive product with a plurality of abrading surfaces, (that is portions of the pattern that contact the surface of the workpiece when the abrasive product is in use), that are more or less equidistant from the backing. Obviously the total area of abrading surface increases with erosion of the layer unless the formation has uniform width from the backing to the abrading surface. Between the abrading surfaces, channels allow circulation of grinding fluids and removal of swarf generated by the abrasion. Channels also allow for momentary cooling before the surface is contacted by the next abrading surface.
[0026] The surface structures of the coated abrasive of the present invention can be created by any process adapted to the shaping of a structure whose composition varies with distance from the backing surface. Thus a process in which a sequence of horizontal layers of varying composition is deposited on a surface of a backing material and thereafter a shape is imposed on the layers to give a patterned surface, is in accordance with the present invention. Such imposition could be by molding the deposited layers. The molding process referred to above could also include a process in which the consecutive layers are deposited through a mask on the surface of the backing which remains in place until the binder components of the layers have been cured.
[0027] The structures can also be formed by an embossing process accomplished using an embossing tool such as a plate forced into contact with the layer of formulation or, often more simply, the tool can comprise a roller with the desired pattern engraved on its surface which when contacted with the slurry formulation imposes the reverse of the pattern engraved on the surface.
[0028] Another means of forming the structures includes the technique known as “free-forming”. In free-forming the final structure is built up in a sequence of deposited layers with the pattern of deposition being controlled to result in a structure having the desired shape. By varying the composition of the material deposited in sequential layers a product according to this invention can be obtained.
[0029] Yet another forming mechanism employs a substrate that is contoured, that is to say has a relief pattern formed on its surface for example by an embossing process. Layers deposited on this contoured surface would then adhere to the contours to give a pattern of shaped structures. Such a process is extremely versatile since the pattern on the substrate can be varied readily and the need for a very hard, abrasion resistant tool to impose a shape in a highly abrasive material would be avoided. To avoid the problem of the formulation comprising the layer collecting in the spaces between the shapes on the patterned backing, it is desirable to deposit each layer in the form of an extruded film that adheres and conforms to the surface of the patterned backing or the most recent layer previously deposited thereon.
DESCRIPTION OF DRAWINGS
[0030] FIGS. 1 - 4 are SEM photographs, taken at 50x magnification, of cross-sections of abrasive sheets made according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] The present invention differs from the prior art approaches in which a shaped structure is given a surface coating of a different composition. According to the present invention the composition of the actual shaped structure is varied so as to yield different characteristics as wear progresses. A preferred way in which this can be done is by decreasing the size of the abrasive particles in the lower portion of the structure. In this an initial rapid aggressive cut as a result of the use of a relatively coarse grit at the surface, (which would produce a relatively rough finish), would be followed by a polishing action as a result of the use of much finer abrasive particles in the layers exposed after erosion of the upper layers of the structure.
[0032] Alternatively and sometimes preferably the grains closer to the backing can be made coarser to make the cut rate at constant applied pressure more uniform with the more aggressive cutting larger grits compensating for the larger contact area as the abrasive structure wears down.
[0033] Besides varying the abrasive characteristics of the coated abrasive as erosion of the structure proceeds by changing the grit size, it is also possible to include additives in the lower levels having specific properties. For example it is possible to provide that the lower layer comprise a conductive material such as carbon black or graphite to inhibit the build up a static electricity during abrading.
[0034] It is also possible to incorporate in the lower levels of the structure an erodable filler to ensure that abrasive particles in that part of the structure are part of a more open structure that permits the particles to work more efficiently.
[0035] The use of conventional patterned coated abrasive structures is rarely continued until the backing is exposed such that it is often useful and economic to provide that the lowest levels, whose function is merely support for the upper levels, comprises no abrasive at all or alternatively a lower quality and/or less costly abrasive or even only a filler.
[0036] It is also a useful variation to provide that the different layers of the structure have a different color such that the state of wear of the abrasive structure can be readily determined by visual examination.
[0037] Where the finished structure comprises a cured binder material, it is often convenient to include cure initiators or catalysts in amounts that reflect the distance from the source of the curing mechanism. For example if the binder is a UV-curable resin and the overall thickness of the structure is significant, it can be convenient to include in the lower levels a higher level of initiator or perhaps an initiator that is responsive to the heat generated during cure of the upper levels. The objective is to ensure complete cure throughout the shaped structure and all additive/initiator variations that promote this objective are within the intended scope of this invention.
[0038] The invention is now described with particular reference to the Drawings. Examples 1 - 4 below detail the production of the products illustrated in FIGS. 1 - 4 respectively.
General Process Operations
[0039] A cloth substrate was prepared and a first layer of a slurry comprising fused alumina abrasive grain dispersed in a UV-curable binder formulation, (a resin mixture of 30% Ebecryl 3700 acrylated epoxy oligomer and 70% TMPTA monomer with 4% Irgacure 819 photoinitiator based on the resin weight), was deposited on the substrate using a knife blade coater with a gap of 10 mil, (0.25 mm). A second layer of slurry was then deposited over the first layer. The second layer contained abrasive particles of a different size from those in the first layer. The curable binder formulation was however the same and the deposition technique was the same except that a gap of 20 mil, (0.51 mm) was used.
[0040] A surface layer of abrasive particles was then deposited on top of the second layer. The particle size in this layer can be the same as one of the previous layers or different.
[0041] The surface was then embossed using a rotogravure roll engraved with a 25 lines per inch trihelical pattern and the embossed surface was immediately subjected to UV cure conditions using a 400 W/inch “V” bulb and a 300 W/inch “D” bulb at a speed of 50 ft/minute.
[0042] The UV-cured, abrasive-containing layers of the samples were then peeled from the substrate and a cross-section made and polished for SEM photography. In some cases this resulted in minor damage to the first layer, especially where the first or lower layer comprised a very fine grit particulate material such as in Examples 1 and 2 as shown in FIGS. 1 and 2.
EXAMPLE 1
[0043] First layer: 7 micron alumina in a 68% solids slurry.
[0044] Second layer: 97 micron alumina in a 70% solids slurry
[0045] Surface Powder layer: 97 micron alumina.
[0046] In FIG. 1 it is possible to distinguish clearly the first layer from the second but the surface powder layer can not readily be distinguished from the second layer except by the absence of binder all round the grains on the surface.
EXAMPLE 2
[0047] First layer: 20 micron potassium fluoroborate in a 65% solids slurry.
[0048] Second layer: 97 micron alumina in a 70% solids slurry
[0049] Surface Powder layer: 97 micron alumina.
[0050] In FIG. 2 it is possible to distinguish the KBF4 layer wherein the particles are darker but again the second layer and the powder layer, having the same abrasive particles included are distinguished only by their location at the surface of the binder layer.
EXAMPLE 3
[0051] First layer: 97 micron alumina in a 70% solids slurry.
[0052] Second layer: 7 micron alumina in a 68% solids slurry
[0053] Surface Powder layer: 7 micron alumina.
[0054] [0054]FIG. 3 shows the cross-section of this product.
EXAMPLE 4
[0055] First layer: 97 micron alumina in a 70% solids slurry.
[0056] Second layer: 7 micron alumina in a 68% solids slurry
[0057] Surface Powder layer: 97 micron alumina.
[0058] [0058]FIG. 4 shows the delineation of the various layers quite clearly by virtue of the different sizes. | Coated abrasives comprising shaped structures deposited on a backing can be given increased versatility by varying the composition comprising the structure such that different characteristics are revealed as the structure is eroded during use. | 1 |
FIELD OF THE INVENTION
The present invention relates to a method and a keyboard for inputting Chinese characters, which can input both simplified Chinese characters and their original complex forms.
BACKGROUND OF THE INVENTION
So far there are many methods for inputting Chinese characters, for example, Five-Stroke Character Form Code, Nature Code, etc. Most of the stroke-form codes and the combination codes of phoneme and stroke-form are difficult to learn and to bear in mind. The crucial question is that they are limited in the encoding method using radicals which are structural components of Chinese characters, so it is difficult for them to avoid the following shortcomings:
1. There are many, up to hundreds of, encoding elements. For example, Five-Stroke Character Form Code has more than 190 encoding elements, Nature Code has more than 250 encoding elements, Four-stroke Phoneme And Stroke-form Code has more than 440 encoding elements, both of Two-stroke Phoneme And Stroke-form Code and Zheng Code have up to 540 encoding elements, and Taiji Code has 152 encoding elements only in so far as the elements of pictographic character elements and mere character elements for exemplification(it is difficult to count up the actual total number of its encoding elements). Because of the large number of encoding elements, users have to remember a large amount when they learn to use these encoding methods.
2. The encoding rules are very complex. Since there are many encoding elements, it is not clarified how a character can be broken down into encoding elements. For example, Chinese character "" can be either broken down into "" or "". The rules for breaking down Chinese characters are very complicated and the theories thereof are not easy to understand. The rules for encoding and the corresponding keyboard arrangements of the encoding elements are also very complicated.
3. The codes are long. At present all the input methods which have lower rate of duplication codes and which can realize blind typing(typing without looking at the display) are four-code input methods, and the long codes cause the increasing of thinking levels for encoding a character and increasing the number of key-striking times, as well as the slowing down of input speed.
4. Their applications are limited in scope. Normally, the encoding methods now available are applicable only to a small collection of Chinese characters, e.g. 6763 Chinese characters in Chinese National Standard GB2312-80, but not applicable to a collection with 20,902 Chinese characters in the international standard ISO-10646 for China, Japan and Republic of Korea. When applying to the ISO-10646 Chinese character collection, it is difficult to encode the phoneme codes in the combination codes of phoneme and stroke-form because there are a large number of Chinese characters, which people do not know their pronunciation, in this large character collection, and it is also very difficult to avoid the high rate of duplication codes or the increase of code length when using mere stroke-form codes, therefore it causes inconvenience to the users.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a method and a keyboard for inputting Chinese characters based on the two-stroke forms and two-stroke symbols which are used as basic codes for encoding Chinese characters. It is easy to learn to use and can be inputted with high speed, therefore it overcomes the disadvantages of the prior arts.
The keyboard of the present invention is realized by setting up keys corresponding to 25 two-stroke form code elements and 25 to 28 two-stroke symbol code elements and a code ending key on a standard keyboard.
Said two-stroke form code elements include: ##STR1##
The above two-stroke form code elements are arranged in three lines, with each line has at most 10 elements. The 5 elements beginning with a "horizontal" stroke are marked on the left 5 keys of the middle line; the 5 elements beginning with a "vertical" stroke are marked on the right 4 keys of the middle line, and the second right key of the lower line; the 5 elements beginning with a "left-falling" stroke are marked on the left 5 keys of the upper line; the 5 elements beginning with a "right-falling" stroke are marked on the right 5 keys of the upper line; and the 5 elements beginning with a "turning" stroke are marked on the left 5 keys of the lower line.
The code elements of said two-stroke symbols are:
If necessary, three code elements can be added to the code elements of said two-stroke symbols as follows:
Said two-stroke symbol code elements are arranged on corresponding keys according to the principle of minimizing the rate of duplication codes.
The Chinese character inputting method of the present invention includes following steps:
1. composing 25 two-stroke form code elements according to the basic strokes which construct Chinese characters, that is:
classifying the single strokes which construct Chinese characters into five types: horizontal, vertical, left-falling, right-falling and turning, which can be symbolized as:
;
combining every two of the above five strokes together to compose two-stroke form code elements, the total number of which are 5*5=25, and which are provided as follows: ##STR2## 2. selecting following 25 two-stroke symbol code elements among frequently used basic structural components of Chinese characters:
If necessary, the following additional elements can be further selected:
;
3. performing operations for inputting Chinese characters in following 3 manners:
i. for a character of four strokes or fewer, extracting the first and the last code elements of the character according to the handwriting sequence; for a single block character of 5 strokes or more, extracting the first, the second and the last code elements of the character; for a character which is made up of separated blocks and has 5 strokes or more, dividing it into two blocks, and extracting only the first code elements from the beginning block and the first and the last code elements from the end block, then striking the keys corresponding to these code elements; if the number of the code elements extracted is less than 3, striking the code ending key thereby completing the input of this Chinese character.
ii. for a character of four strokes or fewer, extracting the first and the last code elements of the character according to the handwriting sequence; for a single block character of 5 strokes or more, extracting the first, the second and the last code elements of the character; for a character which is made up of separated blocks and has 5 strokes or more, dividing it into two blocks, and extracting the first and the last code elements from each block, then striking the keys corresponding to these code elements. If the number of the code elements is less than 4, striking the code-ending key thereby completing the input of this Chinese character.
iii. for a character of 4 strokes or fewer, extracting the first letter from its standard phonetic alphabet combination, and the first code element of the character according to the handwriting sequence; for a character of 5 strokes or more, extracting the first letter of the standard phonetic alphabet combination, the first code element and last code element of this character, then striking the keys corresponding to these letters and code elements. If the number of the code elements is less than 3, striking the code-ending key thereby completing the input of this Chinese character.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the keyboard on which 25 two-stroke forms and 25 two-stroke symbols are marked according to the present invention;
FIG. 2 is a schematic diagram of the keyboard on which 25 two-stroke shapes and 28 two-stroke symbols are marked according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The embodiments of the present invention will be described in detail with reference to the drawings hereinafter.
Chinese characters are made up of about 30 kinds of single strokes, which are classified in the present invention into five types: horizontal, vertical, left-falling, right-falling and turning, and symbolized as:
Every two of said five types of stroke are combined together to form a code element of the two-stroke form, thus there are altogether 5*5=25 two-stroke form code elements, which are shown as follows: ##STR3##
In order to enhance the efficiency for inputting Chinese characters and decrease the duplication codes, 25 two-stroke symbols are provided in the present invention as code elements. All the 25 two-stroke symbols are selected among the traditional Chinese character components and combinations of frequently used strokes by means of a number of tests. Using them can decrease the rate of duplication codes effectively. The actual strokes of a two-stroke symbol may have more than two stroke, but they all are deemed as having two stokes in the present invention, thus being so called two-stroke symbols. For example, Chinese character "" is defined as a two-stroke symbol, which has 4 strokes in reality, according to the present invention, therefore Chinese character "" is deemed as having 4 strokes. The purpose is to make the encoding rules simple, clear, easy to learn and to bear in mind. These 25 two-stroke symbols are:
According to different requirements of different object characters, some changes may be made on the basis of these 25 two-stroke symbols, for example, the following 3 code elements may be added:
Said 25 two-stroke forms and 25 two-stroke symbols are the code elements which are selected by the present invention for inputting Chinese characters. They are marked on the surfaces of 25 keys, as shown in FIG. 1.
On the basis of the 50 code elements, the present invention provides three kinds of methods for inputting Chinese characters: Four Code Input Method based on Mere Stroke-form (hereinafter referred to as MSFC input method); Three Code Input Method based on Mere Stroke-form (hereinafter referred to as MSTC input method); and Three Code Input Method based on the Combination Of Phoneme and Stroke-form (hereinafter referred to as CPSTC input method), wherein as the most important one of the three input methods, the MSFC input method comprises the following steps: dividing a Chinese character into two half-block characters; extracting the first and the last code elements from both half-block characters, totally 4 code elements, according to the handwriting sequence, then striking the keys corresponding to these 4 code elements, thereby completing the input of said Chinese character.
In the present invention, during extracting code elements from a character or a half-block character, the principle of "two-stroke symbol comes first, two-stroke form second" must be abided by. That is to say, if a two-stroke symbol can be extracted, this two-stroke symbol, instead of the two-stroke form, must be extracted. Only if the strokes of a part of a Chinese character do not form any two-stroke symbol, can 2 single strokes thereof be extracted to form a two-stroke form code element. For example, the first code element of Chinese character "" must be a two-stroke symbol "", instead of a two-stroke form "", because the two-stroke symbol "" is formed from the first stroke of the character, On the other hand, the first code element of Chinese character "" must be "", instead of "", because "" is not a two-stroke symbol defined in the present invention. The correct sequence of handwriting must be followed when code elements are extracted.
Chinese characters are classified into two types in MSFC or MSTC input method. One is called single-block characters, the other is called separated-block characters. When a separated-block character is inputted, it must be divided into two parts, the first one is called "the beginning block", the second one is called "the end block".
Separated-block characters are broken down in following manner:
i. For a character of Up-down construction, the group of strokes which are first completed from left to right in handwriting sequence is referred to as the beginning block, and the residual strokes form the end block, e.g., for Chinese character "", the first group of strokes which are written from left to right is "", therefore "" is the beginning block, and "" is the end block.
ii. For a character of Left-right construction, the group of strokes which are first completed from top to bottom in handwriting sequence is referred to as the beginning block, and the residual strokes form the end block, e.g., for character "", the first group of strokes which are written from top to bottom is "", therefore "" is the beginning block, and "" is the end block.
iii. For a character of Embracing construction, which means a group of strokes embracing another group of strokes from two, three or four directions of the character, and can be divided into a embracing block and a embraced block, the group of strokes which are completed first in handwriting sequence is referred to as the beginning block, the residual strokes form the end block. For example, for character "", "" is the block which are first written, therefore it is the beginning block, and the rest part "" is the end block.
iv. Characters other than the above three kinds of constructions are single-block characters.
Said MSFC, MSTC and CPSTC are names of three kinds of input methods of Chinese character in the present invention, wherein "Four Code" or "Three Code" does not represent the actual times of key-striking for each character, but means that at most four codes or three codes are provided for inputting a character. The MSFC and the MSTC inputting method will be described in detail below.
i. for a character of 4 strokes or fewer, extracting the first and the last code elements in handwriting sequence, and striking the keys corresponding to these elements successively.
ii. for a single-block character of 5 strokes or more, extracting the first, the second and the last code elements, and striking the corresponding keys successively.
iii. for a separated-block character of 5 strokes or more, dividing it into two blocks, extracting the first and the last code elements from each block, totally 4 code elements (for MSFC input method) or extracting only the first code element from the beginning block and the first and the last code elements from the end block, totally 3 code elements(for MSTC input method), then striking the corresponding keys successively.
For the above-mentioned MSTC input method, the code-ending key shall be struck when the number of the code elements is less than 3. For the above-mentioned MSFC input method, the code-ending key shall be struck when the number of the code elements is less than 4.
For example, the selected code elements of character "" are ", , , " (for MSFC) or ", , " for (MSTC).
Using CPSTC input method according to the present invention, a Chinese character is inputted in a manner as follows:
a) for a character of 4 strokes or fewer, extracting the first letter of the standard combination of the phonetic alphabet and the beginning code elements of the character, then striking the corresponding keys and the code-ending key successively.
b) for a character of 5 strokes or more, extracting the first letter of the standard combination of the phonetic alphabet, the beginning code element and the end code element, then striking the corresponding keys successively.
For example, the selected code elements of character "" are "B, , " in the CPSTC input method.
The MSFC input method is mainly used for encoding and inputting the characters of a large Chinese character collection including several ten thousand of characters.
The MSTC or CPSTC are mainly used for encoding and inputting commonly used Chinese characters the number of which is less than ten thousand.
The table below shows preferred embodiments of the input method according to the present invention based on the 25 two-stroke forms and the 25 two-stroke symbols.
Preferred embodiments of the input method using 25 two-stroke forms and 25 two-stroke symbols:
__________________________________________________________________________ CorrespondingChineseInput Number Blocks Extracting code keys of AlphabetCharacterMethod of Strokes Construction divided elements Keyboard__________________________________________________________________________CPSTC MSTC MSFC <4 XF FL FLCPSTC MSTC MSFC =4 MT TA TACPSTC MSTC MSFC =4 LK KK KKCPSTC MSTC MSFC =5 single block WGW GKW GKWCPSTC MSTC MSFC >5 single block WTW THW THWCPSTC MSTC MSFC >5 seperated- blocks (Up-down construction) BTA TTA TSTACPSTC MSTC MSFC >5 seperated blocks (Left-right construction) BJW JRW JFRWCPSTC MSTC MSFC >5 seperated blocks (Embracing construction) BPJ PMJ PDMJCPSTC MSTC MSFC >5 seperated blocks (Up-down construction) JKM KGM KKGM__________________________________________________________________________
With 25 two-stroke forms and 25 two-stroke symbols as code elements, the input method of the present invention are applicable to small Chinese character collection of 6,763 characters of Chinese national standard GB2312-80.
With 25 two-stroke forms and 28 two-stroke symbols as code elements, the input method of the present invention are applicable not only to the large character collection of 20,902 Chinese characters of ISO-10646, which includes simplified Chinese characters, their original complex forms, Japanese and Korean characters, but also to the large character collection of 60 thousand Chinese characters.
A special keyboard arrangement suitable for the input methods according to the present invention is provided.
The keyboard comprises at least 25 keys corresponding to the code elements, and a code-ending key. The spacebar of the keyboard shown in the Figures can be used as the code-ending key. These 25 keys are arranged in three lines, with each line has at most 10 keys. 25 two-stroke forms are marked on these 25 keys respectively. The 5 two-stroke forms beginning with a horizontal stroke are marked on the left 5 keys of the middle line. The 5 two-stroke forms beginning with a vertical stroke are marked on right 4 keys of the middle line, and the second right key of the lower line. The 5 two-stroke forms beginning with a left-falling stroke are marked on the left 5 keys of the upper line. The 5 two-stroke forms beginning with a right-falling stroke are marked on the right 5 keys of the upper line. The 5 two-stroke forms beginning with a turning stroke are marked on the left 5 keys of the lower line.
25 to 28 two-stroke symbols are marked on certain keys. Some of the keys are marked with multiple two-stroke symbols, while some of them with none.
The two-stroke form code elements and the two-stroke symbol code elements must be arranged in the keyboard according to the following combination rule: ##STR4## -(Without two-stroke symbol)-(Without two-stroke symbol)
When two-stroke symbol code elements are added, these three code elements are marked on the same key with code element "".
FIGS. 1 and 2 further provide the details of the keyboard in which 25 or 28 two-stroke symbol code elements and 25 two-stroke form code elements are arranged.
The above-mentioned keyboard is the preferred arrangement derived according to the structural features of Chinese characters, and having passed a number of encoding tests, and decreasing the rate of duplication codes greatly.
Because the present invention uses 25 two-stroke forms as the basis for encoding and combined with 25 two-stroke symbols, it breaks through the limit of the encoding method based upon components of Chinese characters, therefore it has following significant advantages as compared with prior arts:
i. The encoding elements are greatly decreased. As code elements, there are only 25 two-stroke forms which are made up of "" and 25 to 28 two-stroke symbols selected from frequently used character components. The amount of symbols which must be remembered is decreased by a factor of 8 to 20. So it is easy to learn and to remember for the operators.
ii. The encoding rules are simple. Because only the beginning and the end strokes or parts of characters are used for encoding, it is simple, clear and overcomes the problems occurred when characters are broken down in the prior arts.
iii. There are fewer codes as compared with prior arts. For small Chinese character collection of less than 10 thousand of characters, only three codes are used for inputting. It is one code fewer than that of prior arts. Using fewer codes cause the decrease of thinking levels for encoding a character and therefore decrease the times of key-striking.
iv. It can be applied more widely. The present invention can apply to encoding of Chinese, Japanese and Korean characters using the same methods and the same code elements. It can also encoding characters in ISO-10646 collection of characters world-wide used and in large collection of Chinese characters which has more than 60 thousand characters.
INDUSTRIAL APPLICABILITY
Because the 25 two-stroke symbols used in the present invention have an ability to greatly decrease the rate of duplication codes, the present invention has very low rate of duplication code. Among 20,902 Chinese characters in international standard ISO-10646, more than 17,000 of them can be directly inputted by MSFC input method of the present invention without having to select from characters represented by same codes. Among 6,763 Chinese characters in Chinese national standard GB2312-80, more than 5,000 of them can be inputted directly by CPSTC input method of the present invention without having to select from characters represented by same codes. In addition, since the default mode that frequently used characters are of priority are used, most of the characters that must be inputted through selection are rarely used words, characters that have to be selected from several characters represented by same codes are rarely met during ordinary inputting. Therefore, the present invention is not only easy to learn, but also can realize blind-typing with very high speed. | The present invention relates to a method and a keyboard for inputting Chinese characters, which can input both simplified Chinese characters and their original complex forms.
The invention defines 25 double strokes of the kind and 25-28 auxiliary roots containing the double strokes as codes for inputting Chinese characters, further, the invention also defines 25 common use words. Three methods for inputting Chinese characters will be disclosed in the invention. In the input method of which 4 simple shape codes will be used for the coding, a word that can be leaved each other may be broken down into 2 blocks and then 2 codes respective of the first and last double strokes or roots containing the double strokes of each block will be taken into the coding. The inputting methods of the invention are simple and easy for studying. | 6 |
TECHNICAL FIELD OF THE INVENTION
The present invention pertains in general to the fabrication of MOS transistors and, more particularly, to the fabrication of a MOS current source utilizing trenching techniques.
BACKGROUND OF THE INVENTION
As integrated circuit technology advances, demands for increased packing density, low power dissipation per square centimeter and compatibility between the various technologies increases. High packing density, usually obtained through device shrinkage, requires highly sophisticated processing techniques such as E-beam lithography, reactive ion etching, transient annealing, etc. However, in addition to these techniques, additional techniques are necessary to further reduce size, thereby reducing the required silicon overhead.
One type of device widely utilized in MOSFET circuits is a current source. The current source is conventionally fabricated by either connecting the gate of a transistor to the source thereof or the gate to the drain thereof. This results in a two terminal device. In conventional layout design, this element, although requiring only two terminals, consumes the same area as a three terminal transistor in addition to the area required to connect the gate to the doped drain or source. In conventional fabrication of the current source, buried source and drain regions are disposed on either side of a channel region which is covered by the gate. A polycrystalline silicon layer is then wrapped around from the gate to either the source or the drain. Therefore, a current source is merely a modification of the three terminal device with no savings in silicon overhead.
In view of the above disadvantages with present layout techniques for current sources, there exists a need for improved methods for fabricating a current source to minimize the silicon overhead.
SUMMARY OF THE INVENTION
The present invention disclosed herein comprises a method for forming a semiconductor current source. A first buried region is formed by doping a silicon substrate of a first conductivity type with a dopant of a second conductivity type. A trench is then formed in the first buried region by anisotropically etching the silicon substrate to a predetermined depth below the first buried region. A gate oxide layer is formed on the sidewalls of the trench and then a second buried region is defined at the bottom of the trench by ion implanting a dopant of the second conductivity type therein. A layer of polycrystalline silicon is then conformally deposited over the substrate to cover the sidewalls and the bottom of the trench such that the trench is filled. The polycrystalline silicon layer is then patterned and etched to define a first terminal for the current source. A metallic contact is then formed to the first buried region to form a second terminal for the current source. A channel region is defined between the first buried region and the second buried region in the silicon substrate adjacent the sidewalls of the trench.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying Drawings, in which:
FIGS. 1a, 1b and 1c illustrate a prior art current source and the conventional layout topology thereof;
FIG. 2 illustrates a cross-sectional view of the initial step of fabrication of the silicon substrate to define the moat area and form a buried n++ region;
FIG. 3 illustrates a cross-sectional view of the silicon substrate with the trench defined therein and a buried n+ region positioned at the bottom thereof;
FIG. 4 illustrates a cross-sectional view of the silicon substrate with a gate oxide and a layer of polysilicon formed in the trench;
FIG. 5 illustrates a cross-sectional view of the silicon substrate with the polysilicon layer and oxide layer etched away to expose the n+ region in the bottom of the trench;
FIG. 6 illustrates a cross-sectional view of the silicon substrate with polysilicon deposited in the trench;
FIG. 7 illustrates a cross-sectional view of the silicon substrate with the gate to source (drain) contact formed with the final metallization step forming the contact with the drain (source) region; and
FIG. 8 illustrates a planar view of the layout topology for the current source of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1a, there is illustrated a schematic diagram of a current source 10. The current source 10 is comprised of a depletion mode transistor having a drain, a gate and a source. The gate is connected to the source to form a two-terminal circuit element. alternatively, as shown in FIG. 1b, a current source 11 is formed with an enhancement mode transistor having the gate connected to the drain. FIG. 1c illustrates the prior art layout topology. In the layout, an n++ buried region 12 is patterned and implanted to define the source (drain) and an n++ buried region 14 is patterned and implanted to define the drain (source). The regions 12 and 14 are connected to n+ source/drain regions 17 and 19 separated by a gate 18 formed from polycrystalline silicon (poly) disposed thereover. A channel region underlies the gate 18. A contact 20 is made to the source (drain) region 12 and connected to gate 18 through a poly run 22 to form the gate-to-source (gate-to-drain) connection. A contact 24 is made to the drain (source) region 14 and interconnected with a metal run 26. For a process utilizing one micron minimum feature size and one-quarter micron alignment tolerance, the topology of FIG. 1b lays out 6.5 microns on one side and 4.5 microns on the other side.
Referring now to FIG. 2, there is illustrated a cross-sectional diagram of the initial step in the fabrication process of the trench based current source of the present invention. In the preferred embodiment, NMOS technology is utilized. In conventional fabrication of MOSFETs, a thin wafer of semiconductor material of one type conductivity, such as that identified by reference numeral 28 is first masked by a stack of oxide and nitride. The nitride is then removed in a pattern to expose only those areas where field oxide is to be formed. The substrate 28 is then subjected to oxidation in steam with an ambient temperature of approximately 900° C. A surface insulating layer 30, referred to as a field oxide of silicon, results from oxide growth and diffusion steps in the process, thus creating a layer of sufficient thickness so that later, when the thin layers of metalizations are applied, any electric fields developed in normal operation of the devices are insufficient to adversely affect operation of the portion of the semiconductor element, other than those where the insulating layer is intentionally thin.
After forming the field oxide layer 30, a buried n++ region 32 is formed in the moat area. The n++ region 32 is formed by implanted arsenic therein followed by a subsequent annealing step. The arsenic is implanted to a level of 5×10 +15 /cm 2 to result in a doped region with a thickness of approximately 0.5 microns.
After forming the buried n++ region 32, a layer of oxide 34 is deposited on the substrate, as illustrated in FIG. 3. The surface of the substrate is then patterned and a trench 36 formed through the oxide layer 34 and the buried n++ region 32 with an anisotropic etching procedure. This procedure essentially uses reactive ion etching in HCl. The trench 36 is formed to a depth of approximately 2 microns with a width of approximately 1 micron such that the bottom of the trench 36 is below the buried n++ region 32. A buried n+ region 38 is then implanted in the bottom of the trench utilizing arsenic with a dose of approximately 5×10 +14 /cm 2 . As will be described hereinbelow, that portion of the silicon substrate 28 adjacent the sidewalls of the trench 36 and between the n++ region 32 and the bottom of the trench 36 comprises the channel region of the current source.
A dummy gate oxide is grown on the inner surfaces of the trench 36 followed by a wet etch to remove the dummy gate oxidation. This essentially cleans the surfaces of the trench 36.
A layer of gate oxide 40 is grown on the exposed silicon surfaces of the trench 36. The gate oxide layer 40 is grown by disposing the wafer in an oxygen environment at a temperature of approximately 900° C. for sixty minutes. This results in a thickness of silicon dioxide (SiO 2 ) of approximately 300 Å on all exposed silicon surfaces.
After formation of the gate oxide layer 40, a layer of n+ doped polysilicon 42 is deposited to a thickness of approximately 1000 Å, as illustrated in FIG. 4. The poly layer 42 is a conformal layer and is deposited with an in situ dopant process utilizing either arsene gas or phosphene gas as the dopant material. The purpose of the layer 42 is to protect the gate oxide layer 40 from degradation as a result of further processing steps. As a result of the formation of the gate oxide layer 40, the n+ source region 38 diffuses deeper into the substrate and extends laterally outward.
After formation of the gate oxide layer 40 and the polysilicon layer 42, the wafer is subjected to an anisotropic plasma etch which s a directional etching process. With this process, the portion of the poly layer 42 overlying the oxide layer 34 and the portion of the poly layer 42 overlying the n+ region 38 are removed, as illustrated in FIG. 5. This plasma etching utilizes an HCl-HBr plasma etch.
After exposing the surface of the n+ region 38, a layer 46 of in situ doped poly is then deposited by LPCVD techniques to a thickness of approximately 0.5 microns. This is a conformal coating such that the poly layers 42 on the sidewalls of the trench 36 are coated and the trench 36 is filled. The poly layer 46 comes into direct contact with the n+ region 38 and forms both the contact with the n+ region 38 and also forms the gate in conjunction with the poly layer 42. Therefore, the gate and source (drain) are connected together in this configuration.
Although the thickness of the poly layer does not have to completely fill the trench 36, it is desirable to do so to ensure that no gap is present where the portions of the poly layer 46 extend outward from the poly layers 42 to form a "crease" 48. This crease 48 is closed. If not, subsequent processes utilizing techniques such as spin-on resist would not allow the substrate surface to be adequately cleaned.
The channel region for the transistor illustrated in FIGS. 2-6 is directly adjacent the gate oxide 40 between the region 38 and the region 32. As can be seen from FIG. 6, this channel region extends all the way around the sidewalls of the trench 36. This results in a relatively "wide" device wherein the width to length ratio of the transistor has been increased. Conventionally, as device dimensions decrease, the channel regions also decrease, resulting in "narrow" transistors. This usually involves some significant performance tradeoffs. With the process of the present invention, the channel width can be maintained for a relatively compact device since it is determined by periphery of the trench 36.
After deposition of the poly layer 46, the poly layer 46 is patterned and then etched to define a poly run 49. Thereafter, another conformal layer of LPCVD oxide is deposited on the substrate to a thickness of approximately 4500 Å. This layer is then subjected to an anisotropic etch to clear the oxide from flat surfaces. This etch leaves a sidewall oxide 50 adjacent the exposed edges of the poly run 49. The purposes of the sidewall oxide is to seal the edges of the poly run 48 for a subsequent siliciding process.
After formation of the sidewall oxide 50, titanium is then sputtered on the surface of the device in a vacuum apparatus to a thickness of approximately 900 Angstroms. The titanium is then reacted at a temperature of approximately 675° C. in an inert atmosphere such as hydrogen, argon or a vacuum for thirty minutes. This reaction allows the titanium to consume silicon or polysilicon only where it is in contact therewith to form titanium di-silicide. This results in a thickness of titanium di-silicide of approximately 1500 Å. The substrate is then etched in an acid solution to remove the titanium without affecting the titanium di-silicide. For example, a suitable etching in the case of titanium is a wet etch comprising a solution of H 2 SO 4 and H 2 O 2 . Since titanium only reacts with silicon, all areas which are covered by oxide have the titanium removed therefrom. The substrate is then annealed for thirty minutes at approximately 800° C. to stabilize and further lower the resistivity of the titanium di-silicide. Titanium di-silicide increases the conductivity of all silicon areas over which it was formed and constitutes a self-aligned process. This results in a silicide layer 52 over the poly run 49. The titanium di-silicide process is described in U.S. Pat. No. 4,545,116, assigned to Texas Instruments Incorporated.
After formation of the silicide, the substrate is covered by a layer of oxide 54 and then a contact area 56 is formed therein to the n++ region 32. A metal contact 58, such as aluminum, is then formed in the contact area 56 by conventional process.
Referring now to FIG. 8, there is illustrated a planar view of the topological layout for the current source of the present invention. Although the region 32 is illustrated as extending beyond the meCtal contact 58 and the poly run 49, in the preferred embodiment it is not necessary to extend this n++ region to that extent. It is only necessary that it extends around the trench 36 and to a point in contact with the contact area 56. Therefore, the n++ drain region 32 has the peripheral edges thereof aligned with the peripheral edges of the metal contact 58 and the poly run 49. This topology results in a configuration which is 4.25 microns on one side and 2.5 microns on the other side. This is a reduction of 2.25 microns on one side and 2.0 microns on the other side over the prior art device when considering one micron definition, giving about a factor of three density improvement.
In summary, there has been provided a trench based current source wherein a trench is formed in and extends through an n++ drain (source) region. A source region is formed at the bottom of the trench with a gate oxide formed around the sidewalls of the trench. Metalization is then formed in the trench to both form the gate and the contact with the buried n+ region. This forms a vertical gate which does not take up any silicon overhead for defining the channel region which is also vertical.
Although the preferred embodiment has been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | A current source MOSFET is fabricated by forming a trench (36) in an n++ drain (source) region (32) and extending below the trench (36). A gate oxide layer (40) is disposed on the sidewalls of the trench (36) and a conductive region (38) formed in the bottom of the trench (36). A gate-to-source (gate-to-drain) contact (49) is then formed in the trench (36) and then a drain (source) contact (58) formed. The vertical gate structure defines a vertical channel region on all sides of the trench (36) to allow a wider devive to be fabricated in a smaller overall silicon area. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to devices and processes of making and using devices for cell culture. In particular, the present invention relates to devices and processes of making and using devices for growth or maintenance of eukaryotic cells.
BACKGROUND
[0002] Artificial organs, which are devices made entirely of non-biological materials, have greatly advanced health care. Artificial organs and tissue substitutes, including kidney dialysis machines, mechanical respirators, cardiac pacemakers, and mechanical heart pumps have sustained many people with desperate life-threatening diseases. The utility of such artificial organs is reflected in their widespread use.
[0003] Bioartificial organs are artificial organs designed to contain and sustain a viable biological component. Many biological functions are even more complex than simply generating a voltage potential at regular intervals, as occurs in the simplest of pacemakers. Examples include biosynthesis of blood components and catabolic processing of deleterious agents. The liver, endocrine glands, bone marrow, and kidney are prominent in such specialized biochemical functions. Artificial organs without a biological component cannot reproduce the complex biochemical functions executed by these organs.
[0004] The artificial kidney, sometimes termed the kidney dialysis machine, for example, serve admirably as substitutes for their biological analogs. Kidney dialysis machines illustrate both the benefits and shortcomings of purely artificial organs. Kidney dialysis machines effectively remove urea, creatinine, water, and excess salts from the blood, thus partly fulfilling major roles of the natural kidney. Artificial kidneys have postponed deaths of patients in renal failure. However, kidney dialysis machines are insufficiently selective and inappropriately remove biological components, such as steroid hormones, that a functioning natural kidney does not. Consequently, dialysis over an extended period may result in bone loss, clotting irregularities, immunodeficiencies, and sterility. Thus, considering the artificial kidney as a model, the capacity of artificial organs to mimic biologic functions is limited and may result in adverse implications for the patient under treatment.
[0005] Liver failure is classified into several major types, including acute liver failure, chronic liver disease, and multiorgan failure. The main etiologies of liver failure are viral hepatitis and hepatotoxicity induced by drugs and toxins. Advanced liver failure results in encephalopathy and coma, and may be fatal. Treatment focuses on stabilizing the patient until spontaneous recovery of liver function, or until liver transplantation. In the aggregate, the annual mortality attributable to liver failure exceeds 27,000 annually in the United States.
[0006] A patient in hepatic failure, unlike a patient in renal failure, cannot be specifically treated because there is no hepatic equivalent to renal dialysis. Currently, the only available treatment for refractory liver failure is hepatic transplantation. Many patients in hepatic failure do not qualify for transplantation because of concomitant infection, or other organ failure. Because of organ shortages and long waiting lists, even those who qualify for liver transplantation often die while awaiting an allograft. UCLA reported that one quarter of their transplant candidates died before a liver could be obtained. Organs suitable for transplant in the pediatric age group are even more scarce (Busuttil, R. W. et al. Ann Surg 1987, 206, 387).
[0007] The natural liver has four major classes of biochemical functions. First, the liver biosynthesizes a wide range of proteins, including major acellular components of blood, such as serum albumin, alpha-anti-trypsin, alpha-macroglobulin, enzymes, clotting factors, carrier molecules for trace elements, and the apo-lipoproteins. The liver then releases these components to the blood circulation. The liver also maintains appropriate plasma concentrations of amino and fatty acids. Second, the liver has a major role in detoxification reactions. The liver oxidizes or conjugates many harmful external poisons, processes that usually, but not always, diminish the poisonous character of the toxins. The liver also destroys excess hemoglobin, metabolizes the porphyrin molecules of hemoglobin, and recycles the iron component. Third, waste products, such as bilirubin, are conjugated and excreted via the biliary tree. Fourth, the liver synthesizes and secretes the bile salts, which serve as detergents that promote the emulsification and digestion of lipids. The multiplicity and biochemical character of liver function vastly increase the complexity of extracorporeal hepatic support.
[0008] Historically, non-biologic artificial liver substitutes have depended on hemodialysis and hemoperfusion, but have been of very short-term and highly limited benefit (Abe, T. et al., Therapeutic Apheresis 2000, 4:26). In contrast to purely artificial organs, an effective liver replacement must have a biological component. The liver is the most massive organ in the human body, exclusive of distributed organs such as skin, gut, hematopoietic system, and vasculature. Sustaining a large mass of functioning liver cells in vitro presents a variety of hurdles. At least eight major problems to developing a functional bioartificial liver can be described: 1) growing or obtaining appropriate and viable cells; 2) providing for a critical minimum mass of cells; 3) supplying oxygen to the cells; 4) supplying nutrients to the cells, and removing cell waste products efficiently; 5) limiting shear forces and hydrostatic pressures, 6) inducing or sustaining a differentiated cell phenotype with the capacity for biosynthesis and biotransformation of toxins; 7) maintaining sterility; and 8) preventing liver tissue rejection or lysis by complement.
[0009] 1) Growing or obtaining appropriate and viable cells. Liver cells for potential use in bioartificial livers can be established cell lines, primary isolates from human or animal livers, or primordial liver cells however, secretion of tumorigenic factors is negatively affecting FDA approval of BAL designs incorporating cell lines (Xu, A. S. L. et al., 2000 in Lineage Biology and Liver, Lanza, R. P., Langer R., and Vacanti, J. (Ed.), Academic Press, San Diego, pp. 559-597). Cell lines of liver are available, for example HepG2 and C3A, that express many functions of differentiated liver. Cell lines offer the potential of growing sufficient numbers of cells in an extracorporeal mass cell culture system, or bioreactor, for sustaining a patient because the growth of cell lines is not limited by cell senescence, but by nutrient availability. Primary human or animal liver cells can also be obtained in the numbers required for a functional bioartificial liver. However, the use of human liver for cell preparation is limited by its lack of availability, and the use of animal liver for cell preparation suffers from some degree of cellular incompatibility. Acute cellular incompatibility results from the binding of antibodies that recognize foreign cells followed by the binding of proteins of the complement system and lysis of the foreign cells. Longer-term cellular incompatibility mechanisms also exist, but should not present any problems for the use of bioreactors as interim or “bridge” medical products. A possible alternative to initial inoculation with a large mass of differentiated cells is the expansion of liver stem cells that are progenitors of mature liver cells. Recent reports suggest that liver progenitor cells go through multiple cell divisions on the path toward maturation and differentiation (Brill, S. et al., Differentiation 1995, 59, 95; Sigal S. H. et al., Differentiation 1995, 59, 35). Suitable control of the growth and differentiation processes with staged application of appropriate cytokines can permit preparation of a clinically useful quantity of cells.
[0010] 2) Providing for a critical minimum mass of cells. The adult human liver has a mass of about 1400-1600 grams, and features a considerable reserve, or redundant, capacity. It is estimated that human survival can be sustained with about 15-20% of the total liver mass. The figure of 20% of the liver mass corresponds to about 5×10 10 cells (Kasai et al. Artif Organs 1994, 18, 348). Most, if not all, previous bioartificial liver designs suffer from a woefully inadequate cell capacity. That is, such devices are capable of sustaining far fewer than 5×10 10 cells, often orders of magnitude fewer cells. Without the cell mass critical for biosynthesis of plasma components and detoxification reactions, these other designs have little clinical utility.
[0011] 3) Supplying oxygen to the cells. The functional units of most organs such as nephron, acinus, alveoli, microvilli, skin, etc. consists of a capillary bed across which is a physico-chemical gradient. These gradients are controlled by mass transfer effects. Oxygen is the primary nutrient that is limiting in cell cultures (Macdonald, J. M. et al. NMR Biomed 1998, 11, 1; Glacken M. W. et al. Ann NY Acad Sci 1983, 413, 355). ‘Integral’ oxygenation, or aeration inside the bioreactor containing the biological or chemical material of interest, greatly enhances mass transfer of oxygen and carbonic acid. The formation of the latter can be used to control pH.
[0012] Oxygen is generally the limiting nutrient in hollow fiber bioartificial livers (Catapano, G. et al. Int J Art Organs 1996, 19, 61) primarily because hepatocytes are highly aerobic cells which causes problems of oxygen mass transfer. Oxygen has a relatively high diffusion coefficient and its mass transfer from blood in the liver sinusoids to hepatocytes is dominated by diffusion rather than convection (i.e., convection and perfusion are caused by pressure gradients). These effects are because an oxygen molecule is much smaller than other nutrients such as a glucose molecule, or than biosynthetic products such as proteins, and because the hepatocytes generate steep concentration gradients in bioartifical livers. With known rates of oxygen diffusion and oxygen consumption, and reasonable estimates of cell density, the diffusion distance at which oxygen utilization becomes the rate-limiting factor for growth is approximately 200 μm (Macdonald, J. M. et al., 1999, in Cell Encapsulation Technology and Therapeutics, Kuhtreiber, W., Lanza, R. P. and Chick, W. L. (Eds.) Birkhauser Boston, Cambridge, pp. 252-286. In bioartificial livers with serial oxygenation aerated with air, oxygen becomes axially limiting in perfusion media by 25 mm (Macdonald et al., 1999, supra).
[0013] Hepatocytes have a high metabolic rate and require a continuous oxygen supply. The oxygen consumption rate ranges from 0.59 to 0.7 nmole/s/10 6 cells for HepG2 cells (Smith, M. D. et al Int J Artif Organs 1996, 19, 36) and is 0.42 nmole/s/10 6 cells for isolated hepatocytes (Rotem, A. et al. Biotech Bioeng 1992, 40, 1286). Integral oxygenation, that is, continuous supply of oxygen along the path of media supply to the cells, is essential to supplying oxygen to liver cells. Serial oxygenation, which is oxygenation at one or a few places in the fluid line of media supply cannot sustain the mass of liver cells needed for an effective bioartificial liver. A difficulty with serial oxygenation is that the solubility of oxygen in aqueous media unsupplemented with oxygen carriers is so low that any oxygen present is quickly depleted by cell metabolism. In fact, in longitudinal flow along a conventional bioreactor semipermeable membrane, hepatocytes deplete oxygen within 2.5 centimeters along the path and therefore convective oxygen mass transfer via increasing Starling flow is improved. Increasing flow rates through conventional bioreactors can cause fiber breeches and adversely affect hepatocyte function (Callies, R. et al., Bio/Technology 1994 12:75). Thus, bioartificial liver designs that do not provide for adequate oxygen delivery are able to support only a limited number of cells. In addition, the flux of oxygen in a diffusion-limited system constrains cells to grow very near (less than about 0.2 mm) to the supply of oxygen. For example, U.S. Pat. No. 5,622,857 to Goffe discloses a bioreactor with some coaxial and some parallel semi-permeable hollow fibers. The Goffe design allows integral oxygenation but does not constrain the thickness of the cell compartment. The fiber-to-fiber spacing in that design is 3-5 mm so that there is not strict control of the oxygen diffusion distance. Similarly, U.S. Pat. No. 5,183,566 to Darnell et al. discloses a bioreactor with bundles of hollow fibers in parallel. The Darnell et al. design does not permit a multitude of individual multi-coaxial fiber bundles to be built-up with accurate and reproducible diffusion distances, and the design is not easily scaled-up. The Darnell et al. design uses bundles of parallel fibers, again not effectively addressing the issue of oxygen diffusion.
[0014] 4. Supplying nutrients to the cells, and removing cell waste products efficiently. The issue of supplying nutrients such as carbohydrates, lipids, minerals, and vitamins has been successfully solved by several variants of hollow fiber technology, and these features must be successfully incorporated into any viable bioartificial liver or bioartificial organ design. Similarly, the issue of removing metabolic wastes is usually handled by the same system that supplies the nutrients. The consumption rates for glutamate, pyruvate, and glucose are typically in the range of 0.03 to 0.3 nmol/s/10 6 cells, with reasonable assumptions for cell density and growth rate (Cremmer, T. et al. J Cell Physiol 1981, 106, 99; Imamura, T. et al. Anal Biochem 1982, 124, 353; Glacken, M. Dissertation 1987). The diffusion rates of oxygen in tissue are similar to those of pyruvate in water, and higher than those of glucose. As these consumption rates are less than the oxygen consumption rate, oxygen is the limiting nutrient in most conditions.
[0015] 5. Limiting shearforces and hydrostatic pressure. For a given bioreactor there is an optimum balance of convection and diffusion for adequate oxygen mass transfer without creation of severe oxygen gradients. For example, using a nontoxic oxygen range, <0.4 mM (solubility constant is 1.06 mM/atm, for air solubility is 0.2 mM at 37° C.), the convective component of oxygen mass transfer should be increased as cells are increasingly farther than 0.2 mm from supply of oxygen (Macdonald et al., 1999, supra.). Although the partial oxygen tension in the liver sinusoid is about 70 mm Hg near the portal triad dropping to 20 mm Hg near the central vein, which equates to a range of 0.096 to 0.027 mM of free oxygen, the hemoglobin-bound oxygen ranges from 6.26 to 2.91 mM. The velocity of blood flow in the liver sinusoid is about 0.02 cm/s while the oxygen diffusion coefficient is about 4 orders-of-magnitude less, or 2×10 −6 cm 2 /s. However, hepatic function is adversely affected with increasing shear forces, and in vivo hepatocytes are protected by a layer of endothelia and extracellular matrix in the space of Disse. Sufficient shear forces will kill hepatocytes. Others have found that shear forces induce specific cytochrome P450's (Mufti N. A. and Shuler, M. L., Biotechnol. Prog., 1995, 11, 659). A recent study has shown that liver regenerates faster with 90% than with 70% hepatectomy and this was attributed to greater shear forces (Sato, Y. et al., Surg. Today, 1997, 27, 518). However, this faster regeneration could also be due to enhanced oxygen, nutrient, and agonist mass transfer. Therefore, there is some maximum level of shear force that hepatocytes can sustain while still displaying optimal function. This maximum level can be increased if a layer of endothelia protects hepatocytes.
[0016] To increase convection, hydrostatic pressure gradients are increased. Elevated hydrostatic pressures can implode hepatocytes. Therefore, it is important to stay below these pressures. It is possible to cause 100% mortality of isolated rat hepatocytes by generating hydrostatic pressures of greater than 7 psi (>300 mm Hg) for longer than 2 minutes while inoculating these cells into coaxial bioreactor using a syringe.
[0017] 6) Inducing or sustaining a differentiated cell phenotype with the capacity for biosynthesis and biotransformation of toxins. The use of the differentiated phenotype of liver cells is necessary to produce a useful bioartificial liver because the specialized functions of the liver, including biosynthesis of blood components and detoxification of toxins, are associated with the differentiated phenotype. These specialized functions are lost in whole, or in part, as the cells dedifferentiate, which often happens in isolated primary cell culture. In contrast, the form of liver cells capable of rapid growth is the dedifferentiated phenotype, leaving the practitioner to balance two opposing needs (Enat, R. et al. Proc Natl Acad Sci USA, 1984, 81, 1411). Some reports suggest that the phenotype of liver cells may be modulated by the presence of cytokines and extracellular matrix components. In particular, the extracellular matrix components rich in collagen IV and laminin, produced by the Engelbrech-Holm Sarcoma (EHS) cells and available commercially as MATRIGEL™, when used with hormonally defined media induces a differentiated phenotype (Enat, R. et al., supra; Bissell, D. M. Scan J Gasterenterol-Suppl 1988, 151, 1; Brill, S. et al. Proc Soc Exp Biol Med 1993, 204, 261 ).
[0018] 7) Maintaining sterility. The implementation of facile sterilization procedures for bioreactors and associated components is essential for clinical utility of extracorporeal bioartificial organs. Fortunately, the procedures for sterilization are well established, including standard methods both for sterilization of extracorporeal devices and for maintaining asepsis by standard in-line filters.
[0019] 8) Preventing liver tissue rejection or lysis by complement. Rejection of foreign tissue can occur by a rapid process known as complement-mediated lysis that involves binding of circulating antibodies to the foreign cell surface, attachment of the proteins of the complement system, and lysis of the offending cell. The cell-mediated immune system is responsible for delayed rejection reactions. However, the cell-mediated immune system should not play a major role in bioreactor systems that do not permit direct contact of host and donor cells. Foreign body reactions, for example, against the structural components of bioreactors, are also cell-mediated and should therefore not constitute substantial obstacles.
[0020] Examples of current bioreactors used for expansion and/or maintenance of cells include those that make use of hollow fiber bioreactors, flatbed bioreactors, flatbed microchannel bioreactors, and roller bottles.
[0021] Hollow fiber bioreactors incorporate hollow fibers that are extruded hollow tubes and prepared from polypropylene, polysulfone, polyamide, regenerated cellulose, and other extrudable polymers. These hollow fibers do not have adequate permeability to allow long-term survival and functioning of cells in the bioreactor.
[0022] Flatbed bioreactors use impervious, rigid surfaces such as glass or culture plastic as a surface for cells. The mass transfer of nutrients is achieved by flow of the media directly across the cells. These bioreactors are unable to achieve the requisite mass of cells needed for clinical use or for some tissue-specific functions. Moreover, the rigid and impervious surfaces used block requisite three-dimensional shape changes essential for cells to express tissue-specific functions.
[0023] Flatbed microchannel bioreactors use cells sandwiched in extracellular matrix and between two plates of rigid, impervious surfaces such as glass or culture plastic. These bioreactors are incapable of achieving the requisite mass needed for clinically useful bioreactors and are difficult to use for most experimental studies.
[0024] Roller bottles consist of glass or plastic bottles in which cells are expanded and/or maintained on the inner surface of the bottles. The cells are grown as monolayers on the surface of the bottles making the achieving of high density cell populations dependent upon the surface area of the inner surface of the bottles. Also, the cells are blocked in achieving three dimensional shapes requisite for optimal expression of tissue-specific functions.
[0025] It would be desirable to enable the cells to expand to high densities or be inoculated in the bioreactors at high densities to yield very high density, three-dimensional cultures and yet be able to survive long-term (weeks to months theoretically) by providing the supply lines, the hollow fibrous structures, with the needed permeability for mass transfer of nutrients, gases, and wastes. To this end, Applicants disclose herein a use of optimized medical textile products.
[0026] From the first appearance more that 4000 years ago to their present use in products ranging from gowns and wound dressings to arterial and skin grafts, fibers and fabrics have been explored as potential materials for applications in medicine and surgery. This continuing interest has its basis in the unique properties of fibers—which in many respects resemble biological materials—and in their ability to be converted into a wide array of desired end products.
[0027] Medical textile products are based on fabrics of which there are four types: woven, knitted, braided, and nonwoven. The first three of these are made from yarns, whereas the fourth can be generated directly from fibers, or even polymers. There is, therefore, a hierarchy of structure. The performance of the final textile product is affected by the properties of the polymer whose contribution in the final product is modified by the structure at two to four different levels of organization.
[0028] Textile medical products are made from biocompatible polymers. Biocompatibility, or the reactivity of body tissues and fluids when in contact with polymeric structures, is governed both by chemical and physical characteristics of polymers (See for example, Gupta, “Medical Textile Structures: An Overview,” Medical Plastics and Biomaterials, 5 (1): 16-30 (1998) incorporated herein by reference in its entirety). Absorbable materials (e.g. polyglactin, polyglycolic acid, polyglyconate) typically excite greater tissue reaction whereas semiabsorbable materials (e.g. cotton, silk) cause less reaction. Non-absorbable materials (e.g. polyester, nylon, polypropylene, polytetraflouroethylene, polyurethane) tend to be inert and relatively the most biocompatible. Polymers are extruded to make monofilament fibers, which are converted to yarns by twisting or entangling processes that improve strength, abrasion resistance, and handling. Nonwoven fabrics are made directly from fibers or polymers, creating high bulk absorbent and usually isotropic fabrics. These are used in numerous medical applications (wipes, sponges, dressings, gowns) and, with proper polymer base, as biodegradable scaffolds in tissue engineering of liver implants (see for example, Mooney, et al, “Long-term Engraftment of Hepatocytes Transplanted on Biodegradable Polymer Sponges,” J. Biomed. Mater. Re., 37: 413-420 (1997) incorporated herein by reference in its entirety). Weaving, knitting, or braiding of yarns make highly organized anisotropic fabrics that are suited for many implants.
[0029] Fabrics that are woven are usually dimensionally highly stable but less extensible and porous than are the knitted or the braided structures. One disadvantage of wovens is their tendency to unravel at the edges when cut squarely or obliquely for implantation. However, the stitching technique known as a Leno weave—in which two warp threads twist around a weft—can be used that substantially alleviates this fraying or unraveling problem (See for example, Kapadia et al., “Woven Vascular Grafts.” U.S. Pat. No. 4,816,028 (1989) incorporated herein by reference in its entirety). The primary problems with knits are that they are dimensionally unstable and their porosity is difficult to control and engineer. Braiding technology can be used to produce a flat or a cylindrical structure; however, it does not easily lend to producing a stable hollow tube. Some of the current research in the biomedical field is focused on the use of absorbable and elastomeric yarns or fibers into woven materials, and the use of coatings such as albumin (See for example, Mehri, et. al., “Cellular Reactions to Polyester Arterial Prostheses Impregnated with Cross-Linked Albumin: In Vivo studies in Mice,” Biomat. 10(1): 56-58 (1989)), gelatin (Bordenave et al., 1989), and collagen (Frey, et al., “Prosthetic Implants,” U.S. Pat. No. 5,176,708 (1993) each incorporated herein by reference in its respective entirety).
[0030] The ideal artificial vasculature is one that is biocompatible, has the desired porosity and the required mechanical patency (i.e., the ability to resist permanent change in physical size, shape, structure, and properties).
[0031] Specifically, a bioreactor that permits cells to survive and function indefinitely is needed. Preferably this bioreactor enables cells to expand to high densities or be inoculated in the bioreactors at high densities to yield very high density, three-dimensional cultures and yet be able to survive long-term (weeks to months theoretically) by having the needed permeability for mass transfer of nutrients, gases, and wastes. Such a bioreactor is disclosed herein.
SUMMARY OF THE INVENTION
[0032] One aspect of the present invention is to provide varying embodiments of an apparatus which provides efficient oxygen delivery to large masses of cells in a bioreactor cell culture and transfer of beneficial biosynthetic cell products to the patient, and methods of use therefor, comprising multi-coaxial hollow fibrous structures assembled from woven textile fibers with a porosity that is governed by the weave design. Woven textile vasculature may be used to make hollow fibrous structures in hollow fiber bioreactors, as a cell surface for flatbed bioreactors, or in bags for three-dimensional culture systems for expanding and maintaining cells. The woven textile vasculature can be prepared from any fiber or combinations of fiber chemistries such as polyester, cotton (or other forms of cellulose), biodegradable fibers, etc. and with any weave design desired. The weave design and the chemistry of the fibers can be adjusted to provide the requisite permeability of the hollow fibrous structures for engineering of tissues.
[0033] A further aspect of the present invention is to provide an apparatus which permits cells to be contained in a thin annular space adjacent to continuously oxygenated and flowing nutrient medium that provides essential oxygen and nutrients and carries away metabolic products.
[0034] A further aspect of the present invention is to provide an apparatus for the collection of the biosynthetic products of large masses of cells in a bioreactor.
[0035] A further aspect of the present invention is to provide an apparatus to detoxify blood or plasma from a patient unable to remove or inactivate these toxins.
[0036] A further aspect of the present invention is to provide an apparatus to serve as a substitute liver.
[0037] A further aspect of the present invention is to provide varying embodiments of an apparatus which provides efficient oxygen delivery to large masses of cells in a bioreactor cell culture and transfer of beneficial biosynthetic cell products to the patient, and methods of use therefor.
[0038] A further aspect of the present invention is to provide vasculatures in the quality and the quantity ideally suited for the success of bioartifical livers.
[0039] A further aspect of the present invention is to provide bioreactors for use in academic and industrial research on cells.
[0040] A further aspect of the present invention is to provide a means for expansion of cells to high densities for use in biochemical/cell/molecular studies in research or clinical programs (e.g. cell therapies, gene therapies).
[0041] A further aspect of the present invention is to provide protein manufacturing in cells maintained in bioreactors.
[0042] A further aspect of the present invention is to provide organ assist devices (e.g. liver assist devices) to support patients with failing organs.
[0043] A further aspect of the present invention is to provide implantable tissues created ex vivo in woven tubes or woven bags prepared with biodegradable fiber chemistries.
[0044] A further aspect of the present invention is to provide vasculatures in a number of sizes and structures with properties ideally suited for maintaining and expanding cells in bioreactors.
[0045] A further aspect of the present invention is to provide biodegradable vasculatures in which a biodegradable polymeric fiber (such as polylactide) is used along with non-biodegradable material (such as polyester) in the proportion that sets the upper and lower limits of porosity and the transition from one to the other takes place at the desired rate.
[0046] A further aspect of the present invention is to provide elastomeric vasculatures that distend to the required amount in the transverse direction.
[0047] A further aspect of the present invention is to provide such structure for transport of fluid. A further aspect of the present invention is to provide grafts in size and properties suited for by-pass use which are compatible with the transverse elongations of body arteries; e.g. elongations of the level of 20-30%.
[0048] A further aspect of the present invention is to provide these characteristics through the use of elastomeric threads, or threads containing a blend of regular and elastomeric materials, as the weft yarns for construction of vasculatures.
[0049] The bioreactor of the present invention, when used as a bioartificial liver, has a modular design to allow an easy adjustment in liver functional capacity depending on the weight of the patient, whether that patient is child, man, or woman, and on the degree of remaining liver function in the patient. The bioreactor of the present invention further has both plasma and nutrient medium compartments to permit the biotransformation of toxins in the patient plasma and to enhance the effective transfer of biosynthetic products from the bioartificial liver to the patient. When used with liver or other cells, this invention is useful in the preparation of biosynthetic products for patients, in experimental use, and use as a supplemental biotransformation apparatus for detoxification of blood. The toxins in the blood can include, but are in no way limited to, metabolic wastes, products of cell or erythrocyte break-down, overdoses of ethical pharmacologic agents such as acetaminophen, and overdoses of illicit pharmacologic agents. Ease of manufacture of the invention enables cost-effective commercial development.
[0050] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
[0051] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0052] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0053] Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
[0054] These together with other aspects of the invention, along with the various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific aspects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] [0055]FIG. 1 illustrates woven vasculatures shown in flat and cylindrical forms.
[0056] [0056]FIG. 2 illustrates two means by which woven cylindrical tubes can be incorporated into the multicoaxial bioreactor, with the air chamber in the inner-most or outer-most compartments.
[0057] [0057]FIG. 3 illustrates the variables used in the implementation of Darcy's law.
[0058] [0058]FIG. 4 illustrates a liver lineage model.
[0059] [0059]FIG. 5 illustrates a multicoaxial bioreactor design.
[0060] [0060]FIG. 6 illustrates porous, biocompatible, biodegradable PLGA microcarriers for cells in bioreactors.
[0061] [0061]FIG. 7 illustrates physical analysis of the liver acinus.
[0062] [0062]FIG. 8 illustrates membrane fouling studies.
[0063] [0063]FIG. 9 illustrates the effect of no hemoglobin on oxygen mass transfer.
[0064] [0064]FIG. 10 illustrates a comparison of conventional with multicoaxial bioreactor.
[0065] [0065]FIG. 11 illustrates a hydrodynamic model.
[0066] [0066]FIG. 12 illustrates the use of MRI to determine axial flow.
[0067] [0067]FIG. 13 illustrates predicted pressure profile and optimum K 1 and K 2 .
[0068] [0068]FIG. 14 illustrates membrane fouling and its adverse effect on mass transfer.
[0069] [0069]FIG. 15 illustrates dead-end and cross flow configurations for the fouling study.
[0070] [0070]FIG. 16 illustrates results of dead-end and cross flow configurations for fouling study.
[0071] [0071]FIG. 17 illustrates results of dead-end and cross flow configurations for fouling study.
[0072] [0072]FIG. 18 illustrates fouling studies of woven vasculature incorporated into multicoaxial bioreactors.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0073] Annular space. The radial distance separating two adjacent vasculatures.
[0074] BAL. Bioartificial liver. Also, specific embodiments of the present invention: the scaled-up multi-coaxial vasculature bioreactor, the tight packed hollow vasculature bioreactor or the serially-linked bioreactor with a complement of liver cells, nutrient medium, and gases.
[0075] Bioreactor module. Coaxially-arranged semipermeable hollow vasculatures. One module forms the core of the multi-coaxial hollow vasculature bioreactor whereas the scaled-up multi-coaxial hollow vasculature bioreactor comprises many modules.
[0076] Biotransformation. The metabolic detoxification of blood or plasma by tissues or cells.
[0077] Fourth compartment. The compartment, if present, in a bioreactor embodiment that is bounded by the outside of the third hollow vasculature and the inside of the fourth, that is, adjacent, hollow vasculature, and is connected to two ports, the fourth compartment inlet port and the fourth compartment outlet port.
[0078] First compartment. The compartment in any of the bioreactor embodiments that is bounded in part by the inside of the first and innermost coaxial hollow vasculature and is connected to two ports, the first compartment inlet port and the first compartment outlet port.
[0079] Integral aeration. Exposure to a gas, typically air or oxygen with carbon dioxide, at almost all points along a flow path. Integral aeration is distinguished from serial aeration, in which a bubbler or gas exchange device is inserted at one point in the fluid circuit.
[0080] Manifold. A part of the bioreactor located at an end of the fibers and intended to physically separate compartments and split flow of fluids.
[0081] Microvasculature or microbore hollow fiber. A semipermeable hollow vasculature of 200 to 500 micrometer o.d.
[0082] Multi-coaxial hollow vasculature bioreactor. The bioreactor comprising three or more coaxially-arranged semi-permeable hollow vasculatures encased by a hollow housing.
[0083] Nutrient medium. The balanced electrolyte solutions enriched with sugars, trace minerals, vitamins, and growth enhancers. Each particular formulation is named by or for the formulator, sometimes with whimsical or non-illuminating designations. Nutrient media include, but are not limited to: RPMI 1640 (Roswell Park Memorial Institute, formulation #1640), Ham's F-12 (the twelfth formulation by Dr. Ham in his F series), DMEM (Dulbecco's modified Eagle's medium), and CMRL-1415 (Connaught Medical Research Laboratory formulation #1415). Nutrient media are routinely enhanced by addition of hormones, minerals, and factors known to those of ordinary skill in the art, including, but in no way limited to, insulin, selenium, transferrin, serum, and plasma.
[0084] One-sided multi-coaxial hollow vasculature bioreactor. The version of the multi-coaxial hollow vasculature bioreactor that has both inlet and outlet ports on the same end plate. This version is particularly adapted to NMR studies and to studies where access to all ports from one side is necessary.
[0085] Outermost compartment. The compartment in any of the bioreactors that is bounded by the outside of the outermost hollow vasculatures and the inside of the housing, and is connected to two ports, the outermost compartment inlet port and the outermost compartment outlet port.
[0086] Scaled-up multi-coaxial hollow vasculature bioreactor. The bioreactor comprising arrays of from about 20 modules to about 400 modules of coaxially-arranged semi-permeable hollow vasculatures, where the entire set of modules is encased by a hollow housing.
[0087] Second compartment. The compartment in a bioreactor embodiment that is bounded by the outside of the first and innermost coaxial hollow vasculature and the inside of the second, that is, adjacent, coaxial hollow vasculature, and is connected to two ports, the second compartment inlet port and the second compartment outlet port. In the one-sided multi-coaxial hollow vasculature bioreactor and in some dead-ended vasculature designs only one port provides access to the second compartment.
[0088] Serially-linked bioreactor. The system comprising a plurality of scaled-up multi-coaxial hollow vasculature bioreactors or of tight-packed hollow vasculature bioreactors, or a combination, in which two or more compartments are connected in a continuous and serial manner. In this context, each scaled-up bioreactor is referred to as a bioreactor subunit.
[0089] Third compartment. The compartment in any of the bioreactor embodiments that is bounded by the outside of the second hollow fiber and the inside of the third, that is, adjacent, coaxial hollow vasculature, and is connected to two ports, the third compartment inlet port and the third compartment outlet port.
[0090] Tight-packed hollow fiber bioreactor. The scaled-up bioreactor comprising arrays of from about 20 modules to about 400 modules of coaxially-arranged semi-permeable hollow vasculatures. Microvasculatures for aeration are arranged parallel and adjacent to the modules and the whole encased by a hollow housing.
[0091] Vasculatures. Vascular tubes made from woven fabric.
Vasculatures
[0092] Ideally, cells should be expanded and maintained in three-dimensional systems such as bioreactors. In a preferred embodiment, the cells behave as closely as is possible, to their behavior in the body. Although existing bioreactor designs have cell compartments in which cells can be three-dimensional, the bioreactor designs are flawed in how they supply nutrients and gases to the cells or how they manage cellular waste exchange or secretion of specialized cell products. The supply lines for the bioreactors make use of small, hollow tubes called hollow fibers that are prepared from a liquid that is pressed through sieves into an environment that yields a solid, hollow tube that can be made porous. The pore sizes are typically 0.1-0.7 microns. The pores in these hollow fibers quickly become clogged with material secreted by the cells when cells are placed in the bioreactor. The clogging results in an inability of the cells to survive and function in the bioreactors for very long. There is a loss of specialized function within 7 days for normal cells and a loss of viability within 21 days for normal cells and within 60 days for even highly malignant cancer cells. The invention disclosed herein permits the cells to survive and function indefinitely in the bioreactors. For a preferred embodiment of a bioreactor, see co-pending application Ser. No. 09/586,981 entitled “Bioreactor Design and Process for Engineering Tissue from Cells, with a priority filing date of Jun. 3, 1999, incorporated herein by reference in its entirety.
[0093] The present invention provides a means to grow healthy liver stem cell based tissues. These tissues can then be used as a bypass or an implant for patients with malfunctioning or failed livers. The use of vascular tubes constructed from fabrics, rather than the fibers obtained from extrusion technologies, provides the means for solving the membrane-fouling problem of Bioartifical Livers. Of the established vascular tubes, woven polyester materials are best because weaves as opposed to knits or braids can have their porosity easily modified and characterized, and polyester has sufficient mechanical patency due to its relatively high integrity and stability to most environments. FIG. 1 illustrates a preferred embodiment of woven vasculatures shown in flat and cylindrical forms. The general methods for the fabrication of such implants are set forth by Gupta et al., “Bio-mechanics of human carotid artery and design of novel hybrid textile compliant vascular grafts,” J. Biomed. Mat. Res. 34:341-349 (1997) and Mizelle et al., “Development of Biomechanically Compliant Arterial Grafts,” Proc. 15 th South. Biomed. Eng. Conf., IEEE, 110-113, (1996), each incorporated herein by reference in its respective entirety). Further, the use of vascular tubes made from woven fabrics that are composed of biodegradable materials or natural polymers results in a controlled increase in porosity and selective cell attachment focal points, respectively. The porosity can be modified by varying the spacing and the structure of the yarns in the weave, and the cylindrical shape and rigidity can be established by heat setting woven materials in the desired configuration under optimum conditions of temperature, pressure and residence time. In a preferred embodiment, the biodegradable material is extruded into fibers of high mechanical integrity and then used as a yarn for weaving into the desired vasculature.
[0094] Thus, bioreactors and cell compartments are set forth which make use of woven textile vasculatures. The woven textile vasculature is used as a hollow fibrous structure in hollow fiber bioreactors, as a cell surface for flatbed bioreactors, or as bags or tubes for three-dimensional culture systems, for use in expansion and maintenance of cells. The woven textile vasculature can be prepared from any fiber or combination of fiber chemistries such as polyester, polyolefin, cellulose, elastomer, biodegradable fibers, etc. and with any weave design desired. The weave design and the chemistry of the fibers can be adjusted to provide the requisite permeability/porosity of the hollow fibrous structures for engineering of tissues.
Bioreactor
[0095] The instant invention includes a modular multi-coaxial bioreactor, having in theory, no limit to the number of coaxial vasculatures. In a preferred embodiment a scaled-up multi-coaxial bioreactor comprises at least two sets of manifolds, at least three hollow vasculature sizes, at least two sets of endcaps, and a housing. This embodiment of the bioreactor contains at least four separated compartments. The modular design is composed of two sets of manifolds, with each pair of manifolds connected to each end of the vasculatures. There is a series of about 20 to about 400 holes coaxially arranged across the sets of manifolds and coaxially aligning the vasculatures. The manifolds optionally include flow distributors so that fluid and gas phase flow rates through the vasculatures are approximately uniform. The vasculature manifold assemblies are attached radially from the largest to the smallest diameter vasculatures, and axially from the smallest to the largest diameter vasculatures. Vasculatures with smaller diameter are inserted into vasculatures of larger diameter and the respective manifolds are sealed together.
[0096] The bioreactors of the current invention advantageously combine ‘integral’ oxygenation with defined diffusion distances, have ports to accommodate potential bile duct formation, and/or are easily scalable. Integral oxygenation permits efficient mass transfer of dissolved gases and control of pH. Defined diffusion distances permit predictable axial and radial physico-chemico-biological parameters such as shear forces, availability of nutrients, and pH. In use with patients, one or more of the at least four compartments can be used for patient blood plasma while another can be used to perfuse cells with integrally oxygenated media. Optionally, two or more bioreactor units are attachable in series so that toxins can perfuse out of plasma radially through the cell mass in one unit and infuse synthetic factors in the next unit. There is the potential for the biliary system to develop using the ports as the bile duct exit ports.
[0097] [0097]FIG. 2 illustrates two exemplary formats wherein woven cylindrical tubes are incorporated into the multicoaxial bioreactor. FIG. 2A illustrates the air chamber in the outermost compartment. FIG. 2B illustrates the air chamber in the inner-most compartment.
[0098] As shown, FIG. 2A illustrates a multi-coaxial fiber unit according to the instant invention comprising a plurality of compartments. Inner vasculature 202 provides intracapillary space or first compartment 204 for the receipt of standard media or plasma. Middle vasculature 206 provides annular space or first middle compartment 208 for the containment of cells such as liver cells. Outer vasculature 210 provides extracapillary space or second middle compartment 212 for the receipt of media. Housing 214 defines the outermost perimeter of the multi-coaxial fiber unit. Space or outermost compartment 216 between housing 214 and outer vasculature 210 allows for the receipt of a gas.
[0099] Similarly, in FIG. 2B inner vasculature 202 provides intracapillary space or first compartment 204 for the receipt of a gas. Middle vasculature 206 provides annular space or first middle compartment 208 for the containment of cells such as liver cells. Outer vasculature 210 provides extracapillary space or second middle compartment 212 for the receipt of media.
[0100] [0100]FIG. 2C illustrates a photographic view of an embodiment of the woven fabric incorporated into a multi-coaxial bioreactor, with air chamber in the outermost chamber, illustrating inner vasculature 202 , middle vasculature 206 , housing 214 , and aeration fiber 218 .
[0101] [0101]FIG. 2D illustrates openings leading to ports to allow for the movement of materials. Innermost port(s) 220 allow for the flow of media or plasma through the bioreactor. First middle port(s) 222 allow for the inoculation of cells into, or flow of cells through, the bioreactor. Second middle port(s) 224 allow for the flow of media through the bioreactor. Lastly, outermost port(s) 226 allow for the flow of gas through the bioreactor. Alternative uses of ports are also envisioned. For example, media can flow through port(s) 226 , cells into, or through, port(s) 224 , media or plasma through 222 , and oxygen or other gases through 220 .
Identification of Optimum Basic Vasculature for BAL Bioreactor
[0102] Property-structure correlation and hydraulic permeability-tissue growth study are used to identify the specifications that provide an ideal stable vasculature for bioartificial liver application(s) and the technological/structural settings that produce such vasculatures on a consistent basis. Several different polyester yarns, differing in linear density and number of filaments are used. Vasculatures of a number of different tightnesses are woven from each yarn. Vasculatures of two different diameters, for use as co-axial bioreactors, are woven. The heat setting conditions that yield the most stable vasculature configuration are identified. The tubes are characterized for porosity, hydrolic permeability, compressional resilience and pore size distribution. Porosity is determined through the use of a structural model relating to the LaPlace equation, which is based on the spacings between the yarns, the diameters of the yarns, and the geometry of the plain woven fabric. Hydrolic permeability is determined experimentally using Darcy's equation. (Darcy's Equation is a formula stating that the flow rate of water through a porous medium is proportional to the hydraulic gradient, and is defined further below.)
[0103] Compressional resilience is determined using an Instron tensiometer, equipped with a compression cell. Pore size distribution is determined using a liquid extrusion device and flat specimens having the same specifications as the tubular vasculatures.
[0104] Darcy's Equation permits one to estimate the correlation between pressure difference and radial flow given the hydraulic permeabilities of the material under consideration. The model assumes incompressible and Newtonian fluid, that the axial pressure gradient is negligible, and that the flow rate across the vasculatures is constant. Deriving this equation for two concentric hollow vasculatures the following relationship is obtained.
Δ P = Q 2 π L [ ln ( r b r a ) K 1 - ln ( r d r c ) K 2 ] ( II )
[0105] [0105]FIG. 3 defines the variables used in the equation. Q is radial flow rate from compartment 302 characterized by a hydrostatic pressure P 1 , through pores in fiber 304 characterized by hydraulic permeability K 1 , through intermediate compartment 306 , then through pores in second fiber 308 characterized by hydraulic permeability K 2 to compartment 310 characterized by hydrostatic pressure P 2 .
[0106] The values obtained relating to these variables and characterizations are correlated to provide a structure-property correlation model. Thus, data from the bioartificial liver bioreactor study disclosed herein provides a model for selecting optimum specifications for producing the vasculature for use in varying applications, without the need for experimental determinations. These applications include but are not limited to bioreactors, organ assist devices, implantable tissues, grafts, and the like.
Development of Next Generation Vasculatures for BAL Bioreactor Application
[0107] Here, biodegradable and transversely compliant vasculatures are developed. The optimum Basic Vasculature for Bioartificial Liver Bioreactor identified as described above, is used. Biodegradable fibers combined with nonbiodegradable fibers are used as warp and weft elements in construction of tubes. (Warp is the set of fibers that run along the length of the material and weft is the set of fibers that are inserted from the side and cover the width. Warp is wound on a beam and run threaded through a loom. Weft is inserted through warp by lifting and lowering alternative warp threads so that there is interlacing.) The rate at which these degrade and the tissue reaction they cause is examined using standard procedures. A polymer is selected and combined with polyester in novel ways for the construction of grafts. The amount of biodegradable fiber used relative to non-biodegradable provides the means for setting the initial and final limits of porosity for the vasculature.
[0108] A second variant is the development of vasculatures with an elastomer combined with polyester for use as weft yarn. The amount and type is varied in order to get different degrees of transverse stretchabilities and, thus, transverse compliances. The level of transverse compliance can be characterized on a specially equipped Instron tensiometer.
Optimization of Hydraulic Permeability and Flow Configuration
[0109] As disclosed herein, in a preferred embodiment, liver progenitors are expanded on biodegradable microcarriers in the space between the two coaxial fibers to generate the entire liver maturation lineage. Thus, the loading density of the progenitors per fiber pair must be minimized to optimize the number of bioartificial livers per human donor. This requires the resolution of two engineering problems. First, the optimum hydraulic permeability of the two coaxial vasculatures sandwiching the cell mass must be determined. Second, the optimum flow configuration to minimize or compensate for membrane fouling and corresponding decrease in hydraulic permeability with cell growth must be determined. In a preferred embodiment, the hydraulic permeability values of the two fibers are similar, such that a peristaltic type of flow configuration can be used to maintain clean nutrient and waste paths.
[0110] [0110]FIG. 4 illustrates a liver lineage model. In a preferred embodiment, progenitors or stem cells feed the lineage of the bioreactor in the same fashion as in the liver acinus. Thus an architecture is provided similar to that used in the liver acinus, wherein progenitors are used to seed the bioreactor and with the correct flow of blood, will result in maturation similar to that which occurs in the liver.
[0111] [0111]FIG. 5 illustrates a multicoaxial bioreactor design. Through the use of this design a preferred flow is achieved.
[0112] [0112]FIG. 6 illustrates porous, biocompatible, biodegradable polylactide glycolic acid (PLGA) microcarriers for cells in bioreactors. In a preferred embodiment, the progenitors referred to in FIG. 4, above, are seeded onto these PLGA microcarriers/beads.
[0113] [0113]FIG. 7 illustrates a physical analysis of the liver acinus, providing an illustration of Darcy's law. Due to the large distance, diffusion alone cannot provide needed oxygen. Thus, mass transfer is dependent on convention and pressure differentials.
[0114] [0114]FIG. 8 illustrates membrane fouling studies. As shown, pores in the polypropylene fibers clog quite rapidly causing an increase in pressure and cell death.
[0115] [0115]FIG. 9 illustrates the effect of no hemoglobin on oxygen mass transfer. This figure illustrates hemoglobin's efficiency in providing oxygen. It also augments the fact that hemoglobin is the preferred oxygen carrier, and that one cannot depend upon diffusion to oxygenate, particularly when the carrier is water. However, due to the velocity used in the preferred embodiment the drop is not as great.
[0116] [0116]FIG. 10 illustrates a comparison of a conventional, with a multicoaxial, bioreactor.
[0117] [0117]FIG. 11 illustrates a hydrodynamic model, providing an application of Darcy's law.
[0118] [0118]FIG. 12 illustrates the use of MRI to determine axial flow.
[0119] [0119]FIG. 13 illustrates predicted pressure profile and optimum K 1 and K 2 . As shown, 100 percent viability is obtained with a pressure of 103 mm Hg. At a pressure of 517 mm Hg the viability reduces to 40 percent. the average pressure in sinusoid is about 5 to 10 mm Hg. While the average sinusoidal blood flow is 0.01 cm/sec.
[0120] [0120]FIG. 14 provides photographic illustrations of membrane fouling and its adverse effect on mass transfer. As stated, membrane fouling causes pressure increase and cell death.
[0121] [0121]FIG. 15 illustrates dead-end and cross flow configurations used for the fouling study.
[0122] [0122]FIG. 16 provides results of dead-end and cross flow configurations for fouling study.
[0123] [0123]FIG. 17 provides photographic results of dead-end and cross flow configurations for fouling study.
[0124] [0124]FIG. 18 provides photographic results of fouling studies of woven vasculature incorporated into multicoaxial bioreactors.
[0125] The bioreactors of the current invention advantageously combine ‘integral’ oxygenation with defined diffusion distances, have ports to accommodate potential bile duct formation, and/or are easily scalable. Integral oxygenation permits efficient mass transfer of dissolved gases and control of pH. Defined diffusion distances permit predictable axial and radial physico-chemico-biological parameters such as shear forces, availability of nutrients, and pH. In use with patients, one or more of the compartments can be used for patient blood plasma while another can be used to perfuse cells with integrally oxygenated media. Optionally, two or more bioreactor units are attachable in series so that toxins can perfuse out of plasma radially through the cell mass in one unit and infuse synthetic factors in the next unit. There is the potential for the biliary system to develop using the ports as the bile duct exit ports.
EXAMPLES
[0126] The following specific examples are provided to better assist the reader in the various aspects of practicing the present invention. As these specific examples are merely illustrative, nothing in the following descriptions should be construed as limiting the invention in any way. Such limitations are, or course, defined solely by the accompanying claims.
1) NMR Analysis of Liver Cell Function in the One-Sided Multi-Coaxial Hollow Fiber Bioreactor
[0127] Sprague-Dawley rats are anesthetized with pentobarbital (50 mg/kg intraperitoneally). The liver is exposed by a ventral midline incision and the portal vein is cannulated for infusion of cell dissociation solutions. The liver cells are dissociated by sequential infusions of ethylene diamine tetraacetic acid (50 mM) and collagenase (1 to 20 mg/ml) in Krebs-Henseleit buffer, pH 7.4. Adequate perfusion of the liver is indicated by uniform blanching of the liver. Isolated cells are collected and introduced into the cell compartment of the one-sided multi-coaxial hollow fiber bioreactor.
[0128] Nuclear magnetic resonance (NMR) is performed using an NMR probe design composed of two Helmholtz coils photo-etched onto flexible copper-coated composite. The two coils, suitably insulated, are wrapped around the bioreactor and oriented orthogonally to each other. The inner coil is tuned to 81 MHz for study of energy metabolism as measured by changes in the spectrum of 31 P. The probe and bioreactor assembly is placed on a centering cradle in the isocenter of the magnet for optimal comparison of spectra. The aerated nutrient medium is supplied to the first compartment inlet port of the bioreactor. Integral aeration is provided by flow of a 95% air with 5% CO2 mix through inlet port 4, associated with the outermost or fourth compartment of the bioreactor. Ham's F-12 nutrient medium is pumped through compartment 3 with a peristaltic pump. The temperature of the reservoir of medium is maintained at 42° C. with a temperature controlled water bath, so as to maintain the bioreactor temperature at 37° C. The NMR signal from γ-31P nucleotide triphosphates and B- 31 P nucleotide diphosphates, other cellular components of energy metabolism, and biosynthesis are analyzed. The NMR signal is monitored as a function of mass transfer dictated by gas flow rate and oxygen percentage, nutrient medium flow rates, and cell loading densities.
2) Oxygen Flux in the Absence of Cells
[0129] Oxygen microelectrodes are connected to a transducer and Workbench™ software, and then calibrated against known standards. The calibrated oxygen microelectrodes are placed at intervals along the fiber length in the second compartment of the multi coaxial hollow fiber bioreactor. A reservoir of plasma is attached to the inlet port of the first compartment, the innermost compartment of the multi-coaxial hollow fiber bioreactor. A reservoir of RPMI 1640 nutrient medium is attached to the inlet port of the third compartment. Peristaltic pumps are arranged in-line to circulate the plasma and nutrient medium. The second compartment is also filled with nutrient medium. The signal from each microelectrode is acquired at ten-second intervals and processed by the software for conversion to oxygen tensions. The gas phase is switched between 95% air with 5% CO 2 and 95% N 2 with 5% CO 2 at selected intervals. Rates of depletion and recovery of oxygen tension are measured at different flow rates to evaluate oxygen flux in the absence and presence of cells.
3) Use as an Extracorporeal Liver Assist Device for Evaluation of Bilirubin
[0130] The Gunn rat model, (the animal model for Crigler Naijar syndrome in humans) is an ideal model for demonstrating the efficacy of the bioreactor as an extracorporeal liver assist device. The Gunn rat has a defect inherited as an autosomal recessive trait in Wistar rats. The defect, present in homozygous recessive animals, is in the gene encoding UDP glucuronosyltransferase, an enzyme necessary for the conjugation and biliary excretion of bilirubin (a breakdown product of hemoglobin in senescent red blood cells). The Gunn rat therefore cannot conjugate and excrete bilirubin and becomes hyperbilirubinemic, having serum bilirubin levels of about 5-20 mg/dL, compared with 1 mg/dL in normal rats.
[0131] A scaled-up multi-coaxial hollow fiber bioreactor is used as an extracorporeal liver assist device with Gunn rats. The livers of heterozygous (phenotypically normal) Gunn rats are perfused and the cells are isolated. The cells are suspended in Dulbecco's Modified Eagle Medium (DMEM) and 10 9 cells are introduced into the second compartment of the bioreactor. Blood from the femoral artery of a Gunn rat (total average blood volume ca. 10 to 12 mL) is perfused through the third compartment of the bioreactor, separated from the liver cell annular space by the wall of the hollow fiber, at a flow rate of about 0.6-0.8 mL/min with the aid of a peristaltic pump. At the same time, DMEM is flowed through the compartment one of the bioreactor at a flow rate of about 0.5 mL/min. Blood flowing out of the bioreactor is returned to the Gunn rat.
[0132] The levels of unconjugated and conjugated bilirubin in blood exiting the bioreactor are determined over the course of six hours using the Sigma Total and Direct Bilirubin assay system according to the instruction supplied by Sigma Chemical Company (Sigma Procedure #522/553).
4) Biosynthetic Hepatocyte Function in a Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor/BAL
[0133] Isolated liver cells are further separated by zonal centrifugation in sucrose density gradients. Density fractions corresponding to parenchymal cells are collected and introduced into the aseptic cell compartment (compartment 2) of the scaled-up multi-coaxial bioreactor.
[0134] The parenchymal cells are maintained by circulating warm Ham's F-12 nutrient medium through compartments 1 and 3, and 95% air with 5% CO 2 through the fourth compartment. The effluent from the first compartment is collected and fractions are analyzed for parameters of biosynthetic liver function. Albumin synthesis is measured by enzyme-linked immunosorbent assay.
5) Biotransformatory Function in a Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor/BAL
[0135] Isolated liver cells are further separated by zonal centrifugation in sucrose density gradients. Density fractions corresponding to Kupffer cells are collected and introduced into the second compartment (cell compartment) of the scaled-up multi-coaxial hollow fiber bioreactor.
[0136] The cells in the bioreactor are maintained by circulating DMEM (without Phenol Red) through the inlet and outlet ports for the first and third compartments and 95% air with 5% CO2 through the ports for the fourth compartment. The cells are permitted to adhere within the compartment, followed by the introduction of free hemoglobin (1-10 mg/ml) into the first compartment. The appearance of hemoglobin and the metabolic products of hemoglobin in the third compartment are monitored with an in-line spectrophotometer.
6) The Serially-Linked Bioreactor with Human Cells for Patient Treatment
[0137] Human hepatoma C3A cells are cultured as described (Mickelson, J. K. et al. Hepatology 1995, 22, 866) and introduced into all the second compartments of the serially-linked bioreactor. Nutrient medium and 95% air with 5% CO 2 are pumped through the third and outermost compartments, respectively, and cell growth is monitored by glucose utilization. When the cells have attained the plateau, or stationary, growth phase, the albumin output is monitored.
[0138] The blood of a patient suffering liver failure is separated into plasma and cells by plasmapheresis and the plasma is pumped into the first compartment of the first bioartificial liver subunit. A portion of the plasma flows radially from the first compartment through the cell compartment to the third compartment to form biotransformed effluent. The plasma exits the first compartment of the first bioartificial liver subunit and flows into the third compartment of the second bioartificial liver subunit. The biotransformed effluent from the third compartment of the first bioartificial liver subunit and flows into the first compartment of the second bioartificial subunit. Radial flow in the first bioartificial liver subunit detoxifies a portion of the plasma and radial flow in the second bioartificial liver subunit contributes biosynthetic products to the plasma to form supplemented plasma. Vital signs, jaundice, and blood level of toxins are monitored at regular intervals. Flow rates of plasma and medium are adjusted to maximize biotransformation of circulating toxins. Survival of the patient is measured.
7) Extracellular Matrix Effects on Differentiation of Hepatocytes in the Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor
[0139] Parenchymal cells are isolated by zonal centrifugation, suspended in reconstituted basement matrix from the Englebreth-Holm-Swarm mouse sarcoma, and introduced into the second compartment (cell compartment) of the scaled-up multi-coaxial bioreactor. The hepatocytes are arrested in a G 0 state by adhesion to the basement matrix, and are maintained in the normal hepatic phenotype.The highly differentiated state is characterized by synthesis of albumin and hepatic transcription factors such as C/EBP−. The parenchymal cells are maintained by circulating warm Ham's F-12 nutrient medium through the first and third compartments, and 95% air with 5% CO 2 through the fourth compartment. The effluent from the first compartment is collected and fractions are analyzed for parameters of biosynthetic liver function. Albumin synthesis is measured by enzyme-linked immunosorbent assay.
8) Growth and Differentiation of Human Hepatocytes in the Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor
[0140] Human parenchymal hepatocytes are isolated by the method of (Block, G. D. et al. J Cell Biol 1996, 132, 1133) and introduced into the second compartment of the scaled-up multi coaxial hollow fiber bioreactor. The parenchymal cells are propagated by exposure to hepatocyte growth factor (HGF/SF), epidermal factor, and transforming growth factor alpha in nutrient medium HGM introduced into the third compartment and air:CO 2 (19:1) introduced into the fourth compartment. The ratio of transcription factor C/EBP to C/EBP is decreased by this process and the cell synthesis of albumin also is decreased. The medium flowing through the third compartment is modified to include transforming growth factor and epidermal growth factor to induce differentiation of the cells and synthesis of albumin, in the formulation described (Sanchez, A. et al. Exp Cell Res 1998, 242, 27).
9) Biosynthesis of Hormones and Factors in the Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor
[0141] Parathyroid glands are obtained aseptically, minced, and treated with collagenase as described (Hornicek, F. L. et al. Bone Miner 1988, 4, 157). The dispersed cells are suspended in CMRL-1415 nutrient medium supplemented with fetal bovine serum and introduced into the second compartment of the scaled-up multi-coaxial bioreactor. A mixture of 95% air with 5% CO 2 is pumped through the fourth port. Warm medium is pumped through the first and third ports and the effluent from the chamber is concentrated by ultrafiltration for collection of parathyroid hormone, parathyroid hypertensive factor, and other cell products. The hormones and factors are purified by immunoprecipitation and chromatography.
10) The Five Compartment Serially-Linked Bioreactor with Human Cells for Patient Treatment
[0142] Human hepatoma C3A cells are grown as in example VI, above, except in the third compartment of a five-compartment serially-linked bioreactor. The innermost compartment (compartment 1) and the outermost compartment (compartment 5) are suffused with the gas mix, 95% air with 5% CO 2 . Nutrient medium is pumped through the second and fourth compartments, respectively, and cell growth is monitored by glucose utilization. When the cells have attained the plateau, or stationary, growth phase, the albumin output is monitored.
[0143] The blood of a patient suffering liver failure is separated into plasma and cells by plasmapheresis and the plasma is pumped through the serially connected second compartments of the bioreactor. Vital signs, jaundice, and blood level of toxins are monitored at regular intervals. Flow rates of plasma and medium are adjusted to maximize biotransformation of circulating toxins. Survival of the patient is measured.
[0144] Various publications have been referred to throughout this application. 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.
[0145] The purpose of the above description and examples is to illustrate some embodiments of the present invention without implying any limitation. It will be apparent to those of skill in the art, in light of this teaching, that various modifications and variations may be made to the composition and methods in the present invention to generate additional embodiments without departing from the spirit or scope of the invention. The specific composition of the various elements of the bioreactor system, for example, should not be construed as a limiting factor. Accordingly, it is to be understood that the drawings and descriptions in this disclosure are proffered to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
[0146] The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. Thus, the invention is properly limited solely by the claims that follow. | A bioreactor for three-dimensional culture of liver cells is disclosed. The device is characterized by the use of textile vasculatures. A model and method for optimizing vasculature parameters is also disclosed. Liver acinar structure and physiological parameters are mimicked by sandwiching cells in the space between the two innermost woven textile hollow fibers, and creating radial flow of media from an outer compartment, through the cell mass compartment, and to an inner compartment. The theoretical optimum hydraulic permeability for the two innermost semi-permeable membranes is determined based on physiological hepatic sinusoidal blood flow and pressures. Experimental studies using a flow rate and pressure monitoring systems in conjunction with phase-contrast velocity-encoded MRI confirm theoretical results. Novel woven vascular tubes with optimum hydraulic permeability are disclosed for culturing hepatocytes in the multi-coaxial bioreactor. | 2 |
This is a continuation of application Ser. No. 07/969,415, filed Oct. 30, 1992, which in turn was a division of application Ser. No. 07/484,583, filed Mar. 2, 1990, both now abandoned.
FIELD OF THE INVENTION
The invention relates to devices for transporting large numbers of samples to a sampling site preparatory to analysis of those samples.
BACKGROUND OF THE INVENTION
Head space analysis techniques are employed to analyze for volatile components in largely non-volatile mixtures. For example, this analytical technique is used in determining the amount of alcohol in a known quantity of blood. The technique is also used for analyses of volatile components in other body fluids. Further applications include analysis of trace organic compounds in water samples, testing for the presence of solvents in drugs, for solvents or monomers in polymers, for fragrances in toiletries, for flavors or aromas in foods, and the like. It is desirable in these applications to have a transport device capable of transporting samples automatically at high rates to the analyzing instrument. It is also desirable for the transport device to be able to be programmed to automatically repeat the sampling of one or more vials one or a number of times. This feature is useful for improving the precision of the analysis.
The amount of volatile components in the gaseous headspace portion over a liquid sample in a closed vial is known to vary with the temperature of the liquid sample. Therefore, it is very important to maintain the temperature of the liquid sample within a very narrow range in the transport prior to analysis. Further, because the actual quantity of material in the headspace over a liquid sample is very small, any contamination from outside sources would substantially alter the analysis of the headspace gases. Therefore, the risk of outside contamination must be minimized during the sampling process. Also, because sample vials are made in various sizes, it is desirable that the transport device be able to accommodate different sizes.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a transport device which is readily automated and capable of running large numbers of individual samples.
It is another object of the invention to provide a transport device capable of accurately regulating the temperature of samples stored therein.
It is yet another object of the invention to provide a transport device capable of performing repeated analyses on a single group of samples.
It is yet a further object of the invention to provide a transport device capable of accepting and sampling vials of different sizes.
Further objects and advantages of the invention will become evident from the description which follows.
The invention relates to a sample vial transport device having a rotatable heated platen with a plurality of chambers to hold sample vials. The sample vials are loaded into the chambers by a vial transport which conveys the sample vials from a point above the individual chamber. The platen therefore does not have to move axially to input a vial or to sample the vial contents, as discussed below. This significantly reduces the complexity of the vial transport mechanism. Vials from which samples have already been taken are ejected from the individual chamber by reversing the operation of the vial transport.
Sampling of the contents of the sample vial is done at a point removed from the vial inlet point. The sample vial is rotated toward the sampling point, at which time the sample vial is brought into contact with a needle by mating means. The needle extracts at least a portion of the contents of the vial for sampling by puncturing a septum in the cap of the vial.
The platen is preferably heated electrically. Electrical heating is preferred over oil bath heating, which tends to introduce trace materials attributable to the oil into the analysis instrument and thereby alter the analysis results. Further, oil vapors condense on mechanisms and hold dirt. The oil baths need to be constantly stirred to maintain temperature uniformity, and they pose a greater safety hazard to the operator.
The vial from which a sample has been extracted then continues back to the inlet point within the chamber. At that time, it is either ejected from the platen by the vial transport or alternatively remains in the chamber for an additional rotation and sampling operation. The transport device chambers are also capable of holding liner sleeves, or inserts, which permit sampling of different size vials. Typically, the vials utilized have volumes of 5 ml, 10 ml or 20 ml.
In the preferred embodiment of the invention, the needle is stationary and positioned above the platen and a second vial transport is utilized as the mating means to push the sample vial upward from the bottom of the chamber to cause puncturing of the septum with the needle. However, the needle can be movable to puncture the septum as an alternative embodiment.
The rate of transport of gaseous components from the liquid to the headspace of the vial is a function of the mean path length the components must travel through the liquid to reach the headspace. It has been found that mixing the vial contents dramatically reduces the mean path length and thus improves the transport rate. To facilitate the mixing, the invention includes a mixing device having a vertically displaceable rod positioned below the platen which rises through the bottom of the platen to contact the sample vial bottom in a chamber between the inlet point and the sampling point. The rod is preferably connected to a DC solenoid which is repeatedly energized for short periods to cause the rod to pulse and thereby shake the sample vial in an up and down motion within the chamber. This mixing motion aids in equilibrating the concentration of the material to be analyzed in both the liquid and gas phases within the sample vial.
Further objects, advantages and features of the invention will become apparent upon review of the detailed description of the invention and the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the transport device, taken in an axial cross sectional view through the unit with certain features out of position to aid in understanding the invention.
FIG. 2 is a side view of the device, taken with a different cross section, and showing all elevator rods in the retracted position.
FIG. 3 is a schematic of the carrier gas and sample flow patterns.
FIG. 4 is a top view of the transport device.
DETAILED DESCRIPTION OF THE INVENTION
The invention in its broader aspects relates to a transport device for conveying sample vials to a sampling location for effecting withdrawal of at least a portion of the vial contents for analysis thereof, comprising a platen which is rotatable around a central axis having a plurality of counterbored chambers, a heater for the platen, a first vial transport which operates to convey a vial into a chamber from a point above the chamber and the reverse, a needle for extracting at least a portion of the vial contents from the vial, and mating means for bringing the needle into contact with the vial contents to allow extraction thereof.
In referring to the drawings, FIG. 1 shows the sample transport 2 having a platen 4. The platen 4 is a cylindrical block made of heat-conducting material, preferably aluminum, which is manufactured preferably by combining the throughbored block 8 with the bored plate 10 and insulation plate 12. The throughbored holes in block 8 run axially through the block and are positioned near the periphery of the block. These holes mate with the bored holes in plate 10, the holes having a smaller diameter than those in block 8. Mating is facilitated by the use of dowel pins 14 in the bored plate 10 which key into mating holes in the block 8. The mating of throughbored block 8 with bored plate 10 creates individual chambers 16 for holding a sample vial 20 having a septum 22 within cap 23. Alternatively, a single block can be counterbored to form the same chambers as are created by combining block 8 with plate 10. However, the preferred embodiment is easier to manufacture and therefore of lower cost.
Below insulation plate 12 is positioned an encoder wheel 24. This wheel has a series of slots 26, an example of which are shown in FIG. 4, which are read by a photodiode transmissive switch assembly 28 to thereby provide a means both for determining the position of the platen 4 and for centering the chambers 16 over the various mechanisms, to be described in detail below. The transmissive switch 28 has a light generating element and a light detecting element, and the encoder wheel rotates between these two elements. Position is determined by the number and location on the encoder wheel 24 of slots passing light through to the detecting element at any one time. Below the encoder wheel 24 is a support plate 30. Plate 12 is preferably manufactured from a machineable glass fiber, one example of which is known as MARINITE I. MARINITE I, manufactured by Johns-Manville Corp., Denver, Colo. is comprised of calcium silicate with inert filters and reinforcing agents. Alternatively, other materials meeting the requirements of machineability and heat insulative ability may be used. For purposes of discussion, the platen 4 will include the throughbored block 8, bored plate 10, insulation plate 12 and support plate 30. The insulation plate 12, support plate 30 and the encoder wheel 24 are bored to match the borings in plate 10.
The platen 4 with encoder wheel 24 is secured to the guide track 36 through screws 38 and spacers 40, several of which being depicted in FIGS. 1 and 2. Mating is facilitated by matching dowel pins 42 (only one shown) with mating holes in bored plate 10, insulation plate 12, encoder wheel 24 and support plate 30. The guide track 36 in turn is supported on a ball bearing cage assembly 50. The cage assembly 50 is retained in position below the guide track 36 by the inside shoulder of platen gear 52, which is secured to the bottom side of guide track 36. The bearings comprising the ball bearing cage assembly 50 rest on a thrust washer 54, made preferably from hardened tool steel, which is positioned onto the base plate 56 and maintained in position by pins (not shown) driven into the base plate 56 adjacent the outside diameter of the thrust washer 54. Alternatively, a channel corresponding to the diameter and thickness of the thrust washer 54 could be cut into the base plate 56 and the washer positioned therein. However, this operation requires additional machining and is not necessary to the effective operation of the sample transport.
The guide track 36, and therefore the platen 4, is caused to align properly around a single axis during rotation by the presence of roller wheels 60 mounted onto the base plate 56 by bolt and sleeve assemblies 64. The roller wheel 60 mates with the edge of the guide track 36 along its periphery to maintain the proper orientation. The platen 4 is caused to rotate by actuation of drive motor 66 having a drive gear 68 attached thereto which cooperates with the teeth on platen gear 52.
The throughbored block 8 and bored plate 10 are heated preferably by cartridge heaters 76. The temperature of the block 8 and bored plate 10 is measured by temperature measurement probes 78. These probes preferably are thermocouples, but may be resistance temperature devices or other like device. The cartridge heaters 76 may be easily removed for servicing by removal of an epoxy plug 80 secured to the platen 4 by platen bolt 82, which is shown in FIG. 2.
Sample vials 20 are lowered into the platen 4 and ejected therefrom by a first vial transport 86 consisting of an elevator rod 88 connected to a level winding screw 90 by screw follower 92. The elevator rod 88 is displaced vertically by rotating level winding screw 90 through use of transport motor 94. The elevator rod 88 contacts the bottom of sample vial 20 by travelling upward through aperture 100, which is of smaller diameter than chamber 16. The aperture 100 is bored through bored plate 10, insulation plate 12, encoder wheel 24 and support plate 30. The extent of travel of the elevator rod 88 is regulated by lower limit switch 96 and upper limit switches 97, 98 and 99. Switch 97 stops the upward travel of the elevator rod 88 when the sample vial is to be manually loaded or unloaded. When the vials are to be automatically loaded and unloaded, switches 98 and 99 are used. Switch 98 stops the elevator rod 88 at the auto load point, and switch 99 is for the auto unload, or eject, point.
The sample vial 20 shown in the center chamber position in FIG. 1 is mixed by the mixer device 102, consisting of an elevator rod 104 which rises vertically through aperture 100 by rotation of level winding screw 106 connected to the elevator rod 104 by screw follower 108. Rotation is effected by actuation of mixer motor 109. The DC solenoid 110 located on the screw follower 108 and connected to the elevator rod 104 pulses the rod to provide the necessary mixing. The solenoid 111 is supplied with a variable voltage input which varies the power supplied to the elevator rod 104. The higher the power, the further the vial 20 rises in the chamber 16 in response to the pulse. This variable voltage feature allows varying of the intensity of mixing.
As discussed above, the transport device 2 as presently configured is capable of accepting vials of 5, 10 and 20 ml volumes. The figures show the 20 ml vials. The smaller vials require liner sleeves, or inserts (not shown), which support the cap 23 and maintain the septum 22 uniformly near the top of the throughbored block 8. The inserts also have a hole in the bottom through which the elevator rods 104 and 88 travel. Because the caps of the different-sized vials will all be at approximately the same height in the chamber 16, it follows that the bottoms of the vials will rest different distances above the bottom of the chamber 16. During mixing, the elevator rod 104 raises the vial only about 1/16 inch above a rest position. Therefore, with different size vials, the elevator rod 104 must rise different lengths to contact and mix the vials. The limit switches 111a, b, c, d indicate the elevator rod 104 rest position, and mixing points for the 20 ml, 10 ml and 5 ml vials, respectively.
The sample vial 20 in the right chamber is shown in FIG. 1 to be proximate to the needle assembly 112 and is in position for sampling. The vial 20 is raised from a rest position to puncturing contact of the septum 22 with needle 114 by a second vial transport 118, which serves as the mating means to bring the needle into contact with the vial contents. The second vial transport consists of an elevator rod 120 terminating with a rod tip 121 which is raised vertically to contact the bottom of the sample vial 20 (or insert supporting a sample vial) by rotation of level winding screw 122 connected to the elevator rod 120 by screw follower 124. The rod tip 121 has a larger diameter than the hole bored into the bottom of a vial insert to raise the combination of vial and insert. Where the 20 ml vial is used, the rod tip 121 contacts the bottom of vial 20 directly. Rotation of the level winding screw is effected by actuating transport motor 126. After sampling is completed, the sample vial 20 is returned into the chamber 16 by reverse movement of the elevator rod 120. The septum 22 is freed from needle 114 with the assistance of a wiper plate 128 which pushes against the sample vial cap 23 via spring 130 loaded against needle flange 132. The wiper plate 128 is maintained in position relative to the needle 114 by means of guide rods 134. The extent of travel of the elevator rod 120 is regulated by lower limit switch 136 and upper limit switch 138.
FIG. 2 shows the sample transport 2 with all elevator rods in the fully retracted position. It can be seen that the needle 114 is positioned directly above the platen 4. The close positioning of the needle assembly 112 to the top of the platen 4 permits the sample vials 20 to be sampled while only being lifted a short distance inside the chamber. This close arrangement of needle assembly 112 to the top of the platen 4 minimizes temperature fluctuation within the individual sample vials as the sample is withdrawn.
The various components of the platen are secured to each other and to the epoxy plug 80 by the platen bolt 82.
FIG. 4 shows the top view of the transport device and the relationship of the components. The platen 4 has positioned near its outside circumference a plurality of chambers 16. Inside the circumference of the chambers are located the temperature measurement probes 78. Near the axis of the platen 4 are the cartridge heaters 76. The various components comprising the platen 4 are secured by the platen bolt 82. Below the platen 4 at the nine o'clock position is the first vial transport 86. The tip of the elevator rod 88 can be seen in position ready to rise through aperture 100. At the twelve o'clock position below the platen 4 is the mixer device 102, with the tip of elevator rod 104 appearing in aperture 100. At the three o'clock position below the platen is located the second vial transport 118, with the tip of elevator rod 20 showing. In phantom is depicted the needle flange 132 which is located over the chamber corresponding to the second vial transport 118.
The sampling of the headspace contents operates as follows. The headspace contents within a sample vial 20 are removed from the sample vial 20 and conducted to a gas chromatograph (G.C.) for analysis by the following procedure. FIG. 3 is a schematic showing the gas flow pattern into the sample transport, depicted in part as the heated zone 140 and separate platen heated zone 141, out the sample transport and then to the gas chromatograph. Zone 141 is the platen 4 itself. The heating of this zone 141 has been generally discussed and will be described in more detail below. The zone 140 is heated to prevent condensation in the lines between the needle 114 and the gas chromatograph. The temperature in this zone is typically set about 10° to about 25° C. higher than the platen 4 temperature.
Carrier gas, typically helium, enters gas inlet 142 from a tank controlled with a pressure regulator (not shown). The gas supply is split at T-connection 144. The tubing and connections through which the carrier gas flows are made from nickel alloy, copper, stainless steel, or other material which does not evolve any compounds which might affect the G.C. analysis and which is not permeable to compounds in the air which might diffuse through the material and be carried to the G.C. Carrier gas flows through first line 146 at a pressure set at the tank regulator, typically about 60 psi, to a gas chromatograph flow controller 148. The controller 148 is connected in line to pressure gauge 150. Carrier gas then flows into six port valve 152 having ports A, B, C, D, E and F. The carrier gas flowing through the first line 146 ultimately enters six port valve 152 at port C, exits through port D and continues through the heated transfer line 154 into the gas chromatograph. This flow of gas is always on to constantly purge the gas chromatograph.
The remaining flow of carrier gas after splitting passes through second line 156. The carrier gas flowing through this second line is used to purge the needle 114 and to pressurize the sample vial 20 after the septum 22 has been punctured by needle 114. Pressure is adjusted by regulator 158 within a range of about 5 to about 30 psi, depending on the application. The flow is regulated by flow controller 160. Carrier gas flow through the needle 114 is turned on and off by a solenoid operated pressurization valve 162. The flow controller 160 is set at a level sufficient to pressurize the sample vial in a reasonable time, but not so high as to waste excessive amounts of carrier gas as the needle is being purged. Typically, the valve 162 is open to constantly purge the needle 114. With the pressurization valve 162 on, and vent valve 164 off, carrier gas flows through T-connection 168 to inlet line 170 and then into the six port valve 152 at port A. The carrier gas flows from port A into port B, through sample loop 172, into port E, out port F and through the needle 114 into the sample vial 20. After a programmed amount of time sufficient to pressurize the vial 20 to at least the same pressure as that set at the regulator 158, the pressurization valve 162 is turned off and the pressure within the lines from that valve to the sample vial is allowed to equilibrate.
After a preprogrammed equilibration time of several seconds to several minutes, the vent valve 164 is opened to allow the vial gases, consisting of carrier gas and headspace contents, to vent. Carrier gas with the headspace contents flows back through needle 114, into the six port valve at port F and into the sample loop 172 and out port A toward the vent valve 164. After an additional programmed time, the vent valve 164 is closed and the six port valve 152 is cycled. The carrier gas in the first line 146, which remained on and flowed out port D to the gas chromatograph, is now caused to flow through port C to port B after the cycling. The carrier gas flows into the sample loop 172 and flushes the contents into port E which is now connected with port D. This allows the materials to flow into the gas chromatograph through heated transfer line 154. After the sample contents have been injected into the gas chromatograph, the six port valve 152 returns to its home position, the sample vial 20 is removed from needle 114 and the pressurization valve 162 is again opened to purge the needle of any residual headspace material. When a new sample vial 20 is brought in contact with the needle, the procedure repeats.
The analyzer transport device described above is used preferably for preparing samples for analysis using the headspace analysis technique, wherein the gaseous sample is heated to a set temperature and the contents sent to a gas chromatograph. The operable temperature range is typically room temperature plus 10° C. to about 200° C. The above transport device can be automatically loaded and unloaded, and large numbers of samples can be processed without constant operator supervision. The electrically powered functions of the device are controlled through a keypad or other similar type of control unit (not shown) which, among other functions, adjusts the sample vial processing rate through the transport device, adjusts temperature, severity and time of mixing, sampling order by use of the encoder wheel in combination with the photodiode transmissive switch assembly, and number of repetitions of analysis of the headspace contents of a single sample vial.
Thus it is apparent that there has been provided in accordance with the invention, a sample transport device that fully satisfies the objects, aims, and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. | A method of preparing a volatile sample from a material for gas chromatographic analysis includes the steps of: introducing a vial with the material containing the volatile sample and a headspace therein into a chamber of a platen adapted to transport the vial to a location for removal of at least a portion of the volatile sample for gas chromatographic analysis; heating the material containing the volatile sample while the vial is being transported to the location for removal; agitating the vial while in the chamber to enhance a transport rate of the volatile sample from the material to the headspace of the vial; and introducing a needle to the vial to withdraw at least a portion of the volatile sample from the headspace of the vial. | 6 |
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] Small clothing items such as socks, handkerchiefs, and the like are generally washed loose among larger clothing items. The smaller items get caught in the washing machine agitator and damaged, get caught and hidden in larger clothing items, and paired or grouped items such as socks get separated. After being laundered, the clothing items must be sorted, folded, and stored. For paired items such as socks, the sorting includes matching pairs together, which is time consuming.
[0002] There are several methods that people try in order to prevent losing small items in the laundry, keeping paired items together, and managing storage of paired items; however, existing methods have faults and none addresses the issue of sorting and storage of paired items. For example, there are several mesh-type bags available for washing small and delicate items. Mesh-type bags prevent damage to small items, but do not alleviate the sorting and storage problem at the end of the laundry process. Paired items such as socks can be held together by safety pins, clothes pins or other types of clips or holders, but pins can damage socks by rusting and staining, tearing small holes in the socks, or pulling threads out of the socks. Clothes pins or clips keep items together, but can come unclipped or caught by other articles of clothing, resulting in items becoming separated, or if they remain together, the items must be unclipped for convenient storage.
[0003] The present invention comprises a device for holding small clothing items together which overcomes the foregoing and other difficulties which have long since characterized the prior art. In accordance with the broader aspects of the invention, the small clothing item management system comprises a center beam and a flexible strap for securing items thereto.
[0004] In accordance with more specific aspects of the invention, a small clothing item management system comprises a rigid center beam and a rigid flexible strap which secures therearound. Clothing items are held on the center beam by the flexible strap. The strap holds the items securely during the wash and dry cycles of laundry and keeps paired items together during laundry folding and storage. Additionally, the clothing items are held flat against the center beam and can be stored either folded, rolled, or laid flat in a drawer or storage container or the like. Both the center beam and strap are constructed with durable materials to withstand the pressure and heat of the wash and dry cycles.
[0005] The small clothing item management system prevents loss or damage to small clothing items during the household washing and drying cycles, eliminates the need for sorting at the end of the laundry process, and assists in convenient storage and management of the paired items such as socks.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] A more complete understanding of the present invention may be had by reference to the following Detailed Description when taken in connection with the accompanying Drawings, wherein:
[0007] FIG. 1 is a perspective view of a small clothing item management system comprising a first embodiment of the present invention;
[0008] FIG. 2 is a perspective view of the strap of the management system of FIG. 1 ;
[0009] FIG. 3 is an illustration of an initial step in the utilization of the management system of FIG. 1 ;
[0010] FIG. 4 is an illustration of a later step in the utilization of the management system of FIG. 1 ;
[0011] FIG. 5 is an illustration of a somewhat later step in the management system of FIG. 1 ;
[0012] FIG. 6 is an illustration of a still later step in the utilization of the management system of FIG. 1 ;
[0013] FIG. 7 is a perspective view of a small clothing item management system comprising a second embodiment of the present invention;
[0014] FIG. 8 is a perspective view of the center beam of the small clothing item management system shown in FIG. 7 ; and
[0015] FIG. 9 is a perspective view of the flexible strap of the small clothing item management system shown in FIG. 7 .
DETAILED DESCRIPTION
[0016] Referring now to the drawings and particularly to FIG. 1 thereof, there is shown a small clothing item management system 10 incorporating a first embodiment of the present invention. Small clothing items are held against a center beam 12 by a flexible strap 14 during the washing and drying cycles of laundry, and after the laundry process during storage. The strap 14 wraps around one end of the beam 12 and is secured on both sides at the other end by handles 16 .
[0017] Referring to FIG. 2 there is shown the flexible strap 14 . The strap 14 is fabricated from a high strength rubber, a polymeric material, or other materials known to those skilled in the art for enabling the strap 14 to be both flexible and durable At each end of the strap 14 there is provided a handle 16 . The handles 16 are connected to the strap by end connectors 18 , defined by notches 20 , 22 , 24 , and 26 . Cut out of each side of the strap are two drying vents 28 that allow air to pass through to the item of clothing attached underneath. At the center of the strap 14 is a retainer 30 . The retainer 30 is connected to the strap 14 by center connectors 32 , defined by notches 34 , 36 , 38 , and 40 . On each side of the connectors 32 is a retaining flap 42 . Each flap 42 covers the connectors 32 and their defining notches 34 , 36 , 38 , and 40 .
[0018] Referring again to FIG. 1 the center beam 12 is constructed using wood, a plastic material having both high shore D hardness and deflection temperature, or other materials known to those skilled in the art suitable for withstanding repeated exposure to water and high temperatures. The proximal end of the beam 12 comprises a small semi-circular retaining groove 44 which receives the retainer 30 . The distal end of the beam 12 comprises a receiving groove 46 with four fingers 48 for receiving and retaining the handles 16 . Cut out of the middle of the beam are drying vents 50 to facilitate drying the portion of the clothing item secured against to the beam 12 .
[0019] Referring to FIG. 3 , clothing items are held in place against the center beam 12 by the strap 14 . The retainer 30 fits into the semi-circular retaining groove 44 to hold the strap 14 on the beam 12 . The center connectors 32 fit and extend through openings of the retaining groove 44 , with the retaining flaps 42 resting on top of either side of the retaining groove 44 . A clothing item is placed against the beam 12 and one side of the strap 14 is stretched across the clothing item, placing the end connector 18 between the fingers 48 of the receiving groove 46 . Once the connector 18 is in place and the handle 16 is released, the handle 16 is held in place by the tension against the fingers 48 . Another item is placed on the other side of the beam 12 in the same manner.
[0020] FIG. 4 shows the management system 10 used to retain clothing items during the wash cycle.
[0021] FIG. 5 shows the management system 10 used to retain clothing items during the drying cycle. An important feature of the invention comprises the fact that the management system 10 is quiet in the dryer.
[0022] FIG. 6 shows the management system 10 used in the storage of the small clothing devices. After completing the washing and drying cycles of the laundry, paired items such as socks remain secured against the beam 12 for storage. Each item is laid flat, folded, wrapped around the clothing-holder device, or otherwise manipulated for storage.
[0023] FIG. 7 shows a small clothing item management system 54 incorporating a second embodiment of the present invention. Many of the component parts of the small clothing item management system 54 are substantially identical in construction and function to component parts of the small clothing item management system 10 illustrated in FIGS. 1 through 6 and described hereinabove in conjunction therewith. Such identical component parts are designated in FIG. 7 with the same reference numerals utilized above in the description of the small clothing item management system 10 , but are differentiated therefrom by means of a prime (′) designation.
[0024] The small clothing item management system 54 differs from the small clothing item management system 10 in that the small clothing item management system 54 comprises a center beam 56 having a serpentine shape with multiple drying vents 50 ′ on each side thereof. The serpentine shape of the center beam 56 enables more air flow to the portions of a small clothing item affixed to the beam 56 . The small clothing item management system 54 comprises two flexible straps 58 secured on the top and bottom of the center beam 56 instead of one continuous strap 14 .
[0025] The proximal end of each strap 58 secures onto the proximal end of the beam 56 leaving the distal end of the strap 58 unfastened while clothing items are placed against the beam 56 . The strap 58 is received onto strap retaining members 60 on the proximal end of the beam 56 , the retaining member 60 slightly tapering outward thereby facilitating a secure mating engagement between the strap 58 and the beam 56 . After a small clothing item is placed against the beam 56 the distal end of the strap 58 fastens onto a receiving member 62 on the distal end of the beam 56 .
[0026] FIG. 8 illustrates the center beam 56 of the small clothing item management system 54 . The beam 56 is constructed using wood, a plastic material having both high shore D hardness and deflection temperature, or other materials known to those skilled in the art suitable for withstanding repeated exposure to water and high temperatures.
[0027] FIG. 9 illustrates the flexible strap 58 of the small clothing management system 54 . The strap 58 comprises a retaining aperture 64 on the proximal end thereof for securing the strap 58 onto the proximal end of the center beam 56 . The distal end of the strap 58 comprises a fastening aperture 66 for fastening the strap 58 onto the beam 56 over a small item of clothing placed thereon. A handle 16 ′ on the distal end of the strap 58 enables a user the better grasp the strap 58 when fastening it onto the beam 56 and covers the end of the beam 56 such that the small clothing item management system 54 is quiet in the dryer. The strap 58 is fabricated from a high strength rubber, polymeric material, or other materials known to those skilled in the art which enable the strap 58 to be both flexible and durable.
[0028] Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention. | A small clothing item management system holds small clothing items on a beam and prevents damage or loss to the clothing items. The clothing items are secured against a center beam by a flexible strap during the wash and dry cycles of the household laundry process. After completion of the laundry process, the small clothing items remain secured to the center beam for storage. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority of U.S. Provisional Application Ser. No. 60/661,280, filed Mar. 11, 2005, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field
[0003] This disclosure relates to software and more particularly to a system and method for assisting job seekers in their job search efforts.
[0004] 2. General Background
[0005] Various job search vehicles are available to a job searcher or recruiter today on the Internet, e.g. the World Wide Web (web). However, the available resources that can be scrutinized are somewhat limited. Accordingly there is a need for a system that more completely searches and organizes information that can be obtained from as many sources as possible via the Internet and present search results in an effective manner to a job searcher in response to a query.
SUMMARY
[0006] The system described herein is a system for improved job search that operates through the use of several techniques including scraping technology to scour the web and obtain job opportunity information from career sites available on the Internet, and particularly the World Wide Web, although, as job information may be distributed on other networks now known or to become known, the system and functionality described herein is applicable to any distributed information environment whereby information can be obtained by manual or automated systems.
[0007] A job seeker seeking information about jobs will have a larger universe of job information to review when utilizing the system described herein. Specifically, the system makes use of scraping technology, to build a database that is populated with job information data sets. The database may also include job information from other sources such as job information supplied by corporations seeking applicants and/or provided by methods other than through scraping. The system receives the job information and then, utilizing an internal quality management process, maximizes the quality of the information contained in each individual job information data set to maximize usefulness to the user and to improve the user's overall job searching experience when utilizing the system described herein.
[0008] This system includes a scraping module having one or more scraping engines operable to scrape job information data from job listings on the corporate career sites and job boards, wherein the scraping module receives and stores the scraped job information data set in a database. The system also has a scraping management process module coordinating operation of and communication between the scraping engines and the career sites and job boards. A scraped listing quality management process module is coupled to the scraping management process module analyzing selected scraped job information data sets stored in the database. A job categorization module examines and categorizes job information stored in the database into one or more of a predetermined set of categories and returns categorized job information sets to the database. An extractor module communicates with the database and compiles and transfers categorized job information data from the database to a search bank. The search bank is then accessible by a job searcher through a job search client server cluster connected to the Internet.
[0009] A preferred embodiment of the method of this disclosure includes operations of scraping job information data sets from one or more job listings on one or more corporate career sites or job boards, storing the scraped job information data corresponding to each scraped job listing in a database, analyzing each scraped job information data set stored in the database for conformance to predetermined quality criteria, categorizing each job information stored in the database into one or more predetermined job categories and returning the categorized job information data sets to the database, and transferring categorized job information data sets from the database to the search bank.
[0010] The categorizing operation preferably includes operations of comparing text of each scraped job information data set with previously categorized job information text in a categorization database, and determining a confidence value in each predetermined category for each scraped job information data set. More preferably, the method includes flagging each categorized scraped job information data set that has a confidence value below a predetermined value for manual review, and providing a manual review interface permitting a reviewer to verify any flagged categorizations.
[0011] The method further may include assigning a confidence value for the category assigned to each job information data set returned to the database and flagging any job information data set returned to the database having an assigned confidence level below a predetermined threshold. The techniques utilized in automatic categorization of a product, including such products as job listings, are described in detail in U.S. patent application Ser. No. 10/920,588, filed Aug. 17, 2004, and entitled Automatic Product Categorization, assigned to the assignee of this disclosure.
DRAWINGS
[0012] The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:
[0013] FIG. 1 is a block diagram of a system in accordance with an embodiment of the present disclosure.
[0014] FIG. 2 is an exemplary user (job seeker) search results interface for use in an embodiment of the exemplary system shown in FIG. 1 .
[0015] FIG. 3 is an exemplary user (job seeker) search input query interface for use in an embodiment of an exemplary system shown in FIG. 1 .
[0016] FIG. 4 is a simplified process flow through system shown in FIG. 1 .
[0017] FIG. 5 is a functional diagram of scraping in accordance with an embodiment of the present disclosure.
[0018] FIG. 6 is diagram of the job categorization control module in the embodiment of the system shown in FIG. 1 .
[0019] FIG. 7 is an operational flow diagram of the job categorization process in accordance with an embodiment of the system shown in FIG. 1 .
[0020] FIG. 8 is a screen shot of an exemplary document categorization platform service user interface for the job categorization process.
[0021] FIG. 9 is a process flow diagram for a job categorization manual review interface module.
[0022] FIG. 10 is a screen shot of an exemplary user interface for a job categorization manual review interface module.
[0023] FIG. 11 is a screenshot of an exemplary user interface of job information being manually reviewed.
DETAILED DESCRIPTION
[0024] An overall architecture diagram of the job search system 100 in accordance with an embodiment of this disclosure is shown in FIG. 1 . The system 100 can be thought of as having three sections: an external input section 101 , a data handling section 103 , and an output handling section 105 . Basically the data handling section reaches to the external input section 101 for job data, processes the data, organizes and verifies validity of the data, categorizes the job data, and provides the data to the output section which may be accessed eventually by a job seeker 107 via the internet 110 .
[0025] The external input section 101 includes the job postings that may be accessed by the data handling section from such sources as corporate and company career sites and a number of other job boards 102 . These corporate career sites and job boards 102 currently consist of several thousand company career sites. Also providing input to the data handling section 103 are systems operations personnel 104 , listing reviewers 106 and categorization experts 108 . These entities provide various input via an intranet 109 through suitable web browser interfaces such as Internet Explorer marketed by Microsoft Corporation utilizing administrator user interfaces appropriate to their purpose.
[0026] The data handling section 103 comprises a series of modules that together assimilate job information scraped from the sites 102 into an orderly configuration generally described as follows. A scraping module 112 in the data handling section 103 has one or more job scraping engines 114 . These job scraping engines are software routines that are used to query each of the several thousand sites and job boards 102 for new job postings and job information data sets. Such job information data sets include parameters unique to the job posting such as title, company, city, state, salary, hours, skills, qualifications, experience etc. and a detailed job description that describes, in paragraph form, the duties, experience and tasks to be performed in the job. The scraping module 112 comprises one more scraping engine farms 114 that typically use different scraping technologies and methodologies which may be developed as a matter of design choice but are preferably specifically directed in a preferred embodiment herein for searching over a global electronic network such as the Internet 110 , with each engine 114 being optimized for either a particular type of scraping task or particular type or set of corporate sites. For example, the Kelkoo scraping engine farm, developed by Kelkoo, Inc. in Europe, now a subsidiary of Yahoo, Inc., is optimized to thoroughly scour a predetermined known corporate site or listing site. The Kelkoo scraping engine is optimized to follow internal links within the site to specific internal locations to extract job information data sets. However, it does not follow external links. The Café/Kelsa Scraping engine farm, developed by Yahoo, Inc., and described in U.S. patent application Ser. No. 11/064,278, filed Feb. 22, 2005 and entitled Techniques for Crawling Dynamic Web Content, is optimized to systematically examine a seed URL and follow every link within the site and follow every internal and external link that may be provided on that URL as well as links it finds on its “crawl.”
[0027] Preferably, a scraping agent is created for each career site 102 that is desired to be searched for job postings/listings and corresponding job information. The scraping agent uniquely has a URL address for its particular destination site, and essentially is a file that provides the parameters to the Kelkoo scraping farm as to what areas on a particular site can be searched, how often, and when for each particular site so that the individual sites are not overused and overscraped. In contrast, the scraping agent for the Cafe Kelsa scraping engine farm preferably simply contains the site URL and scraping frequency requirement information.
[0028] Once the scraping module 112 performs a scrape of the desired career sites, the results of the scraping exercise are passed to a scraping management process module 118 and stored in a Raw Database 122 . This scraping management process module 118 performs functions such as scrape scheduling, error handling, recovery in the event of software failures, error logging and reporting, and monitoring of the scraping process. Thus, for example, scraping management process module 118 may perform objective tests against the raw data to identify gross errors such as non-delivery of information from a site designed to be scraped, garbled data, or data that is comprised of fewer than a predetermined number of bytes, which would be indicative of a failed scraping exercise. Scraping management module 118 is administratively operated externally by operators 120 via an internet 110 connection into the module 118 in a known manner. The resulting output of the scraping management module 112 is fed back to and updates the raw database 122 . This database 122 contains the raw data as received by the scraping process performed by the scraping module 112 , and as corrected in the scraping management module 118 . The output of module 118 is also collected in a cooked, i.e. modified, database 126 .
[0029] The scraping management process module 118 communicates with the scrape listing quality manager module 124 . The scrape listing quality management module 124 instructs the scraping management process module 118 when to transfer a job information data set to the cooked database 126 and then this module 124 preferably begins examination of that data set. The scraped listing quality management module 124 pulls scraped data from the cooked database 126 and performs further quality management tests on the scraped job information received as part of the scraping exercise in module 112 . For example, the listing quality management module 124 performs a high level of quality management such as collecting byte count or job count information from the scraping exercise, performs site comparisons, checks for required fields, compares with previously encountered listings from the same job site to compare data formatting and also to delete duplicates, i.e. “de-dupe,” data to avoid redundant listings. This module also detects and removes dead links and filters profanity and offensive text. The scrape listing quality management module 124 then updates the data set and returns it to the cooked database 126 . Again, this module 124 is administered and operated by operations via an intra 109 connection via a suitable web browser.
[0030] If, in examining a job information data set in module 124 , it is determined that the quality does not meet predetermined criteria, for example, a manual review quality flag can be set in that data set when it is returned to the cooked database 126 by the listing quality management module 124 . A scrape listing quality manual review interface module 128 permits an operator to periodically examine the cooked database 126 for data sets having these set flags. This module 128 indexes these data sets and then utilizes the services of human listing reviewers 130 to perform the highest level of quality management on the scraped job listings to ensure the highest level of quality or to review listings that automated modules 118 and 124 were unable to pass as quality listings.
[0031] Depending on the nature and scope of the quality issues presented by a particular listing, the job listing (job information data set) may be passed to the cooked database 126 through the scraped listing quality management module 124 . This cooked database 126 contains job listings that have undergone a satisfactory level of quality management. Thus, modules 118 and 124 all have the ability to pass approved job listing data sets to the cooked database 126 as well as job listings that have been manually reviewed as part of the manual review process module 128 .
[0032] A job categorization control process module 132 then reviews the job information data sets that pass the quality reviews in the cooked database 126 in order to accurately categorize each job listing. It is important that a job listing be placed in the proper job category, such as for example, information technology, healthcare, accounting, etc. The job categorization control process module 132 preferably is automated.
[0033] In addition, a manual review interface module 134 is available to review job information data sets that the module 132 flags for manual review. This module permits categorization experts 136 to verify categorization data via an intranet connection 109 and update content of a manual categorization “mancat” database 138 and the DCP service 140 . However, the function of the experts 136 may alternatively, as is the case with listing reviewer entities discussed earlier, be automated routines in the future as such systems become more sophisticated.
[0034] The job categorization control process module 132 is preferably automated, while the manual review process module 134 provides a manual check on quality, thus providing a high degree of accuracy in job categorization. The results of this categorization process are stored in “mancat” database 138 , which is a contraction name for the manual categorization database.
[0035] The job categorization process module 132 and the manual review interface 134 both feed job categorization information to a document categorization platform (DCP) service module 140 , identified herein as DCP 140 . The DCP service module 140 looks at the jobs and analyzes the entire text of each job description in each job information data set for comparison to a database of other text to determine a confidence value. Thus, the DCP service module 140 is an automated process that, over a time period, can be “trained” to accurately characterize job information data sets scraped and passed through various levels of quality management.
[0036] The DCP service module 140 functionality is described in more detail in U.S. patent application Ser. No. 10/920,588, mentioned above, along with the related U.S. patent applications referred to therein. The DCP service module 140 preferably compares the text of a newly submitted job description with existing job information data sets in the same category, and look for specific characteristics such as education, use of similar terminology, length, companies worked for, etc., to arrive at a particular level of confidence that the categorization is accurate. Failure to achieve a particular level of confidence through this text matching, for example, a 70% match or less would result in job information being held and placed into the manual characterization database 138 for manual review. A 90% match, would result in job information having a high degree of confidence. This information is attached, or otherwise associated with job information that is stored in the cooked database 126 . Similarly, a job description that has been manually characterized can be identified to cooked database 126 as a job description with a high degree of confidence that has been correctly characterized or categorized.
[0037] For archival storage purposes, periodically the contents of the cooked database 126 are placed in the archive database 142 . Similarly the content of the other databases 138 and 122 may be periodically rotated and dumped for archival purposes to the database 142 .
[0038] Another component in the data handling section 103 is an extractor module 144 . This extractor module 144 works in conjunction with and interfaces directly to a scraped job search bank 146 in the output section 105 of the system 100 . The extractor component or module 144 takes cleansed and categorized job information data sets from the cooked database 126 . It reformats them into a format for use by the scraped search bank 146 and transfers the reformatted data sets to the search bank 146 .
[0039] The server cluster 148 , for example, in reaction to search terms provided by a job seeker 107 through the Internet 110 , accesses the search bank 146 , searches the database 126 , and passes identified scraped job search listings to the cluster 148 and then to a job seeker 107 through the Internet 110 for depiction on a search result user interface screen such as is shown in FIG. 2 . The extractor module 144 preferably also periodically queries the cooked database 126 to provide new scraped job postings to the scraped search bank 146 so that this scraped search bank 146 maintains a current bank of listing data sets.
[0040] The data output section 105 comprises the job search web server/client cluster 148 and a number of data source modules to this cluster 148 . The scraped search bank 146 is one of these. An ad system premium listing module 150 , a paid search bank 152 , an overture system content match module 154 and a link builder module 156 are queried by the job search web server/client cluster 148 .
[0041] The ad system premium listing module 150 organizes and provides the cluster 148 with advertisements from specific employers or recruiters that have a paid premium account with the host of the system 100 . These premium advertisements may be displayed to the job seeker in a special box, bannered, highlighted, or otherwise set off from the other listings that may be presented to a job seeker 107 in response to a particular search request.
[0042] The paid search bank module 152 is a special search bank for which an employer member 160 may access upon a fee payment to the host of the system 100 . This paid search bank module 152 identifies, stores, and tracks job listings from those job recruiter employer or corporations who pay a fee to ensure that their posted job listings receive a higher or emphasized placement on a user interface presented to the job seeker 107 . Thus the paid postings are provided directly into the search bank 152 by the member company via a member desktop 162 or gateway 164 . Paid search bank 152 contains information provided by job listing entities that have paid a premium to the operator of the system 100 described herein to push listings in connection with certain desired search categories provided by a user, so that such search results are provided in a prominent position to the user via the user interface 200 in exchange for a premium payment.
[0043] The Overture system content match module 154 queries whether there are any advertisements that match the job searcher's search criteria. These advertisements are previously stored in or linked to a paid database for use by the host of the system 100 . Examples of such advertisements are shown in the search results user interface screen shot shown in FIG. 3 .
[0044] The link builder module 156 provides linkage cookies and addresses to link to other sources of jobs that match the search terms provided by the job seeker 107 . In some instances, in order for a job description to be viewed, the job seeker must be passed to a particular website to see the listing. In such circumstances the site might require a particular security element such as cookie, password etc. before the job information may be viewed. Accordingly, link builder module 156 provides the necessary interface characteristics in the case where a site needs a particular cookie or other identifier. The link builder module 156 manages the process to build a URL which includes the necessary information required by the site such as for example, a session cookie to access the job listing. The result of the link builder module 156 may be provided to the job seeker 107 in addition to the particular jobs of interest from his/her search request.
[0045] With continued reference to FIG. 1 , the web server cluster 148 acts as a gateway interface to a job seeker 107 seeking to utilize the system 100 described herein. The job seeker 107 , in order to initiate a search request on the system 100 , is preferably presented with a user interface similar to that shown in FIG. 3 . The cluster 148 then searches to obtain information from the system search banks 152 , 154 , 146 and 150 and presents it in an easy to use and efficient manner to the querying job seeker 107 such as in the exemplary results interface shown in FIG. 2 .
[0046] A job seeker 107 entering a search request 302 into a user interface 300 such as that depicted in FIG. 3 interfaces with the server cluster 148 , which in turn presents an aggregated result to the job seeker 107 as shown in FIG. 2 . Thus the user would see, as described below, premium listings through the provision of listings identified by the ad system premium listing module 150 , job search bank 152 , the banks 154 , 150 , 146 and crawled jobs from bank 156 .
[0047] Turning now to FIG. 2 , an exemplary screen shot of a user query result interface 200 is shown. This user interface 200 gives the job seeker an opportunity to review all of the job information that match his query. In addition, it permits the job seeker to submit a different or more refined query. Display portion 202 gives the user an opportunity to review all of the job information that would match a particular search criteria, for example, in FIG. 2 , a software developer position in Illinois. The job seeker may review all of the job information available as a result of the search for software developer positions, or may review only those descriptions that have been updated in the past 24 hours, 7 days, or other preselected time period. Also the job seeker may structure his or her search by experience level, location, or other characteristic or subcategories within a job description.
[0048] The interface 200 also displays result segments separated by multiple preferable result groupings. Thus the system 100 may present a segment for premium listings 204 obtained from ad system premium listing module 150 , which permits the host of the system 100 to utilize the system 100 as a revenue enhancing tool by providing the opportunity for business seeking employers to pay premium to have their job listings obtain a more prominent position in the result portion of the user interface 200 presented to the job seeker 107 .
[0049] The user interface 200 also preferably includes a second subsection 206 which presents results of the search from the paid job search bank 152 . A third subsection 208 presents non-premium algorithmic search results which is a direct result of searching the scraped search bank 146 . A fourth section 210 provides more general paid links from the overture system content match module 154 . Finally, a number of advertisements 209 may be displayed from a search of the ad system premium listing module 150 .
[0050] With reference to FIG. 4 , a simplified functional flow diagram 400 of the scraping performed by the system 100 is shown. This scraping process begins at operation 402 where career sites 102 are scraped. Control then passes to operation 402 where the scraped listings are fed to storage in the raw database 122 . Once stored, control passes to operation 404 . In operation 404 , the scraped listings are submitted to quality assurance/quality management processes described above and further herein with reference to modules 124 and 128 . Control then passes to operation 406 . In operation 406 the clean scraped listings are fed into storage in cooked database 126 . Control then passes to operation 408 . Here the clean scraped listings are categorized in modules 132 and 134 . Control then passes to operation 410 . In operation 410 the clean and categorized scraped listings are fed to storage again in the cooked database 126 . Control then passes to operation 412 . In operation 412 , the cleaned and categorized scraped listings are indexed and formatted in the extractor module 144 for use by the semi-structured search engine described herein. Control then passes to operation 414 . In operation 414 the indexed listings are stored and compiled in the scraped search bank 146 for use. Control then passes to return operation 416 .
[0051] Scraping involves the following components 500 shown in FIG. 5 : the Kelkoo “Sniffer” and Café/Kelsa crawlers in scraping engine 114 , a series of Agents 502 to scrape web sites 102 for jobs, preferably a MySQL database such as raw database 122 to store the scraped jobs and agent logs, and Runner scripts 504 to launch the agents 502 .
[0052] The following is a summary of how data flows preferably through the scraping farm 112 in the system 100 . At the beginning of the scraping cycle the “job_current” table 500 is truncated and its contents are copied to an archive table (not shown). Archives of scraped jobs are preferably stored for a limited period only (e.g. 7 days).
[0053] The Kelkoo “Sniffer” in the scraping engine 114 is a Java program that is used to launch adapters (a.k.a. agents 502 ). The scraping engines 114 scrape the job boards 102 , via the Agents 502 . Each agent 502 preferably consists of three text files: agent.info, agent.props, and agent.sql. A single agent is used to scrape a single web site. The agent files are stored in an agent specific directory. Then the agents 502 dump the scraped job information sets into a “job” table (note that there can be several job tables) 506 , two of which are shown in FIG. 5 . The Runners 504 copy the job information sets, or records, from the “job” table(s) 506 to the “job_current” table 510 . Components downstream from the runner 504 , such as the Quality Manager module 124 and the Categorizer modules 132 and 134 pull copies of the job records from the cooked database 126 and perform quality management and categorization operations on the records in the job_current table 510 , which is preferably part of the cooked database 126 . The results are then passed back to the cooked database 126 shown in FIG. 1 .
[0054] The Kelkoo Sniffer search engine 114 thinks about agents 502 as virtual SQL tables. The schema of the virtual table is defined in the agent.sql file. The agent.info file is a SELECT statement against the virtual table that the Sniffer search engine 114 runs. The agent.props file contains the scraping logic that is used to fill the virtual table. The scraping logic is a sequence of steps that are carried out by various filters. Filters are Java classes that make up an Adapter Development Kit (ADK). Filters are executed sequentially and can read and write variables to a common context. There are filters to: find a string or a pattern in an html page and save it, manipulate variables of the context, loop over a re-occurring pattern and execute other filters in a loop, go to a page identified by a URL and retrieve its content, etc.
[0055] The output of an agent 502 is a text file that contains SQL INSERT statements for each scraped job. The Sniffer search engine 114 uses this data file to load the scraped job information data sets or records into a MySQL table, called “job” (the actual table name is a configuration parameter) 506 . The Sniffer 114 is configured via various command line parameters and an arbitrary number of property files that are passed in on the command line. The most important configuration parameters of the Sniffer search engine 114 are: Name of the MySQL database, database user and password, name of the table to dump the scraped records to; and the Path to the agent request files and the directory that contains the agents 502 .
[0056] The Sniffer search engine 114 is preferably single threaded: it loads and runs one agent 502 at a time. After running an agent 502 the Sniffer search engine 114 inserts a record to the “report” table 508 with information about: the time of the run, the name and path of the agent 502 , the number of scraped records (jobs), and possible errors.
[0057] The agent files are stored in a CVS repository. The version of the agent 502 that has passed QA is tagged with a special CVS tag. This scheme allows agent developers, testers and the production system to work on the same tree, yet to avoid running un-tested agents in production.
[0058] The agent runner 504 is a Perl script that is developed for the system 100 . The Runner 504 requires that the agent files be available on the local file system. Before the Runner 504 is started the local CVS tree is synced to the production tag to download all the agent files that should be run.
[0059] The runner 504 performs the following steps:
1. It reads its configuration file. This contains the list of agents 502 to run. Each Runner has an id that is passed in as part of the configuration. 2. It generates configuration files for the Sniffer 114 based on its own configuration. 3. It deletes all the records from the job_current table 510 that belong to the agents 502 to be run (this in most cases is unnecessary, since preferably the job_current table is truncated every day). 4. It launches the Sniffer search engine 114 that runs the agents 502 . 5. It preferably processes each record in the job table to strip the job information from html tags. Each Runner has its “own” job table 506 whose name is generated using the runner's id (e.g. “job1”). 6. It dumps all the records from the job table 506 to the job_current table 500 . The job records contain the id of the Runner, which helps downstream components to easily identify records that came from a particular Runner 504 . 7. It writes a summary of the agents run to its log file. This information is retrieved via queries to the job, job-current and the report tables 506 , 500 and 508 respectively. 8. Finally, it invokes the Quality Manager management process module 124 via a secure shell such as SSH, so it can execute on a separate machine. The ID of the Runner 504 is passed to the Quality Manager module 124 , so it knows which records to process from the job_current table 500 .
[0068] The system 100 is primarily designed to handle scraped jobs in addition to listings provided from standard sources that generally have standardized formats and categorizations. These scraped jobs typically may not have category assignments such as Accounting, Banking, Engineering, medical, dental, etc. In order to support a “browse by category” feature that jobseekers are most familiar with, we could have many human categorizers spend a great deal of time to manually classify jobs as they are scraped. However, this has substantial drawbacks. It is a very time consuming process. By the time the jobs are manually classified, they may be outdated already. Such a process requires a lot of human resources. Further different categorizers may not categorize in the same consistent manner. For this reason, an exemplary automatic Job Categorization System 600 that may be used is shown in FIG. 6 . This system 600 is capable of categorizing a job in a fraction of a second. It is substantially faster than human categorizer, and, it is consistent.
[0069] This Job Categorization System 600 contains several modules. A job categorization (Job Cat) Service module 602 which carries out the actual categorization routine. The Job Categorization Control Process module 132 is one example, which is described with FIG. 1 , which manages communication between the Job_current table 510 in the cooked database 126 , the ManCat database 138 , and the DCP 140 . The DCP 140 corresponds to one example of a Job Cat Service module 602 . The Categorization Training Process, which is used to enhance or maintain the accuracy level of the Job Cat Service 602 . This categorization training process involves the use of the job categorization manual review interface 134 and categorization experts 136 shown in FIG. 1 .
[0070] As described above, the jobs scraped are added to a MySQL job_current table 510 . Then the Job Categorization Process 600 will take each job from the job_current table 510 , and send it through the job categorization control process module 132 to the Job Cat Service module 602 to get a category and confidence assignment. Then the scraped job is sent back to the categorization control process module 132 and returned to the job_current table 510 . However, if a job falls below a predetermined confidence threshold it will be flagged, i.e. a flag set, and when it passes through the categorization control process module 132 a copy is also sent to the mancat database 138 for manual review via the manual review interface module 134 . The results of the manual review process performed in review module 134 are then used by the Categorization Training Process 606 to tune a new Job Cat Service value to replace the old one. The result of classification is written back to job_current table 510 and sometimes the mancat table 138 . The Manual review module 134 provides a UI to review both jobs in job_current and mancat tables.
[0071] FIG. 7 is an operational flow diagram of an implementation of the job categorization process 600 . The process begins in operation 702 when a sequence of job scrapings has been performed. Control transfers to operation 704 . In operation 704 the job attributes for the next job are retrieved from the job_current table 510 and the job information is properly formatted. The job attributes are then transferred to the job cat service 602 to find a proper category. Control then transfers to operation 706 where the job category and confidence level for that categorization are paired with the job. Control then transfers to query operation 708 .
[0072] Query operation 708 asks whether there is a matching URL existing in the mancat table for the latest particular job information. If there is, then control transfers to operation 710 . If not, the job is a new job, and control transfers to operation 716 .
[0073] In operation 710 , a string compare routine is performed on the last job with the same URL. Control then transfers to query operation 712 . Query operation 712 asks whether the listing in the mancat table 138 is the same as the current job being examined. If the job string compare is equal, then the answer is yes, and control transfers to operation 714 since it appears that the job is the same job. On the other hand, if the answer is no, the job is new, and control again transfers to operation 716 .
[0074] Query operation 714 asks whether the dcp_cat matches the man_cat of the latest job with the same URL. If the answer is yes, then the man_cat and dcp_cat are set equal and the dcp_cat confidence is set equal to 1.
[0075] The job parameters back to the job_current table 510 , and control transfers to query operation 718 . Query operation 718 asks whether there are more scraped jobs in the job_current table to be categorized. If not, control transfers to return operation 720 . If there are more scraped jobs to be categorized, control passes back to operation 704 and the job parameters for the next job are retrieved and formatted.
[0076] Returning to query operation 708 , if the URL does not exist in the mancat table, then control transfers to operation 716 . In operation 716 , the Dcp_cat and dcp_confidence are set, the confidence value is checked against the threshold that has been predetermined, and if the threshold is greater than the confidence value, the review_flag is set equal to 1. The job parameters are then passed to the job_current table 510 and again, control passes to query operation 718 .
[0077] Returning to query operation 714 , if the current jog has a URL in the mancat table 510 , the job is the same as the last job with the same URL, but the dcp_cat and an_cat of the latest job do not match, then something may be wrong or missing, and the job parameters are passed to both operations 724 and 726 . Operation 724 sets the dcp_cat, the dcp_confidence values, sets the expert_review flag=1 and feeds this data to the Job_current table 510 . Operation 726 sets the expert_review flag=1 and sends a copy of this job's parameters to the mancat database 138 so that manual review will be performed. In parallel, control again passes to the query operation 718 as described above.
[0078] Thus, for each job, the Job Categorization Control Process take job attributes from the job_current table, formats them, and sends them over to Job Cat Service managed by a well known public domain routine called Apache, method=POST), gets back a category and confidence score, goes through a chain of decision questions, and writes results back to the tables.
[0079] The Job Cat Service 602 also provides a web UI that allows administrators and system operators in a job (at least the job description) and submit the job to the Job Cat Service for categorization separately from the normal operation of the system 100 . Such an exemplary user interface 800 is shown in FIG. 8 .
[0080] The Job Cat Service 602 depends on Apache, a well known management routine to manage the training process 606 shown in FIG. 6 . The JobCat Service 602 contains a binary package that is a shared library of PHP extensions and also includes a Categorization library. Building the Job Cat Service 602 first requires a set of basic definitions i.e. a taxonomy 608 , of job categories and associated unique ID numbers. An exemplary set is shown in Table 1 below.
TABLE 1 Cat_id Cat_name 1 Accounting_Finance 2 Advertising_Public_Relations 3 Arts_Entertainment_Publishing 4 Banking_Mortgage 5 Clerical_Administrative 6 Construction_Facilities 7 Customer_Service 8 Education_Training 9 Engineering_Architecture 10 Government 11 Health_Care 12 Hospitality_Travel 13 Human_Resources 14 Insurance 15 Internet_New_Media 16 Law_Enforcement_Security 17 Legal 18 Management_Consulting 19 Manufacturing_Operations 20 Marketing 21 Non_Profit_Volunteer 22 Pharmaceutical_Biotech 23 Real_Estate 24 Restaurant_Food_Service 25 Retail 26 Sales 27 Technology 28 Telecommunications 29 Transportation_Logistics 30 Work_At_Home
[0081] An exemplary table of training job information, training data 610 , is associated with each of the categories in Table 1. This set of descriptions, plus the content of the mancat database 138 , is used to teach the Service to recognize classifications from the provided job information parameters that are preclassified. An example of this table is shown in Table 2 below.
TABLE 2 Field Type Null Comment Pindex Varchar(11) No, Primary key Title Varchar(11) Yes Ldesc Text No Mancat Varchar(101) No Actually set to the first industry setting initially Gid Int Yes Group id, some id are used by HJ internal for testing, they should not be used for training Hiretype Varchar(21) Yes Companyname Varchar(101) Yes Salarytype Varchar(21) Yes Sdesc Varchar(101) Yes Sourcetype Varchar(11) Yes Source Varchar(21) Yes Duration Varchar(3) Yes Position Varchar(21) Yes Experience level Degrees Varchar(31) Yes Salaryfrom Float Yes Salaryto Float Yes Ownerid Varchar(11) Yes Creatorid Varchar(11) Yes Editorid Varchar(11) Yes Ctime Date Yes Date created Mtime Date Yes Date modified Score Int Yes The YSS score, not used
[0082] For new training sessions, it is preferable to use both jobs from this table and those in the mancat table. As more and more manual reviewed jobs become available, it is preferable to eventually drop the original training set from the HotJob's read-only database.
[0083] In a preferred embodiment the columns of this table 2 and the mancat table are different, and this difference will remain, and the script that creates the training file will do all necessary mappings. The training process 606 consists of several PEARL scripts. A “create-training-file.pl” script takes jobs from both the mancat table 138 and a train data table 610 , and writes out a file containing all jobs in a DCP accepted format to generate the merged training data 612 . A “train-hj-dcp.pl” script is used to tune a few of the most useful parameters for classification. Each of the configurations specified will leave an output directory containing all the parameters that are needed to build a Job Cat Service data package, and a log file. A “parse-training-log.pl” script reads each of the log files generated by the train-hj-dcp.pl script and generates a report on accuracy for each configuration. An “archive-training-results.pl” script is used to archive the training results for that configuration after a configuration is used for deployment.
[0084] The training process 614 is basically a manual process that draws from the training data 612 , the taxonomy 608 , and sets of rules and schema 616 . Various dictionaries and tuning parameters 618 may also be utilized. The results involve optimization of new classifier parameters 620 with the results being provided into the job categorization service 602 as shown in FIG. 6 . Since the training process 614 is mostly manual, it is preferable to train on a few parameters, manually check the results, e.g. detail pages of classification, term weights, etc, and change some of the rules and dictionaries by hand, and repeat the process with different configurations in order to find the optimal settings for deployment. When such an optimal configuration is achieved, the new classifier parameters 620 are passed to the Job Categorization Service 602 . Once the Job Categorization Service is built up and running, scraped jobs can then be processed as described above.
[0085] The screen shot of the exemplary user interface 800 is presented to an administrator, operator or categorization expert 136 through the internet 110 using a web browser. The interface 800 provides three different modes 802 via a pull down menu as shown. The “all categories” mode lists all categories and their corresponding confidence values, sorted in descending order by confidence. The “Detail Statistics” mode shows the details on why a particular category is chosen. This mode is useful for an operator who tunes the system 100 . The “Best Category” mode shows only the top category for the job and its confidence. This is equal to the first result shown in “All Categories” mode, except here we show the category ID number, not a string. This mode is intended for automatic classification of jobs in the database, where the category ID number is preferred over the category name.
[0086] An operational flow diagram of the job categorization manual review process 900 that takes place in the job categorization manual review module 134 is shown in FIG. 9 . Operational flow begins when an administrative operator or a categorization expert 136 logs in via backyard in operation 902 . When the administrator logs in, he or she is presented in operation 904 with a user interface 1000 as shown in FIG. 10 . This user interface 1000 permits the administrator or expert reviewer choices of job category 1002 , company 1004 , and selection of a type of review 1006 to conduct. Control then transfers to operation 906 . In operation 906 , a first/next job information is retrieved from the mancat database 138 or the job-current file 510 in the cooked database 126 , depending on the administrator's prior selections in operation 904 . The administrator is presented with a user interface such as the exemplary interface 1100 shown in FIG. 11 .
[0087] This user interface 1100 displays the first/next job information 1102 along with the category confidence level s determined for each category. In this example, the job is a post-doc position at IBM Corp. The confidence levels are zero for all but Engineering_Architecture and Pharmaceutical_Biotech, and none of the levels match 100%. This position has been categorized as Engineering Architecture, but the confidence level is only 0.657, so it was flagged for manual review.
[0088] Referring back to FIG. 9 , when the job information is retrieved in operation 906 , control transfers to operation 908 where the administrator analyzes the categorization based on the full job information. The administrator then has three choices of action. First, he can invalidate the job in query operation 910 . Second, he can get more job details in query operation 912 by clicking on the job URL 1110 to enhance his review. Third, he can update a category definition or insert a new category in query operation 914 . If his decision is to invalidate the job in query operation 910 , then control transfers to operation 916 where the job is removed from the database 126 and from the mancat database 138 . Control then transfers to query operation 918 . Query operation 918 asks whether there is another job information in the queue of the mancat database 138 or job_current table 510 that has its expert_review flag=1 set. If so, control transfers back to operation 906 where the next job is retrieved for review.
[0089] However, if the decision in operation 910 is not to invalidate the job, control resets the expert_review flag=0, returns the job to the job_current table 510 and control transfers to query operation 918 . If the choice in operation 908 is to get more job details, control transfers to operation 920 , where the details are retrieved and control transfers back again to operation 908 . If the administrator then chooses not to get more details, the job listing record is again returned to the job_current table 510 after resetting the expert_review flag=0 and control passes again to query operation 918 . If the choice in operation 908 is to update the category in query operation 914 , then control passes to operation 922 .
[0090] In operation 922 the category of the job listing is changed or a new one added, and saved. The expert_review flag is set=0 and the job listing information is then transferred to the job_current database 510 and control transfers to query operation 918 . If there are no more job listings with expert_review flags set=1, control transfers to return operation 924 and the review session is complete.
[0091] Although functional components, modules, software elements, hardware elements, and features and functions described herein may be depicted or described as being fixed in software or hardware or otherwise, it will be recognized by persons of skill in the art that the features and functions described herein may be implemented in various software, hardware and/or firmware combinations and that the functions described herein may be distributed into various components or subcomponents on the network and are not fixed to any one particular component as described herein. Thus the databases described may be separated, unified, federated, or otherwise structured to best suit the preferences of the implementer of the features and functions described herein. Also, the functions described herein as preferably being performed manually may be performed manually or may be divided into subtasks which may be automated and ultimately performed by intelligent subsystems which mimic human operator interaction such as artificial intelligence systems which may be trained by human operations and ultimately function autonomously. Further features, functions, and technical specifications are found in the attached descriptions further below as well as the figures contained therein.
[0092] While the apparatus and method have been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all embodiments of the following claims. | A computer system and method for capture and handling job listings obtained from various often unrelated corporate and job board postings via the internet for examination by a job searcher. This system includes a scraping module having one or more scraping engines operable to scrape job information data set from job listings on the corporate career sites and job boards, wherein the scraping module receives and stores the scraped job information data set in a database. The system also has a scraping management interface module coordinating operation of and communication between the scraping engines and the career sites and job boards, a scraped listing quality management module coupled to the scraping management interface module analyzing selected scraped job information data stored in the database, and a job categorization module that examines and categorizes each job information stored in the database into one or more of a predetermined set of categories and returns categorized job information to the database, and an extractor module communicating with the database for compiling and transferring categorized job information data from the database to a search bank. The search bank is then accessible by a job searcher through a job search client server cluster connected to the Internet. | 8 |
This application is a continuation of U.S. patent application Ser. No. 13/042,402, filed Mar. 7, 2011, now U.S. Pat. No. 8,164,459 which is currently allowed and is a continuation of U.S. Ser. No. 11/999,398, filed Dec. 5, 2007, now U.S. Pat. No. 7,902,985, both of which herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
This invention relates to a radio frequency identification (RFID) systems that use RFID tags to track product inventory, or other mobile items.
BACKGROUND OF THE INVENTION
Information management systems are being developed to track the location and/or status of a large variety of mobile entities such as products, vehicles, people, animals, etc. A widely used tracking technology uses so-called RFID tags that are placed physically on the items being tracked. Reference herein to “items” being tracked is intended to include the variety of entities just mentioned as well as, more commonly, product inventories.
RFID tags may be active or passive. Active tags typically have associated power systems and can transmit data over modest distances. Passive systems lack internal power but derive transmitting signal power from an incoming RF signal. However, transmitting distances with passive RFID tags are very limited. To read a large number of RFID tags, spread over a wide physical area, requires either a large number of RFID readers, or a reliable system of moving RFID readers. One proposed solution to this problem is to use active RFID tags on the products. However, active tags are relatively costly. Although they lend more function to a tracking system, and transmit more effectively, passive tags are typically more cost effective where inventories being tracked are large.
What is needed is an improved system for RFID tracking where the scale of the application exceeds the performance capability of conventional RFID approaches.
STATEMENT OF THE INVENTION
We have developed a new architecture for RFID systems that is adapted to process large numbers of RFID tags and provide information about a large number of items. The system provides for multiple tag readers. The tag readers are active and have both transmit and receive capability. The system includes a new element called a gateway tag that receives information about individual items from the multiple readers and thus contains data on the entire inventory of items. This allows each of the multiple readers to access data for the entire inventory of items. The gateway tag may interface with an information storage center that also contains data for the entire inventory of items.
BRIEF DESCRIPTION OF THE DRAWING
The invention may be better understood when considered in conjunction with the drawing in which:
FIG. 1 is a schematic view of a typical RFID tag system;
FIG. 2 is a representation of a passive RFID tag;
FIG. 3 is a representation of an active RFID reader;
FIG. 4 is a schematic view of the RFID tag system of the invention; and
FIG. 5 is a representation of a gateway RFID tag according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic representation of a typical RFID system wherein the RFID tag is shown at 11 , the RFID reader at 12 and a central information store at 13 . A wide variety of implementations are used for the function of tracking large numbers of items, many of which use the basic elements shown in FIG. 1 . Typically, the RFID tag 11 is a passive device attached to the item being tracked. The reader 12 is an active RFID device that communicates with large numbers of passive RFID tags, and typically either stores data in the reader, and/or relays data to a central database 13 . The central database keeps data for all items in the system. In many applications, for example, large retail outlets, the RFID readers are mobile devices that are moved around the vicinity of the RFID tags to record the RFID tag data. Mobility in this application is necessary since the transmission distance between the RFID tags and the RFID readers is very limited, for example, tens of meters maximum, and typically less than 10 meters. The RFID readers are typically powered, which extends the range of transmission between the RFID readers and a remotely located receiver. That allows the option of using a RFID reader to simply relay RFID tags to a central database. More typically, the reader reads the passive RFID and stores the information locally. This data may be downloaded to the central store periodically, by placing the reader in a docking device that is connected by wireless or hardwired link to the central database. In the latter case, a wireless link between the RFID reader and a remote receiver may or may not be used.
A passive RFID tag is shown at 21 in FIG. 2 . RFID tags are miniaturized as much as practical to allow for the essential elements of a semiconductor IC chip 22 , typically a CMOS chip, and an antenna 23 . The IC chip contains a memory, usually a read-only memory encoded with item data. The antenna is a serpentine metal conductor that receives small amounts of power from the RFID reader by inductive coupling. When the IC chip is powered, it transmits item data back to the RFID reader via antenna 23 .
Passive RFID tag designs are available in many sizes and designs. Common characteristics are a platform, an IC chip, and an antenna. Depending on the application the platform may be glass, ceramic, epoxy, paper, cardboard, or any suitable plastic. An onboard power source is not included in a passive RFID tag. All power for the tag is derived from RF signals in the vicinity of the tag. The tag responds to the reader using RF backscatter, which basically reflects the carrier wave from the reader after encoding data on the carrier wave. Variables in the communication specification include the frequency of the carrier, the bit data rate, the method of encoding and any other parameters that may be needed. ISO 18000 and EPCGlobal are the standards for this interface. The interface may also include an anti-collision protocol that allows more than one tag in the range of the reader to signal concurrently. There are many specific implementations of this, and these form no part of the invention.
A typical schematic for an RFID reader is shown in FIG. 3 . The reader 31 includes RF transceiver chip 32 , microprocessor chip 33 , and battery 34 . The transceiver chip communicates through an attached antenna as indicated. These components allow the reader to not only receive data from the passive RFID tags, but to store and process the data and transmit the data to another device or station. Since the reader is powered, it can transmit data over significant distances, for example, 100 to 3000 thousand feet.
A schematic of an RFID tag system according to the invention is shown in FIG. 4 . The RFID tags are shown organized in groups A, B, and C. These groups may represent different departments in a retail outlet, separate floors or buildings in a warehouse complex, separate railroad cars or shipping containers, etc. In the arrangement shown, each group communicates with an associated RFID reader 41 , 42 , and 43 . It should be understood that this arrangement is shown by way of example only. There are many alternative configurations using RFID tags and readers. The RFID readers communicate with gateway RFID tag 45 . The link between the RFID readers and the gateway RFID tag may operate at a frequency different than the frequency used in the link between the RFID readers and the passive RFID tags. The readers collectively provide data to the gateway RFID tag for all of the items in the system. This arrangement allows any reader in the system to access data on any item in the system via the gateway RFID tag. Since the transmission to and from the gateway RFID tag to the RFID readers is powered, that link may be essentially any distance within the facility served by the RFID system. The gateway RFID tag may be a standalone unit, or, as indicated in FIG. 4 , interfaced via network 46 to a central database and memory store 47 . The network may be a wireless network, or a wired network (land line).
A schematic of the gateway RFID tag 45 in FIG. 4 is shown in FIG. 5 . The gateway RFID tag is an active tag, with battery 54 . It also has a processor 53 , a large memory 56 , and an RF transceiver 52 . The gateway RFID tag interfaces with each of the RFID readers as shown in FIG. 4 , and may interface with a central database via a wireless or wired network. The latter is an optional feature. The system may be designed with a direct interface between the RFID readers and the central database, as described in conjunction with FIG. 1 , and with a parallel link between the RFID readers and the gateway RFID tag. Adding a link between the gateway RFID tag and the central database allows data consistency between the two to be verified. Both of these subsystems typically contain data on all of the items being tracked by the system, i.e. universal system data. However, using an arrangement like that shown in FIG. 4 allows the universal system data stored at the gateway RFID tag to be different (typically less detailed) than the data stored at the central database.
For the purpose of defining terms used herein, a passive RFID tag means a device containing at least an integrated circuit chip operating at a given frequency and an antenna, but no onboard power source. The antenna operates as a low power RF transceiver. The integrated circuit chip contains a memory. An RFID reader means a device containing at least an integrated circuit chip, an antenna, an RF transmitter, an RF receiver, and a power source. The integrated circuit chip in the RFID reader contains a memory. The RFID reader has an RF transmitter that operates at the same frequency as the RFID tags, and an RF transmitter that may operate at a frequency different from that of the RFID tags. A gateway RFID tag means a device containing at least an integrated circuit chip, an antenna, an RF transmitter, an RF receiver, and a power source. The integrated circuit chip in the gateway RFID reader contains a memory. The gateway RFID reader has an RF transmitter that operates at the same frequency as the RFID readers, and may have a communications link to a remote central database. A remote central database has a microprocessor and a memory store. It may or may not be located on the same physical premises as the gateway RFID tag.
Transmitting range means the range over which signals transmitted from a transmitting device can be received by a receiving device.
In summary, an aspect of the invention is that data from an item that is not in the vicinity of an RFID reader, and thus not accessible directly from that reader, can nevertheless be accessed by that reader through the gateway RFID tag. The sequence of operations for accomplishing this involves transmitting an RFID signal between a first RFID reader and a first group of passive RFID tags, receiving at the first RFID reader first data from the first group of passive RFID tags, transmitting said first data from the RFID reader to a gateway RFID tag, receiving and storing the first data at the gateway RFID tag, transmitting an RFID signal between a second RFID reader and a second group of passive RFID tags, receiving at the second RFID reader second data from the second group of passive RFID tags, transmitting said second data from the RFID reader to the gateway RFID tag, receiving and storing the second data at the gateway RFID tag, transmitting to the gateway RFID tag a query from the first RFID reader, receiving the query at the gateway RFID tag, and transmitting second data from the gateway RFID tag to the first RFID reader.
Various additional modifications of this invention will occur to those skilled in the art. All deviations from the specific teachings of this specification that basically rely on the principles and their equivalents through which the art has been advanced are properly considered within the scope of the invention as described and claimed. | A system and method are disclosed for transporting deterministic traffic in a gigabit passive optical network. A system that incorporates teachings of the present disclosure may include, for example, an Optical Line Termination (OLT) for exchanging data traffic in a Gigabit Passive Optical Network (GPON) having a controller programmed to generate a timeslot schedule for transport of a desired bandwidth of constant bit rate (CBR) data traffic by selecting one or more timeslots from periodic frame clusters operating according to a GPON Transmission Convergence (GTC) protocol. Additional embodiments are disclosed. | 6 |
This application is a continuation-in-part of application, Ser. No. 374,692, filed July 3, 1989 and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a method of manufacturing a pultruded part which is particularly but not exclusively developed for manufacturing a spacer for a sealed window unit which is manufactured so that it is moisture impermeable.
As is well known, sealed window units comprise two glass panes which are coextensive so that the edges are overlying, a spacer element which is arranged at each edge of the panes and holds the panes in the properly spaced relationship and a sealing material which is applied around the exterior of the spacer. It is essential that moisture does not enter the area between the panes since that moisture will then condense on one of the panes and prevent the proper transparency of the window unit. For this purpose a dessicant is generally introduced into the hollow interior of the spacer and the spacer is designed either by a slot or by other techniques so that the moisture that remains within the area between the panes can escape for collection by the desicant. It is also essential that the spacer is sealed relative to the panes so that no moisture can enter from the exterior edges of the window unit.
Conventionally such spacers have been manufactured from aluminum which is entirely moisture impermeable. Aluminum spacers have a number of disadvantages however particularly in relation to the thermal expansion characteristics and the relatively high thermal conductivity.
Many attempts have been made therefore over the years to design a spacer which is manufactured from other materials. Many of these attempts have failed completely. One attempt which has met with a significant degree of success is that shown in European Patent Publication No. 113209 which shows a spacer which is manufactured by pultrusion from a thermosetting resin material which is reinforced by fibers which are preferably glass fibers. This spacer has the advantage of an improved thermal conductivity and a coefficient of thermal expansion which is much closer to that of glass.
One problem which has arisen with a product of this type is that the resin material is not itself impermeable to moisture so that it is possible for moisture to penetrate the part known as moisture vapor transmission or MVT so that the moisture can enter the area between the panes and interfere with the proper usage of the product.
One solution to this problem has been to replace the conventional sealant around the outside of the spacer by an improved sealant which itself is impermeable to moisture and thus prevents the moisture from reaching the spacer itself. However this disadvantage of the poorer MVT of the spacer has led to some adverse criticism and a reduction in the success which should otherwise be achieved in view of the improvements in other qualities relative to the conventionally used aluminum.
It is known that foil material when applied as a layer on an outer surface of a part can provide a complete impermeability to moisture. Attempts have therefore been made to adhesively attach a foil onto the exterior of a part and particularly to the exterior of a spacer formed from a resin material so as to provide for the spacer an improved MVT. However this technique is unsatisfactory in that it requires the adhesive application of a foil in an additional step, it leaves the foil exposed and accessible to damage and it weakens the structure of the part since the foil can be torn away. This technique has therefore achieved little success.
SUMMARY OF THE INVENTION
It is one object of the invention, therefore to provide an improved pultruded part and a method for manufacturing a pultruded part in which the moisture vapour transmission or MVT is significantly improved.
According to the first aspect of the invention, therefore, there is provided a method of manufacturing a pultruded part comprising collating a plurality of reinforcing structures which are longitudinally continuous, each structure having a plurality of reinforcing fibers, impregnating the structures with a settable resin, passing the collated structures through a die to form the structures into a required shaped part, causing the resin to set to form the shaped part, applying a pulling force to the part when set, and introducing into the structures a layer of a moisture impermeable material at a position upstream of the die so that the layer is formed with the structures into the part.
According to a second aspect of the invention, therefore, there is provided a pultruded part comprising a plurality of reinforcing fibers, a settable resin material in which the fibers are embedded and a moisture impermeable foil layer extending continuously in a longitudinal direction of the part, the layer being at least partly covered on both sides by the reinforcing fibers.
According to a third aspect of the invention, therefore, there is provided a spacer for a sealed window unit comprising an elongate body having two spaced side surfaces each for engaging a glass pane such that that the glass panes are held spaced in the sealed window unit, a top surface for facing inwardly of an edge of the window unit, a bottom surface for facing outwardly of an edge of the window unit and a hollow interior surrounded by said surfaces, the spacer being formed by pultrusion from a thermosetting resin material reinforced by a fibrous material and including a layer of a moisture impermeable material embedded in the resin material so that it extends continuously longitudinally of the spacer and across at least the bottom surface, the layer being at least partly covered on both sides thereof by said fibrous material.
With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the best mode known to the applicant and of the preferred typical embodiment of the principles of the present invention, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a pultrusion system according to the invention.
FIG. 2 is a cross sectional view of a sealed window unit incorporating a spacer according to the invention.
FIG. 3 is a cross sectional view of a spacer according to the invention on an enlarged scale and of a different type from the spacer shown in FIG. 2.
FIG. 4 is a cross-sectional view of a further spacer according to the invention.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
A sealed window unit is a conventional item and as well known comprises a pair of panes 10 and 11 which lie parallel and are spaced at their side edges by spacers generally indicated at 12. Each of the spacers comprises an elongate body which is cut to length and joined at corners to form a frame system which fits inside the panes at the edges of the panes to the hold the panes in the required spaced position. In the embodiment shown in FIG. 2, the spacer is of the type which uses a double sealing system including a first portion of sealant 21 along the sides of the spacer and a second sealant 22 at the outer surface of the spacer. A covering layer of a further sealing material is applied at 23. To accommodate the sealant material 21, each of the side surfaces is slightly recessed.
A second type of spacer element is shown in FIG. 3 in which the side surfaces 25 and 26 are substantially flat and a bottom surface 27 includes a pair of inclined portions 28 and 29 which extend downwardly toward a lowermost portion 30 thus defining a larger area for receiving the additional amount of sealing material around the edge to make up for the absence of sealing material at the sides.
Generally, therefore, the spacer element has a top surface 31, the sides 25 and 26 and a bottom surface 27. The spacer shown in FIG. 2 is of a similar configuration although as described above the design is slightly different. The four surfaces surround a hollow interior 32 which can be filled with a desicant as indicated at 33 in FIG. 2.
The general structure of the sealed window unit and the spacer element are shown for example in European patent application no: 113209 published July 11th, 1984. In addition the general system of the pultrusion technique shown in FIG. 1 is also described in more detail in the above European patent application and is known to those skilled in the art.
Turning therefore now to the details of the present invention, the spacer element is modified in two ways. Firstly the spacer element is formed so it includes embedded within the element a layer 40 consisting of a foil layer 41 and a mat layer 42. The layer 40 is supplied to the pultrusion process on a supply reel 43 and in addition to the pultrusion process is supplied a plurality of rovings on reels or spools 44. The supply material is collated into a bundle of material which is dipped into a bath 45 of a suitable thermosetting resin 46 so that the bundle or collation of the fiber elements or structures is impregnated with the thermosetting resin. The impregnated bundle is then fed into a die 46 which has a mandrel 47 so that the die and mandrel cooperate to shape the spacer into the four sides and the hollow interior described above. The die includes heating elements 48 which set the thermosetting material into the required shape while the material is held in the shape by the elongate die. Downstream of the die the set part is pulled from the die by a pulling system indicated at 50 and is subsequently cut to required lengths by a cutting system 51. The layer 40 comprises a continuous tape or strip of material carrying foil on one side and a fibrous mat on the other side adhesively attached to the foil. The mat comprises bi-directional fibers preferably of glass and generally in nonwoven form although other forms may be possible. The width of the layer 40 is chosen so that it takes up the position shown in FIGS. 2 and 3 that is it extends from one end at a position at a mid-height of the side wall 25, across the bottom wall 27 and to a position mid-height of the side wall 26. The layer is continuous from one edge to the other edge. The foil portion of the layer is impervious to moisture or moisture vapour so that the lower portion of this spacer as shown in FIG. 3 is substantially totally impervious to moisture vapour transmission. The layer is formed in the pultrusion process so that the foil is covered on both surfaces by the fiber reinforcements. One side of the layer carries the mat which may or may not be covered by further layers of roving and the other layer of the foil is covered by the layers of roving so the foil is held away from the inner surface of the die and is fully embedded within the part when the part is complete. The control of the rovings and the layer as they are fed toward the die so that the required positioning is obtained is well known to one skilled in the art and can be properly controlled so that the layer remains continuously at the buried position throughout the continuous manufacture of the spacer element.
The thickness of the walls of the element are arranged such that the thickness at the position containing the layer 40 is greater than the thickness at the remaining part. Thus for example the thickness of the upper wall 31 may be of the order of 0.055 inches and the thickness of the part containing the layer 40 may be of the order of 0.070 inches. This design of the part has two advantages. Firstly the reduction in thickness of the upper wall 31 allows that wall to have an increased permeability to moisture vapour so that it is no longer necessary to provide a slot or other apertures in the upper wall to allow the moisture vapour in the area between the panes to reach the desicant. This moisture vapour can therefore be transmitted directly through the upper wall 31 and is gradually over time removed by the desicant 33.
Secondly the advantage in the design of the part by which the upper wall 31 is reduced in thickness allows the part to have an equalized drag on the die as it passes through the die. The layer 40 tends to increase the drag as it is passed through the die and it is necessary therefore to modify the remainder of the parts so that the drag is substantially equalized. This is obtained by reducing the thickness of the upper wall so that the forces on the upper wall are increased as it is formed thus increasing drag. The part can then be formed without a tendency to bow as it is passed through the die.
The manufacture of the spacer element without the necessity for a central slot for communication of the moisture vapour to the desicant allows the element to be manufactured with thinner wall structure thus reducing the amount of material and accordingly the cost.
The element as shown in FIG. 3 is formed substantially wholly from the thermosetting resin which is reinforced solely by roving material which is uni-directional and by the layer 40.
Turning now to FIG. 4, this figure is similar to FIG. 3 in that it includes a spacer as described indicated at 50 which has the moisture permeable layer 51 embedded during the manufacturing technique as previously described. In this case, however, the layer is carefully inserted into the body of the spacer so that it approaches as closely as possible or reaches the outer surface 52 of the spacer at the sides of the spacer. Thus the outermost edge of the layer indicated at 53 lies in or contacts the surface 52 so that the moisture impermeability extends from one side edge of the spacer to the opposed side edge without any path of permeability along the sides of the spacer.
In addition in this case the layer generally indicated at 51 is modified in that it comprises a three part laminate defined by three layers 54, 55 and 56. The central layer 55 is formed of the foil material to provide the moisture impermeability. This layer is arranged to be as thin as possible so that the layer itself does not define sufficient strength to undergo the processing. In this case the layer is supported by the laminated covering layers 54 and 56 each of which covers a respective side of the foil. The laminating layers provide the necessary strength for the product to undergo the processing in the manufacture of the spacer. Thus they act as supporting layers to carry the material into the part. Secondly the laminating layers 54 and 56 act to bond the foil layer into the part. The laminating layers in one example can be provided by a resin which is compatible with the thermosetting resin of which the part is manufactured. Thus the layer is of a type which bonds during the heat processing to the thermosetting resin. One example is the use of polyester for the layers and a similar polyester for the thermosetting resin so that boding automatically takes place to reduce the risk of delamination during use of the part.
Alternatively, the supporting layers can be formed of a paper material which has sufficient strength to transport the foil into the process and at the same time provides bonding wit the resin by the infiltration of the resin into the interstices of the layer.
Since various modifications can be made in my invention as hereinabove described, and may apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense. | A spacer for separating panes of glass in a sealed window unit is formed of a thermosetting resin reinforced longitudinally with continuously extending glass fibres. A layer of a foil material is introduced into the part during the pultrusion process so that the foil is embedded within the part and defines a moisture impermeable layer in the outer wall of the part. The foil can be carried into the part on a layer of paper or polyester which combines with the resin in a bonding action. | 1 |
FIELD OF THE INVENTION
This invention relates to the transport of pulverized coal from the mine to a remote point of use.
BACKGROUND OF THE INVENTION
The bulk of coal transport from the mine to a point of use is accomplished by rail transport, and it has also been proposed to transport pulverized coal from the mine to the point of use by water or oil slurry pipelines. The expansion of railroad unit trains, which now move most of the coal presently used, has many cost limitations, and would have an adverse impact on the environment, as well as using liquid fossil fuel for train propulsion. The use of pipelines and water slurries are satisfactory from an operational standpoint, but the best mine fields are desperately short of water, without the need to use it for slurry transport, while at the delivery end the water degrades the coal and must be removed, as well as clarified as it is returned to the environment.
It is also noted that, in the event that pulverized coal is transported with oxygen containing air as the suspending gas, a dangerous explosive mixture would be present, which could easily be ignited by static electricity generated by the flow of the coal through the pipeline.
A principal object of the present invention is to provide an improved method of transporting coal from the mine to the point of use, which will avoid many of the problems with the previously proposed systems, as outlined hereinabove.
SUMMARY OF THE INVENTION
In accordance with the present invention, coal is finely pulverized at a first location, such as a coal mine, and is carried in a pipeline to the point of use in a gas suspension, using coal gas, which may also be made at the mine location.
Additional features of the invention include the following:
1. Special arrangements may be provided to maintain the pulverized coal in suspension within the pipe, and these arrangements may take a number of forms including helical vanes extending along the periphery of the pipeline and particularly at the bottom of the pipeline, and/or the provision of a separate gas passageway to blow particles which might fall out of suspension toward the bottom of the pipe back into suspension. Special arrangements may also be provided to maintain suspension and avoid undue abrasion at turns in the pipe.
2. Booster stations powered by the coal gas and/or the coal dust, may be provided as needed along the length of the pipeline, so that no separate source of power or electric lines are needed in remote or isolated areas through which the pipeline may pass.
3. The pulverized coal may be fed directly into the furnace along with the suspending coal gas at the point of use, particularly where the principal use involves one or more large utility installations having substantial and continuous fuel needs.
Advantages of the present system include freedom from the water problems, both as to availability and environmental requirements, as well as the avoidance of the need to dry out the coal at the point of use. In addition, the problems of increased capacity and liquid fossil fuel use inherent in the expansion of unit railroad trains is avoided.
Other objects, features and advantages of the present invention will become apparent from a consideration of the following detailed description and of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic showing of a complete coal particle transport system illustrating the principles of the invention;
FIG. 2 illustrates in greater detail the mine head installation which could be employed in the system of FIG. 1;
FIG. 3 indicates schematically a pipe construction including spiralling vanes for maintaining pulverized coal particles in suspension;
FIGS. 4 and 5 show a supplemental high pressure gas passageway for maintaining the particles in suspension;
FIG. 6 shows an alternative high pressure passageway for introducing gas at bends in the pipeline;
FIGS. 7 and 8 are a transverse cross-sectional view and an end view, respectively, of an alternative arrangement for introducing rotary flow into the gas and coal particle mixture passing down the pipe;
FIG. 9 is a diagram useful in the analysis of the coal particle support in the gas stream; and
FIG. 10 shows an alternative booster station which may be used in the system of FIG. 1.
DETAILED DESCRIPTION
Referring more particularly to the drawings, in FIG. 1 the coal mine is indicated at reference numeral 12 and the boiler or furnace of the steam plant where the coal will be employed as a fuel is indicated by reference numeral 14. The extended pipeline or conduit interconnecting the coal mine site and the location of the boiler and furnace is indicated by the reference numerals 16 and 16', with one or more intermediate booster stations 18 being located along the length of the pipeline 16, 16'.
At the coal mine site, initial conventional processing is indicated by the block 20. Some of the processed coal will be employed to supply energy for the compression of the gas which will be employed to move the pulverized coal down the pipeline. Some of the remainder of the coal will be employed to manufacture low Btu gas which is the non-oxidizing transport medium for the coal particles. This conventional process is indicated by the block 22, with the gas compressor being represented by the block 24 in the diagram of FIG. 1. The bulk of the coal will be cleaned, dried, and pulverized to pass through a fine mesh screen (in the order of 200 mesh) for transport as powder down the pipeline 16. The pulverizing plant 26 is also indicated as being located at the coal mine site in FIG. 1.
A gas flow sensor 28 provides signals to the coal powder flow control unit 30 to avoid feeding additional coal into the pipeline, if for any reason, the flow of gas is being retarded along the length of the pipeline 16, 16'.
The booster stations 18 may be in any desired form and will normally be powered by the low Btu coal gas or the coal particles being transported through the pipeline. As shown at 18 in FIG. 1, the booster station may include a separator unit 32, a gas turbine drive 34, and a booster compressor unit 36. Alternative booster station arrangements may include the diversion of a small portion of the gas and/or coal particles to power a booster pump, and the supplying of additional forward thrust to the coal particles and gas being transmitted down the pipeline through forwardly directed nozzles circumferentially arranged around a pipe line section, as indicated schematically in FIG. 10 described below. Other suitable booster station arrangements may be employed. Further, the number of booster stations which are provided will be substantially more than those required to maintain continuous flow of the gas and particulate material, so that, when one of the booster stations is down for repairs, or routine maintenance, there will be no interruption of the flow.
The terminal station may include the separator 38 from which the gas is supplied to the expander 40 which may power an electric generator 42, while the coal dust may be routed either to silo storage 44 or directly to point 46 where it may be recombined with the low Btu gas supplied through line 48 which may be employed to carry the coal dust along line 50 to the boiler or furnace 14. As indicated in FIG. 1, the separated particulate coal from the silo storage 44 may be routed as indicated by the line 52 to other uses or to open storage.
Particularly for large installations where substantially continuous operation takes place, the valve 104 may direct a portion or all of the incoming coal particle and coal gas suspension through line 106 directly into the furnace 14.
FIG. 2 represents a generally conventional arrangement for forming low Btu coal gas from coal and steam. Essentially it involves a process in which the inputs are carbon from the coal, oxygen, and steam, in addition to air, and the result is carbon monoxide and hydrogen gas from the steam, in addition to the inert nitrogen included in the air. The presence of the nitrogen means that the energy content of the gas is relatively low. On the other hand, the resultant mixture of the coal gas and the suspended coal particles is not explosive, and therefore cannot be ignited by static electricity, sparks, or the like which might be generated as the particles flow down the pipe.
With reference to the blocks shown in FIG. 2, the mine mouth coal is indicated by reference numeral 12, and input air is supplied at 54. The initial coal preparation steps are indicated by the blocks 56 and 58. The gasification apparatus is indicated by reference numeral 60 and has as inputs the coal, air, oxygen, and steam; with the output being ash from the spent coal indicated by the arrow 62 and the output untreated coal gas at conduit 64. Incidentally, the optional oxygen plant 66, if used, is employed to provide the oxygen inputs 68 and 70 to the apparatus 58 and 60. The residual particles of ash and any partially burned coal are removed in the unit 72, further gas processing is accomplished in the apparatus 74, involving the cooling and scrubbing of the gas, and condensable (burnable) liquids are captured by the apparatus 76. A final processing step including sulphur removal is indicated by block 78, and the low Btu gas appearing at conduit 80 is supplied to the gas compressor plant unit 24 as shown in FIG. 1 to be supplied to the pipeline or conduit 16.
Now, in conjunction with FIGS. 3 through 8, various structures will be described which serve the purpose of maintaining the finely divided coal particles in suspension within the pipe as the flow continues. As will be discussed in some detail in connection with FIG. 9, inducing a rotary flow of the gas passing down the pipe will insure that particles which tend to settle out to the bottom of the pipe will be picked up and again brought into suspension. While the required rotation of the longitudinally flowing gas for maintaining the particles in suspension will vary, depending on the size of particles and the velocity of flow, a complete rotation of the fluid by about 360 degrees within 200 feet will normally be sufficient to maintain all particles in suspension.
In FIG. 3, the pipe or conduit 16 is provided with vanes 84 and 86 which may be located only in the lower sections of the pipe. They could also extend all the way around the inner surface of the conduit, but they are primarily needed at the bottom. These vanes may extend for an angle of perhaps 45 degrees to the left and right of the center of the pipe, thus encompassing a total angular extent of approximately 90 degrees at the bottom of the pipe 16, over a distance of perhaps 50 feet. The helix defined by the vanes 84 and 86 is such that, if the vanes were continued for a full 200 feet, they would have passed through 360 degrees when viewed directly along the axis of the pipe. However, as may be appreciated, this angle is relatively shallow and the vanes 84 and 86 make only a very slight angle with a line parallel to the axis of the pipe, and extending along the inner periphery of the pipe. The vanes need not be of any very substantial radial extent, but with a pipe having a 40 inch diameter, the vanes might have a height of approximately 3 or 4 inches. It is contemplated that the sections of pipe carrying the vanes will be marked exteriorly to indicate the location of the vanes within the pipes and to insure proper orientation.
FIGS. 4 through 6 illustrate the supplying of booster gas through a longitudinally extending passageway to avoid settling out of the coal particles from the gas and to assist in the maintenance of high speed particle and gas suspension flow down the length of the conduit.
As indicated in FIGS. 4 and 5, the pipe 16 may be provided with vanes 90, normally located along the bottom of the pipe, through which booster gas may be provided from the passageway 92. With the gas being directed upwardly through the slots or nozzle-like apertures between the vanes 90, additional forward thrust is given to the body of the gas and particles within the pipe 60, and further impetus and increased velocity of flow will result.
For use in bend sections, the set of vanes 90' may be arranged as shown in FIG. 6, assuming that the bend is from left to right, as viewed along the axis of the pipe 16. This location of the vanes will tend to prevent undue wear of the pipe on the left-hand side, and also prevent the accumulation of coal particles at this location.
Instead of the spiral vanes 84, 86, as shown in FIG. 3 of the drawings, a set of sheet metal blades or vanes 94 may be provided in a short section of the pipe designated 16". These vanes 94 may have a slight angular orientation so as to provide a amall angular component of rotation of the gas and particle suspension traveling down the length of the tube. Preferably the vanes 94 should be very thin and tapered at their leading and trailing edges to avoid the introduction of drag or turbulence more than is absolutely required. Accordingly, in order to assist in maintaining the particles in suspension, any or all of the techniques shown in FIGS. 3 through 8 may be employed, with those shown in FIGS. 4, 5 and 6 being particuarly applicable for use at an intermediate booster station such as that located at 18' as shown in FIG. 10 of the drawings.
FIG. 9 is a diagram showing a coal particle 96 suspended by upwardly directed gas flow as indicated by the arrows 98. In the following analysis, the gas flow required to maintain the particle in suspension in the case of a directly upward gas flow will initially be developed; and then the corresponding relationship giving the required angular or rotational flow of the gas and particle suspension required for maintaining an individual particle in suspension will be developed.
A particle will be supported in an upward flowing gas stream when the aerodynamic drag of the particle equals its weight, assuming vertical gas flow.
Weight=Drag
Particle volume×density=dynamic gas pressure×exposed area×drag factor ##EQU1## where ##EQU2## This is an estimate of the dense gas velocity required to lift these fine particles vertically. A lower velocity should move them horizontally.
For example, if the gas velocity is 20 ft/s (6.1 m/s) down the pipe it must rotate one turn every 367 ft in a 40 inch diameter pipe to insure particle suspension. This figure is reached by calculating the time required for a particle to travel around the inner periphery of the 40 inch diameter pipe at a speed of 0.18 meters/second, and the time for one circuit is about 18 seconds. With the gas velocity along the pipe being about 20 feet per second, the 367 feet figure is obtained. For the purposes of the vanes in FIG. 3 a figure of 200 feet for one revolution was employed, to give an additional margin of safety.
An alternative booster station arrangement is shown in FIG. 10. The booster station of FIG. 10 is designated by the reference numeral 18' and may be substituted for, or placed in parallel with the booster station 18 as shown in FIG. 1 of the present drawings. The booster station arrangement of FIG. 10 differs from that of unit 18 in FIG. 1 essentially in the omission of the separation step. More specifically, the booster station as shown in FIG. 10 includes the gas turbine drive unit 34' and the compressor 36'. The unit 102 as shown in FIG. 10 involves the principle that additional gas pressure is supplied to the gas and suspended coal particles, without the need for full separation. More specifically, the additional high pressure coal gas, as compressed by the compressor 36' is supplied through nozzles or openings directed in the forward direction along the pipeline 16 to increase the flow velocity and to insure that particles do not separate out of suspension. Structures such as those shown in FIGS. 4, 5 and 6 may be used at the booster station 18', with the supplemental high pressure goal gas being supplied to passageway 92 in FIG. 5, for example. Preferably, gas directed to the turbine drive 34' and to the compressor 36' is drawn from the top of the conduit 16, so that a minimum of particulate material is included in the gas routed to these units.
By way of completeness, certain additional factors may be noted. First, it is contemplated that the conduits or pipelines could be moderately long, in the order of 500 to 1000 miles, for example, in length, to bring coal from coal deposit concentrations to industrial areas of the United States. In such cases the booster stations could be located every 50 to 100 miles, or so, depending on other design parameters of the system. The pressure of the applied gas would normally be in the order of about 300 psi up to about 2,000 pounds per square inch, with the physical pipe design and coal particle size, as well as the intended spacing of the booster stations all being inter-related factors. Using a 100 mesh screen the maximum particle size would be about 0.006 inch in diameter, while with a 200 mesh screen the maximum particle size would be about 0.003 inch. The diameter of the pipe might be in the order of 40 inches, but larger or smaller diameter pipes could also be used.
It is to be understood that the foregoing description relates to one system illustrating the principles of the invention. Other arrangements may also be employed to implement the system without departing from the spirit and scope of the invention. By way of specific example, the booster station pattern may include parallel units each with adequate capacity to maintain the coal particles in suspension, and other forms of non-explosive gases may be employed as the carrier gas for the pulverized coal particles. Suitable alternative controls for restricting the flow of input coal when the line is to be shut down, or upon failure of the booster station may also be provided. Accordingly, the present invention is not limited to that precisely as shown and described herein. | Coal energy is delivered from the mine to a distant point of use by a system involving the pulverization of the coal at the mine, and carrying it as a nonexplosive suspension in a pipeline or conduit, with high pressure coal gas which is made at the mine being employed as the transport medium. At the delivery point, the gas, as well as the coal dust can be fired directly into the furnace, or the coal can be separated from the coal gas and stored. Arrangements are provided for insuring that the finely pulverized coal may be maintained in suspension within the transport pipe, and such arrangements may include spiraling vanes to insure that settling particles are reintroduced into the main gas stream, and separate sections within the pipe, or a supplemental pipe for the high pressured gas to permit restarting of the flow in the event of a power failure and the settling out of the particles. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 654,760, filed Sept. 25, 1984 now abandoned, for Continuous Contact Plating Method and Apparatus.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to improvements in plating apparatus, and more particularly pertains to new and improved zone plating apparatus wherein precious metals such as gold, silver or palladium are plated on electrical contact areas on electrical components.
2. Brief Description of the Prior Art
Those concerned with the development of plating apparatus for plating precious metals such as gold and silver or palladium onto electrical components have long recognized the need for efficiency in the application of the precious metal to the workpiece, both in terms of control over the defined area that is plated and the thickness of the plating material. U.S. Pat. No. 4,064,019 for a continuous contact plater method issued Dec. 20, 1977 describes a system which is directed towards this end. However, the system falls short in several respects. It fails to accurately control the thickness of the precious metal being deposited on the selected area of the electrical components. It fails to plate an accurately defined area. It can only plate one zone on a component at a time. It is designed to plate curved surfaces. The present invention overcomes the shortcomings of the apparatus in U.S. Pat. No. 4,064,019 and all the prior art in this field. Specifically, the present invention can plate multiple zones, at one time, including front and back. It is also capable of plating flat or curved surfaces on a component.
SUMMARY OF THE INVENTION
The present selective contact plater apparatus provides the minimum necessary amount of plating solution to the web workpiece and plates at minimum thickness on curved or flat surfaces, multiple zones at one time, by keeping the anode very close to the web workpiece and utilizing a continuous brush belt that only touches the web workpiece with the electrified plating solution at the desired zone. The belt is constructed using materials and methods that make it structurally stable and impervious to the plating solution and also only apply a minimum amount of plating solution to the web. The belt moves against and across the web workpiece at a rate of speed that facilitates efficient plating. The guide for the web workpiece is guided along a precisely controlled path. The guide for the web workpiece is adjustable along more than one axis to provide for contacting the brush belt with the web workpiece with a range of contact pressure end angles.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and many of the attendant advantages of this invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like references numerals designate like parts throughout the figures thereof, and wherein:
FIG. 1 is a perspective illustration of the continuous contact plating apparatus of the present invention;
FIG. 2 is a partial perspective illustration of a continuous plating apparatus showing the brush belt;
FIG. 3 is a perspective of the continuous contact plating apparatus showing the guide device of the brush belt attached to the plating fluid chamber;
FIG. 4 is an exploded perspective showing the three main parts of the guide for the brush belt;
FIG. 5 is a perspective of a portion of the continuous contact plating apparatus according to the present invention showing the anode positioned with respect to the plating solution chamber;
FIG. 6 is a perspective showing a portion of the continuous contact plater apparatus of the present invention, the anode chamber and the escape channels for the plating solution;
FIG. 7 is a perspective of the brush belt utilized by the continuous contact plating apparatus of the present invention;
FIG. 8 is a side perspective of an alternate embodiment for the guide device for the web workpiece to be plated; and
FIG. 9 is a front perspective of the guide device for the web workpiece shown in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, which illustrates the major features of the continuous contact plating apparatus 11 according to the present invention, a web workpiece 39 is shown coming into contact with the brush belt 35 which effectively plates selective portions of the continuous web workpiece 39. The web workpiece 39 is essentially a continuous web or a strip containing many pieces of electrical components which are to be selectively plated with a precious metal electrical conductor such as gold, palladium or silver, for example. The web workpiece 39, as is understood in the art, is charged cathodically. The manner in which this is accomplished is not shown. Neither are the takeup and supply reels which cause the web workpiece 39 to move past the contained supply of plating solution 12 and the brush belt 35.
The brush belt 35, as is more clearly seen in FIG. 7, is a continuous loop having a backing 69 that is structurally stable and chemically inert to the plating solution utilized. A material such as titanium is preferred. This backing has a plurality of apertures 71 punched therein along its length to allow plating solution fluid to pass therethrough to the brush portion 35, which is a highly absorbent material and chemically inert to the plating solution. An open cell urethane foam or other materials such as felt or neoprene is preferred. The absorbent material must be capable of allowing the solution to pass through from one side to the other and be held by the material.
The brush belt 35 moves over a series of pulleys, only one of which is shown, 31. Pulley 31 can be considered the driving pulley that moves the belt past the face or header 12 of the contained supply of plating solution. Pulley 31 is rotated by driving its rotary shaft 33.
The contained supply of plating solution and its header 12, as well as the guide 37 for the brush belt 35 which is fastened thereto, is contained within a framework which has an upper shelf and a lower shelf 14. The upper shelf 13 carries support structures 15 and 17 which in turn support latching blocks 21 and 19, respectively. Latching blocks 21 and 19 are moved back and forth on their respective shafts by way of knobs 29 and 27, respectively. Knob 29, for example, drives the threaded shaft 20 which threadably engages latching block 21, causing it to move back and forth on carrier shaft 22.
A similar type of adjustable mechanism is utilized at the bottom plate 14 for the plater apparatus. Support blocks 45 and 47 support hinge blocks 49 and 51, respectively, by way of circular shafts such as 40, for example. The knob-screw apparatus 57 and 59, respectively, turn within screw support plates 53 and 55, respectively, to rotate bolt 60, for example, which threadably engages pivotal block 51, causing it to ride back and forth on support shaft 40.
To ensure that the web workpiece 39 makes correct contact with the brush belt 35 moving within the pathway 37, a contact arm such as 63, which is pivotally connected to pivot block 51, is swung up and engaged with latching block 19 by way of a dowel pin 24, for example, which slides through the latching block 19 into its respective connecting head. The workings of the contact arm are more clearly illustrated when unlatched on the right-hand side of FIG. 1, wherein the contact block 65 is clearly illustrated. The connecting head 61 has an aperture 62 therein for receiving the connecting pin. The contact block 65 can be positioned on the arm 63 by way of moving the block in the slots 64 therein by loosening the thumbscrews 65. Once disconnected from connecting block 21, the entire contact arm may be pivoted down around pivot hinge 67.
Referring now to FIG. 2, the guide means 37 for the brush belt 35 is more clearly illustrated. The brush belt guide 37 has a pair of major parts, upper fastening bar 75 and lower fastening bar 73, which fasten to the front of the contained supply of plating solution 12 by way of countersunk bolts 77 in the upper bar 75 and bolts 76 in the lower bar 75. Both the upper and lower bar 75 and 73, respectively, overlay the edges 69 of the brush belt 35, thereby guiding it across the face of the contained supply plating solution 12 in both a horizontal and vertical direction.
Located behind the guide 37 is the anode which has electrical connector arms 41 and 43 shown in FIG. 2 to which electrical connection is made.
Referring now to FIG. 3, the contained supply of plating solution 12 is more clearly illustrated, as is the brush belt guide 36. The contained supply of plating solution 12 is essentially a box manifold 83 which has an inlet port 81 and an outlet port 82 through which plating solution flows. The plating solution can escape from the box manifold 83 and pass through the apertures 87 in slide bar 85, which is part of the brush belt guide 36. Apertures 87 are shown as formed to match the apertures in the titanium backing for the brush belt. However, such an arrangement should not be taken as limiting. Again, the electrical connector tabs 41, 43 and 79 for the anode located within the avenue of escape for the plating solution from the box manifold 83 are shown.
Referring now to FIG. 4, the major parts of the brush belt guide mechanism 36 are most clearly illustrated. Essentially, the brush belt guide mechanism 36 is made up of three parts. The slide bar 85, as already discussed, has a plurality of apertures located therein and stepped edges having two steps 99 and 97 at both edges of approximately equal distance. This slide bar 85 is preferably made out of a high density and smooth material like TEFLON or TIVAR or material having similar characteristics. Slide bar 85 overlays the front of the box manifold 83 and covers the avenue of escape of the plating solution out of the box manifold 83. It is held fast to the front by means of the upper fastening bar 75 and the lower fastening bar 73. Both the upper bar 75 and lower bar 73 have a three-step edge, 101, 103 and 105, which overlays the two-step edge on the slide bar 85. However, the middle step 103 of the fastening bars is greater than the first step 99 of the slide bar so that a gap 89 and 91, respectively, slightly greater than the thickness of the titanium metal ribbon which backs the brush belt is created, allowing the brush belt to slide within the gap. Also, the distance between the first step 99 of the top edge and first step 100 of the bottom edge of slide bar 85 is slightly greater than the width of the brush belt titanium backing. The apertures 93 in the upper fastening bar 75 and the apertures 95 in the lower fastening bar 73 are countersunk apertures to receive the Allen head bolts 77 and 76, respectively.
Referring now to FIG. 5, the preferred anode structure to be used with the box manifold 83 is illustrated. The anode 107 is shown as a mesh or screen of platinum clad material, preferably platinum wire or other chemically inert material having similar characteristics, which has electrical connector tabs 41, 43 and 79 connected thereto and extending therefrom in channels 113, 115 and 117, respectively. The anode 107 lies within a recess 109 (FIG. 6) in the face of the box manifold 83, thereby providing a flat surface for the guide. Three pieces of the brush belt guide 36 to overlay the apertures 109 and 111 in the face of the box manifold 83 are threaded to receive the Allen head bolts that pass through the upper fastening bar 75 and lower fastening bar 73 of the brush belt guide apparatus 36.
FIG. 6 more clearly illustrates the avenue of escape for the plating solution contained within the box manifold 83. The apertures 121 in the face of the box manifold are structured to correspond to the apertures 87 in the slide bar 85 of the brush belt guide apparatus 36. However, such an arrangement should not be considered as limiting, as other relationships may be found useful. The box manifold 83 is made of PVC material or some other material of equally inert characteristics to the plating solution.
The brush belt essentially has two major components, a loop of material which is a carrier for the loop of absorbent material which is the brush. The carrier is preferably a flat titanium ribbon of 10 mil thickness. It could also be made out of fiberglass plastic or similar material which has structural stability and is chemically inert to the plating solution utilized. Assuming the titanium ribbon is used as the carrier, it is formed into a loop by welding the two ends together. Then the apertures are placed therein approximately along a line that is at the center of its width, which apertures are of a desired length and width as may be, to some extent, dictated by the particular electrical components being plated.
An adhesive which can withstand the pH ranges and temperature ranges to which the brush belt will be subjected is utilized to glue the absorbent brush material to the carrier. The adhesive must be chemically inert to the plating solution utilized and must be compatible with the brush material that is being glued to the titanium loop.
A foam, felt, neoprene or similar material which will be the brush portion of the brush belt is formed to be of about equal width with the titanium loop and of equal length. It is preferred that an open cell urethane foam be utilized which has homogeneous pores and grain structure. It has been found that such a material exhibits excellent capillary action in drawing plating solution quickly from the contained supply in the box manifold to the surface that is to contact the electrical apparatus to be plated.
In operation, the belt is the carrier for the plating fluid in that it transmits the plating solution from the box manifold to the exact area on the part being plated, applying it by a brushing lateral movement across that area. The plating solution delivered by the brush belt is electrically charged. The belt is driven in a direction opposite to or with the web workpiece at a speed that will most effectively break down the cathodic film buildup on the interface or contact point between the brush belt and web workpiece.
Referring now to FIG. 8, an alternate preferred embodiment for the structure that receives and guides the web workpiece 39 past and into contact with the brush belt 35 is illustrated. FIG. 9 illustrates the same embodiment from a different perspective. The apparatus illustrated in FIGS. 8 and 9 is designed to provide highly controlled placement of the web workpiece 39 with respect to the brush belt 35. This includes not only the amount of pressure with which the web workpiece 39 contacts the brush belt 35 but also the angle at which the web workpiece 39 engage the brush belt 35.
This control of the relationship between the web workpiece 39 and brush belt 35 is accomplished by the structure illustrated in FIGS. 8 and 9 which includes threaded control knobs 15, utilized for course adjustments, and control knob 161 used for fine adjustments, in moving the rigid backing plate 167 which holds the contoured guide 169 that is channeled to receive the specific construction of the parts in the web workpiece 39. It should be recalled that the brush belt 35 can also be custom contoured for a particular strip of parts.
FIGS. 8 and 9 illustrate the continuous contact plating apparatus built according to the present invention. The brush belt 35 moves over a series of pulleys 31, 125 and 127. Pulley 31 is the driving pulley which is connected by shaft 33 to a driving means 123. Driving pulley 31 moves the brush belt 35 past the header 12 which is contained within a framework having an upper shelf 13 and a lower shelf 14.
The upper shelf 13 carries a pair of shafts 131 and 129. The lower shelf 14 carries a pair of shafts 133 and 135 fastened by any convenient means, such is bolts. A block 137 having bearing surfaces 132 and 134 at opposite ends thereof is journalled on shafts 131 and 133, respectively, for the purpose of sliding along the length of shafts 131 and 133. Block 139 having a pair of bearing surfaces 130 and 136 is journalled on shafts 129 and 135, respectively, for the purpose of sliding back and forth on these shafts. Shafts 131 and 133 are held parallel by a plate 143 which receives the end of shafts 131 and 133 and fastens such ends to the plate by means of threaded bolts 139 and 147, respectively. In turn, shafts 129 and 135 are held parallel by plate 145 which receives the ends of shafts 129 and 135 and holds them fast by means of threaded bolts 146 and 148. Threaded shaft 151 is journalled through a plate 143 and engages block 137 rotatably but fixedly at about its center location 152. In this manner, movement of shaft 151 along an axis parallel to shafts 131 and 133 will cause movement of block 137 along these shafts in a smooth and easy manner as the result of the bearing surfaces 132 and 134.
At the other end of the rigid backing block 167 for the receiving and guiding device for the web workpiece 39 in association with the shafts 129 and 135, a threaded shaft 153 is rotatably but fixedly attached to block 139 at its center 154. Movement of shaft 153 along an axis parallel to shafts 129 and 135 will cause movement of block 139 along these shafts in a smooth manner because of bearing surfaces 130 and 136.
Movement of both blocks 139 and 137 along the respective shafts 129, 135 and 131, 133 is the result of turning threaded knob 155 which threadably engages shaft 151 and threaded knob 157 which threadably engages shaft 153. Turning knobs 155 and 157 in a clockwise direction will cause shafts 151 and 153, respectively, to be drawn outwardly, pulling blocks 137 and 139, respectively, with it. Turning threaded knob 155 and 157 in a counterclockwise direction, pushes shafts 151 and 153 inwardly towards the brush belt 35, pushing the blocks 137 and 139 with them.
Blocks 137 and 139 are connected together by a rigid block 141. Mounted on this block 141 is a plate 159 which has a threaded shaft 163 journalled therethrough and has fixedly mounted on its end a knurled knob 161. Threaded shaft 163 engages block 165 threadably causing block 165 to be moved up and down shaft 163 along its length upon rotation of knurled knob 161 in a clockwise or counterclockwise direction.
Block 165 is fixedly attached to a very rigid backing plate 167 to which is fastened the relatively friction free channeled guiding means 169 for the web workpiece 39. The channeled receiving and guiding device 169 is constructed very similar to the guiding construction 36 for the brush belt (FIGS. 3 and 4). A major difference would be the construction of the center piece 85 which would be shaped not with aperatures 86 therein, but in a manner to compliment the shape of the parts on the web workpiece 39. As a result, the web workpiece 39 is held to a very precise course of travel past the brush belt 35 which in turn is also held to a very precise course of travel past the header wherein it soaks up the charged plating solution needed to accomplish the plating function.
The mechanism shown in FIGS. 8 and 9 determines this precise course of travel of web workpiece 39. A manual adjustment of knobs 155 and 157 is a course adjustment that locates web workpiece 39 in proximity or minimal contact with brush belt 35. Movement of knobs 155 and 157 causes the shafts 151 and 153 to move, pulling with them block 137 and 139 which jointly pull with them block 141 to which is attached the fine adjustment mechanism having a plate 159 and 165 connected to block 141 and backing block 167, respectively. Movement of shafts 151 and 153 causes movement of rigid backing plate 167 in the same direction through threaded screw 163. Once the course adjustment of the backing plate 167 is established by knobs 155 and 157, the fine adjustment is accomplished by means of knurled knob 161 by turning it clockwise or counterclockwise causing movement towards and away from brush belt 35 in very fine or small increments.
Web workpiece 39 need not come into contact with brush belt 35 along an axis perpendicular to the brush belt 35 as illustrated in FIGS. 8 and 9. Rods 131, 133 and 129, 135 can, if desired, be adjusted to extend away from header 12 at any angle desired, depending upon the construction of the individual parts on the web workpiece 39, the contour of the brush belt 35, and the particular part of a web workpiece 39 upon which plating is desired. Changing the angle at which shafts 131, 133 and 129, 135 extend from the header 12 is easily accomplished once presented with the possibility of doing so. Accordingly, such a structure is not illustrated.
It should be understood that the foregoing disclosure relates only to the preferred embodiments of the invention and that modifications may be made therein without departing from the spirit and scope of the invention as set forth in the appended claims. For example, a squeegee apparatus may be placed at a location on the brush belt after it passes by the contained source of supply for the plating solution in order to squeeze out the plating solution remaining in the belt after the plating operation. In addition, plating solution may be added to the brush belt at a place other than from the box manifold and in addition to the solution provided to the belt by the box manifold.
Although the method and apparatus described is most advantageously usable with systems for plating gold, other materials and platable substances can be plated by the method and apparatus, such as silver, palladium, copper, nickel, tin or tin/lead, for example. Indeed, the system could also be used to selectively strip metal from a workpiece or apply lubricant thereto, or remove a fluid therefrom. | A contact plater apparatus and method for plating selected areas of a web workpiece wherein the web workpiece and anode are in close proximity, separated only by the brush belt that contacts the web workpiece. A box manifold continually replenished with plating solution, provides the brush belt with plating solution from openings in a header as the solution passes over an anode. The brush belt of open-cell foam or other absorbent material wicks up the plating solution and brushes it on the desired spot on the cathodic web workpiece. The brush belt is guided past the box manifold in an accurately defined path. The web workpiece and brush belt are brought into precise contact at the openings in the header of the box manifold where the plating takes place. The guide for the web workpiece is adjustable along more than one axis to provide for contacting the brush belt with the web workpiece with a range of contact pressure and angles. Each guide is custom built for the parts to be plated. | 2 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/862,679, filed on Sep. 23, 2015, which is a continuation of U.S. patent application Ser. No. 14/198,764, filed on Mar. 6, 2014, which is a continuation of U.S. patent application Ser. No. 13/944,320, filed on Jul. 17, 2013, which is a continuation of Ser. No. 13/678,983, filed Nov. 16, 2012, which is a continuation of U.S. patent application Ser. No. 12/279,398, filed on Oct. 19, 2009, now U.S. Pat. No. 8,383,855, issued on Feb. 26, 2013, which is a national phase application under 35 U.S.C. §371 of PCT International Application No. PCT/US2007/062152, filed on Feb. 14, 2007, which claims priority under 35 U.S.C. §119(e) to U.S. provisional patent application, U.S. Ser. No. 60/773,172, filed Feb. 14, 2006. Each of these prior applications is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The identification of small organic molecules that affect specific biological functions is an endeavor that impacts both biology and medicine. Such molecules are useful as therapeutic agents and as probes of biological function. In but one example from the emerging field of chemical genetics, in which small molecules can be used to alter the function of biological molecules to which they bind, these molecules have been useful at elucidating signal transduction pathways by acting as chemical protein knockouts, thereby causing a loss of protein function (Schreiber et al., J. Am. Chem. Soc., 1990, 112, 5583; Mitchison, Chem. and Biol., 1994, 1, 3). Additionally, due to the interaction of these small molecules with particular biological targets and their ability to affect specific biological function, they may also serve as candidates for the development of therapeutics. One important class of small molecules, natural products, which are small molecules obtained from nature, clearly have played an important role in the development of biology and medicine, serving as pharmaceutical leads, drugs (Newman et al., Nat. Prod. Rep. 2000, 17, 215-234), and powerful reagents for studying cell biology (Schreiber, S. L. Chem. and Eng. News 1992 (October 26), 22-32).
[0003] Because it is difficult to predict which small molecules will interact with a biological target, and it is oftent difficult to obtain and synthesize efficiently small molecules found in nature, intense efforts have been directed towards the generation of large numbers, or libraries, of small organic compounds, often “natural product-like” libraries. These libraries can then be linked to sensitive screens for a particular biological target of interest to identify the active molecules.
[0004] One biological target of recent interest is histone deacetylase (see, for example, a discussion of the use of inhibitors of histone deacetylases for the treatment of cancer: Marks et al. Nature Reviews Cancer 2001, 1, 194; Johnstone et al. Nature Reviews Drug Discovery 2002, 1, 287). Post-translational modification of proteins through acetylation and deacetylation of lysine residues has a critical role in regulating their cellular functions. HDACs are zinc hydrolases that modulate gene expression through deacetylation of the N-acetyl-lysine residues of histone proteins and other transcriptional regulators (Hassig et al. Curr. Opin. Chem. Biol. 1997, 1, 300-308). HDACs participate in cellular pathways that control cell shape and differentiation, and an HDAC inhibitor has been shown effective in treating an otherwise recalcitrant cancer (Warrell et al. J. Natl. Cancer Inst. 1998, 90, 1621-1625). Eleven human HDACs, which use Zn as a cofactor, have been characterized (Taunton et al. Science 1996, 272, 408-411; Yang et al. J. Biol. Chem. 1997, 272, 28001-28007; Grozinger et al. Proc. Natl. Acad. Sci. U.S.A. 1999, 96, 4868-4873; Kao et al. Genes Dev. 2000, 14, 55-66; Hu et al. J. Biol. Chem. 2000, 275, 15254-15264; Zhou et al. Proc. Natl. Acad. Sci. U.S.A. 2001, 98, 10572-10577; Venter et al. Science 2001, 291, 1304-1351). These members fall into three related classes (class I, II, and III). An additional seven HDACs have been identified which use NAD as a confactor. To date, no small molecules are known that selectively target either the two classes or individual members of this family ((for example ortholog-selective HDAC inhibitors have been reported: (a) Meinke et al. J. Med. Chem. 2000, 14, 4919-4922; (b) Meinke, et al. Curr. Med. Chem. 2001, 8, 211-235).
SUMMARY OF THE INVENTION
[0005] The present invention provides novel histone deacetylase inhibitors and methods of preparing and using these compounds. The inventive HDAC inhibitors comprise an esterase-sensitive ester linkage, thereby when the compound is exposed to an esterase such as in the bloodstream the compound is inactivated. The compounds are particularly useful in the treatment of skin disorders such as cutaneous T-cell lymphoma, neurofibromatosis, psoriasis, hair loss, dermatitis, baldness, and skin pigmentation. The inventive compound is administered topically to the skin of the patient where it is clinically active. Once the compound is absorbed into the body, it is quickly inactivated by esterases which cleave the compound into two or more biologically inactive fragments. Thus, allowing for high local concentrations (e.g., in the skin) and reduced systemic toxicity. In certain embodiments, the compound is fully cleaved upon exposure to serum in less than 5 min., preferably less than 1 min.
[0006] The present invention provides novel compounds of general formula (I),
[0000]
[0000] and pharmaceutical compositions thereof, as described generally and in subclasses herein, which compounds are useful as inhibitors of histone deacetylases or other deacetylases, and thus are useful for the treatment of proliferative diseases. The inventive compounds are additionally useful as tools to probe biological function. In certain embodiments, the compounds of the invention are particularly useful in the treatment of skin disorders. The ester linkage is susceptible to esterase cleavage, particularly esterases found in the blood. Therefore, these compounds may be administered topically to treat skin disorders, such as cutaneous T-cell lymphoma, psoriasis, hair loss, dermatitis, etc., without the risk of systemic effects. Once the compound enters the bloodstream it is quickly degraded by serum esterases. Preferably, the compound is degraded into non-toxic, biologically inactive by-products.
[0007] In another aspect, the present invention provides methods for inhibiting histone deacetylase activity or other deacetylase activity in a patient or a biological sample, comprising administering to said patient, or contacting said biological sample with an effective inhibitory amount of a compound of the invention. In certain embodiments, the compounds specifically inhibit a particular HDAC (e.g., HDAC1, HDAC2, HDAC3, HDAC4, HDAC4, HDAC5, HDAC6, HDAC7, HDAC8, HDAC9, HDAC10, HDAC11) or class of HDACs (e.g., Class I, II, or III). In certain embodiments, the compounds specifically inhibit HDAC6. In still another aspect, the present invention provides methods for treating skin disorders involving histone deacetylase activity, comprising administering to a subject in need thereof a therapeutically effective amount of a compound of the invention. The compounds may be administered by any method known in the art. In certain embodiments, the compounds are administered topically (e.g., in a cream, lotion, ointment, spray, gel, powder, etc.). In certain embodiments, the compound is administered to skin. In other certain embodiments, the compound is administered to hair. The compounds may also be administered intravenously or orally. The invention also provides pharmaceutical compositions of the compounds wherein the compound is combined with a pharmaceutically acceptable excipient.
[0008] In yet another aspect, the present invention provides methods for preparing compounds of the invention and intermediates thereof.
Definitions
[0009] Certain compounds of the present invention, and definitions of specific functional groups are also described in more detail below. For purposes of this invention, the chemical elements are identified in accordance with the Periodic Table of the Elements, CAS version, Handbook of Chemistry and Physics, 75 th Ed., inside cover, and specific functional groups are generally defined as described therein. Additionally, general principles of organic chemistry, as well as specific functional moieties and reactivity, are described in Organic Chemistry , Thomas Sorrell, University Science Books, Sausalito: 1999, the entire contents of which are incorporated herein by reference. Furthermore, it will be appreciated by one of ordinary skill in the art that the synthetic methods, as described herein, utilize a variety of protecting groups. By the term “protecting group,” has used herein, it is meant that a particular functional moiety, e.g., C, O, S, or N, is temporarily blocked so that a reaction can be carried out selectively at another reactive site in a multifunctional compound. In preferred embodiments, a protecting group reacts selectively in good yield to give a protected substrate that is stable to the projected reactions; the protecting group must be selectively removed in good yield by readily available, preferably nontoxic reagents that do not attack the other functional groups; the protecting group forms an easily separable derivative (more preferably without the generation of new stereogenic centers); and the protecting group has a minimum of additional functionality to avoid further sites of reaction. As detailed herein, oxygen, sulfur, nitrogen and carbon protecting groups may be utilized. Exemplary protecting groups are detailed herein, however, it will be appreciated that the present invention is not intended to be limited to these protecting groups; rather, a variety of additional equivalent protecting groups can be readily identified using the above criteria and utilized in the method of the present invention. Additionally, a variety of protecting groups are described in Protective Groups in Organic Synthesis , Third Ed. Greene, T. W. and Wuts, P. G., Eds., John Wiley & Sons, New York: 1999, the entire contents of which are hereby incorporated by reference. Furthermore, a variety of carbon protecting groups are described in Myers, A.; Kung, D. W.; Zhong, B.; Movassaghi, M.; Kwon, S. J. Am. Chem. Soc. 1999, 121, 8401-8402, the entire contents of which are hereby incorporated by reference.
[0010] It will be appreciated that the compounds, as described herein, may be substituted with any number of substituents or functional moieties. In general, the term “substituted” whether preceded by the term “optionally” or not, and substituents contained in formulas of this invention, refer to the replacement of hydrogen radicals in a given structure with the radical of a specified substituent. When more than one position in any given structure may be substituted with more than one substituent selected from a specified group, the substituent may be either the same or different at every position. As used herein, the term “substituted” is contemplated to include all permissible substituents of organic compounds. In a broad aspect, the permissible substituents include acyclic and cyclic, branched and unbranched, carbocyclic and heterocyclic, aromatic and nonaromatic substituents of organic compounds. For purposes of this invention, heteroatoms such as nitrogen may have hydrogen substituents and/or any permissible substituents of organic compounds described herein which satisfy the valencies of the heteroatoms. Furthermore, this invention is not intended to be limited in any manner by the permissible substituents of organic compounds. Combinations of substituents and variables envisioned by this invention are preferably those that result in the formation of stable compounds useful in the treatment, for example of proliferative disorders, including, but not limited to cancer. The term “stable”, as used herein, preferably refers to compounds which possess stability sufficient to allow manufacture and which maintain the integrity of the compound for a sufficient period of time to be detected and preferably for a sufficient period of time to be useful for the purposes detailed herein.
[0011] The term “acyl”, as used herein, refers to a carbonyl-containing functionality, e.g., —C(═O)R′, wherein R′ is an aliphatic, alycyclic, heteroaliphatic, heterocyclic, aryl, heteroaryl, (aliphatic)aryl, (heteroaliphatic)aryl, heteroaliphatic(aryl) or heteroaliphatic(heteroaryl) moiety, whereby each of the aliphatic, heteroaliphatic, aryl, or heteroaryl moieties is substituted or unsubstituted, or is a substituted (e.g., hydrogen or aliphatic, heteroaliphatic, aryl, or heteroaryl moieties) oxygen or nitrogen containing functionality (e.g., forming a carboxylic acid, ester, or amide functionality).
[0012] The term “aliphatic”, as used herein, includes both saturated and unsaturated, straight chain (i.e., unbranched) or branched aliphatic hydrocarbons, which are optionally substituted with one or more functional groups. As will be appreciated by one of ordinary skill in the art, “aliphatic” is intended herein to include, but is not limited to, alkyl, alkenyl, alkynyl moieties. Thus, as used herein, the term “alkyl” includes straight and branched alkyl groups. An analogous convention applies to other generic terms such as “alkenyl”, “alkynyl” and the like. Furthermore, as used herein, the terms “alkyl”, “alkenyl”, “alkynyl” and the like encompass both substituted and unsubstituted groups. In certain embodiments, as used herein, “lower alkyl” is used to indicate those alkyl groups (substituted, unsubstituted, branched or unbranched) having 1-6 carbon atoms.
[0013] In certain embodiments, the alkyl, alkenyl and alkynyl groups employed in the invention contain 1-20 aliphatic carbon atoms. In certain other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-10 aliphatic carbon atoms. In yet other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-8 aliphatic carbon atoms. In still other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-6 aliphatic carbon atoms. In yet other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-4 carbon atoms. Illustrative aliphatic groups thus include, but are not limited to, for example, methyl, ethyl, n-propyl, isopropyl, allyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, sec-pentyl, isopentyl, tert-pentyl, n-hexyl, sec-hexyl, moieties and the like, which again, may bear one or more substituents. Alkenyl groups include, but are not limited to, for example, ethenyl, propenyl, butenyl, 1-methyl-2-buten-1-yl, and the like. Representative alkynyl groups include, but are not limited to, ethynyl, 2-propynyl (propargy1), 1-propynyl and the like.
[0014] The term “alicyclic”, as used herein, refers to compounds which combine the properties of aliphatic and cyclic compounds and include but are not limited to cyclic, or polycyclic aliphatic hydrocarbons and bridged cycloalkyl compounds, which are optionally substituted with one or more functional groups. As will be appreciated by one of ordinary skill in the art, “alicyclic” is intended herein to include, but is not limited to, cycloalkyl, cycloalkenyl, and cycloalkynyl moieties, which are optionally substituted with one or more functional groups. Illustrative alicyclic groups thus include, but are not limited to, for example, cyclopropyl, —CH 2 -cyclopropyl, cyclobutyl, —CH 2 -cyclobutyl, cyclopentyl, —CH 2 — cyclopentyl-n, cyclohexyl, —CH 2 -cyclohexyl, cyclohexenylethyl, cyclohexanylethyl, norborbyl moieties and the like, which again, may bear one or more substituents.
[0015] The term “alkoxy” (or “alkyloxy”), or “thioalkyl” as used herein refers to an alkyl group, as previously defined, attached to the parent molecular moiety through an oxygen atom or through a sulfur atom. In certain embodiments, the alkyl group contains 1-20 aliphatic carbon atoms. In certain other embodiments, the alkyl group contains 1-10 aliphatic carbon atoms. In yet other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-8 aliphatic carbon atoms. In still other embodiments, the alkyl group contains 1-6 aliphatic carbon atoms. In yet other embodiments, the alkyl group contains 1-4 aliphatic carbon atoms. Examples of alkoxy, include but are not limited to, methoxy, ethoxy, propoxy, isopropoxy, n-butoxy, tert-butoxy, neopentoxy and n-hexoxy. Examples of thioalkyl include, but are not limited to, methylthio, ethylthio, propylthio, isopropylthio, n-butylthio, and the like.
[0016] The term “alkylamino” refers to a group having the structure —NHR′ wherein R′ is alkyl, as defined herein. The term “aminoalkyl” refers to a group having the structure NH 2 R′—, wherein R′ is alkyl, as defined herein. In certain embodiments, the alkyl group contains 1-20 aliphatic carbon atoms. In certain other embodiments, the alkyl group contains 1-10 aliphatic carbon atoms. In yet other embodiments, the alkyl, alkenyl, and alkynyl groups employed in the invention contain 1-8 aliphatic carbon atoms. In still other embodiments, the alkyl group contains 1-6 aliphatic carbon atoms. In yet other embodiments, the alkyl group contains 1-4 aliphatic carbon atoms. Examples of alkylamino include, but are not limited to, methylamino, ethylamino, iso-propylamino and the like.
[0017] Some examples of substituents of the above-described aliphatic (and other) moieties of compounds of the invention include, but are not limited to aliphatic; heteroaliphatic; aryl; heteroaryl; alkylaryl; alkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alycyclic, heteroaliphatic, heterocyclic, aryl, heteroaryl, alkylaryl, or alkylheteroaryl, wherein any of the aliphatic, heteroaliphatic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, cyclic or acyclic, and wherein any of the aryl or heteroaryl substituents described above and herein may be substituted or unsubstituted. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein.
[0018] In general, the term “aromatic moiety”, as used herein, refers to a stable mono- or polycyclic, unsaturated moiety having preferably 3-14 carbon atoms, each of which may be substituted or unsubstituted. In certain embodiments, the term “aromatic moiety” refers to a planar ring having p-orbitals perpendicular to the plane of the ring at each ring atom and satisfying the Huckel rule where the number of pi electrons in the ring is (4n+2) wherein n is an integer. A mono- or polycyclic, unsaturated moiety that does not satisfy one or all of these criteria for aromaticity is defined herein as “non-aromatic”, and is encompassed by the term “alicyclic”.
[0019] In general, the term “heteroaromatic moiety”, as used herein, refers to a stable mono- or polycyclic, unsaturated moiety having preferably 3-14 carbon atoms, each of which may be substituted or unsubstituted; and comprising at least one heteroatom selected from O, S and N within the ring (i.e., in place of a ring carbon atom). In certain embodiments, the term “heteroaromatic moiety” refers to a planar ring comprising at least on heteroatom, having p-orbitals perpendicular to the plane of the ring at each ring atom, and satisfying the Huckel rule where the number of pi electrons in the ring is (4n+2) wherein n is an integer.
[0020] It will also be appreciated that aromatic and heteroaromatic moieties, as defined herein may be attached via an alkyl or heteroalkyl moiety and thus also include -(alkyl)aromatic, -(heteroalkyl)aromatic, -(heteroalkyl)heteroaromatic, and -(heteroalkyl)heteroaromatic moieties. Thus, as used herein, the phrases “aromatic or heteroaromatic moieties” and “aromatic, heteroaromatic, -(alkyl)aromatic, -(heteroalkyl)aromatic, -(heteroalkyl)heteroaromatic, and -(heteroalkyl)heteroaromatic” are interchangeable. Substituents include, but are not limited to, any of the previously mentioned substituents, i.e., the substituents recited for aliphatic moieties, or for other moieties as disclosed herein, resulting in the formation of a stable compound.
[0021] The term “aryl”, as used herein, does not differ significantly from the common meaning of the term in the art, and refers to an unsaturated cyclic moiety comprising at least one aromatic ring. In certain embodiments, “aryl” refers to a mono- or bicyclic carbocyclic ring system having one or two aromatic rings including, but not limited to, phenyl, naphthyl, tetrahydronaphthyl, indanyl, indenyl and the like.
[0022] The term “heteroaryl”, as used herein, does not differ significantly from the common meaning of the term in the art, and refers to a cyclic aromatic radical having from five to ten ring atoms of which one ring atom is selected from S, O and N; zero, one or two ring atoms are additional heteroatoms independently selected from S, O and N; and the remaining ring atoms are carbon, the radical being joined to the rest of the molecule via any of the ring atoms, such as, for example, pyridyl, pyrazinyl, pyrimidinyl, pyrrolyl, pyrazolyl, imidazolyl, thiazolyl, oxazolyl, isooxazolyl, thiadiazolyl, oxadiazolyl, thiophenyl, furanyl, quinolinyl, isoquinolinyl, and the like.
[0023] It will be appreciated that aryl and heteroaryl groups (including bicyclic aryl groups) can be unsubstituted or substituted, wherein substitution includes replacement of one or more of the hydrogen atoms thereon independently with any one or more of the following moieties including, but not limited to: aliphatic; alicyclic; heteroaliphatic; heterocyclic; aromatic; heteroaromatic; aryl; heteroaryl; alkylaryl; heteroalkylaryl; alkylheteroaryl; heteroalkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O)R x ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic, heteroaromatic, aryl, heteroaryl, alkylaryl, alkylheteroaryl, heteroalkylaryl or heteroalkylheteroaryl, wherein any of the aliphatic, alicyclic, heteroaliphatic, heterocyclic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, saturated or unsaturated, and wherein any of the aromatic, heteroaromatic, aryl, heteroaryl, -(alkyl)aryl or -(alkyl)heteroaryl substituents described above and herein may be substituted or unsubstituted. Additionally, it will be appreciated, that any two adjacent groups taken together may represent a 4, 5, 6, or 7-membered substituted or unsubstituted alicyclic or heterocyclic moiety. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein.
[0024] The term “cycloalkyl”, as used herein, refers specifically to groups having three to seven, preferably three to ten carbon atoms. Suitable cycloalkyls include, but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and the like, which, as in the case of aliphatic, alicyclic, heteroaliphatic or heterocyclic moieties, may optionally be substituted with substituents including, but not limited to aliphatic; alicyclic; heteroaliphatic; heterocyclic; aromatic; heteroaromatic; aryl; heteroaryl; alkylaryl; heteroalkylaryl; alkylheteroaryl; heteroalkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic, heteroaromatic, aryl, heteroaryl, alkylaryl, alkylheteroaryl, heteroalkylaryl or heteroalkylheteroaryl, wherein any of the aliphatic, alicyclic, heteroaliphatic, heterocyclic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, saturated or unsaturated, and wherein any of the aromatic, heteroaromatic, aryl or heteroaryl substituents described above and herein may be substituted or unsubstituted. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein.
[0025] The term “heteroaliphatic”, as used herein, refers to aliphatic moieties in which one or more carbon atoms in the main chain have been substituted with a heteroatom. Thus, a heteroaliphatic group refers to an aliphatic chain which contains one or more oxygen, sulfur, nitrogen, phosphorus or silicon atoms, e.g., in place of carbon atoms. Heteroaliphatic moieties may be linear or branched, and saturated or unsaturated. In certain embodiments, heteroaliphatic moieties are substituted by independent replacement of one or more of the hydrogen atoms thereon with one or more moieties including, but not limited to aliphatic; alicyclic; heteroaliphatic; heterocyclic; aromatic; heteroaromatic; aryl; heteroaryl; alkylaryl; alkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic, heteroaromatic, aryl, heteroaryl, alkylaryl, alkylheteroaryl, heteroalkylaryl or heteroalkylheteroaryl, wherein any of the aliphatic, alicyclic, heteroaliphatic, heterocyclic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, saturated or unsaturated, and wherein any of the aromatic, heteroaromatic, aryl or heteroaryl substituents described above and herein may be substituted or unsubstituted. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein.
[0026] The term “heterocycloalkyl”, “heterocycle” or “heterocyclic”, as used herein, refers to compounds which combine the properties of heteroaliphatic and cyclic compounds and include, but are not limited to, saturated and unsaturated mono- or polycyclic cyclic ring systems having 5-16 atoms wherein at least one ring atom is a heteroatom selected from O, S and N (wherein the nitrogen and sulfur heteroatoms may be optionally be oxidized), wherein the ring systems are optionally substituted with one or more functional groups, as defined herein. In certain embodiments, the term “heterocycloalkyl”, “heterocycle” or “heterocyclic” refers to a non-aromatic 5-, 6-, or 7-membered ring or a polycyclic group wherein at least one ring atom is a heteroatom selected from O, S and N (wherein the nitrogen and sulfur heteroatoms may be optionally be oxidized), including, but not limited to, a bi- or tri-cyclic group, comprising fused six-membered rings having between one and three heteroatoms independently selected from oxygen, sulfur and nitrogen, wherein (i) each 5-membered ring has 0 to 2 double bonds, each 6-membered ring has 0 to 2 double bonds and each 7-membered ring has 0 to 3 double bonds, (ii) the nitrogen and sulfur heteroatoms may be optionally be oxidized, (iii) the nitrogen heteroatom may optionally be quaternized, and (iv) any of the above heterocyclic rings may be fused to an aryl or heteroaryl ring. Representative heterocycles include, but are not limited to, heterocycles such as furanyl, thiofuranyl, pyranyl, pyrrolyl, thienyl, pyrrolidinyl, pyrazolinyl, pyrazolidiny1, imidazolinyl, imidazolidinyl, piperidinyl, piperazinyl, oxazolyl, oxazolidinyl, isooxazolyl, isoxazolidinyl, dioxazolyl, thiadiazolyl, oxadiazolyl, tetrazolyl, triazolyl, thiatriazolyl, oxatriazolyl, thiadiazolyl, oxadiazolyl, morpholinyl, thiazolyl, thiazolidinyl, isothiazolyl, isothiazolidinyl, dithiazolyl, dithiazolidinyl, tetrahydrofuryl, and benzofused derivatives thereof. In certain embodiments, a “substituted heterocycle, or heterocycloalkyl or heterocyclic” group is utilized and as used herein, refers to a heterocycle, or heterocycloalkyl or heterocyclic group, as defined above, substituted by the independent replacement of one, two or three of the hydrogen atoms thereon with but are not limited to aliphatic; alicyclic; heteroaliphatic; heterocyclic; aromatic; heteroaromatic; aryl; heteroaryl; alkylaryl; heteroalkylaryl; alkylheteroaryl; heteroalkylheteroaryl; alkoxy; aryloxy; heteroalkoxy; heteroaryloxy; alkylthio; arylthio; heteroalkylthio; heteroarylthio; F; Cl; Br; I; —OH; —NO 2 ; —CN; —CF 3 ; —CH 2 CF 3 ; —CHCl 2 ; —CH 2 OH; —CH 2 CH 2 OH; —CH 2 NH 2 ; —CH 2 SO 2 CH 3 ; —C(O)R x ; —CO 2 (R x ); —CON(R x ) 2 ; —OC(O)R x ; —OCO 2 R x ; —OCON(R x ) 2 ; —N(R x ) 2 ; —S(O) 2 R x ; —NR x (CO)R x wherein each occurrence of R x independently includes, but is not limited to, aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic, heteroaromatic, aryl, heteroaryl, alkylaryl, alkylheteroaryl, heteroalkylaryl or heteroalkylheteroaryl, wherein any of the aliphatic, alicyclic, heteroaliphatic, heterocyclic, alkylaryl, or alkylheteroaryl substituents described above and herein may be substituted or unsubstituted, branched or unbranched, saturated or unsaturated, and wherein any of the aromatic, heteroaromatic, aryl or heteroaryl substitutents described above and herein may be substituted or unsubstituted. Additional examples or generally applicable substituents are illustrated by the specific embodiments shown in the Examples, which are described herein.
[0027] Additionally, it will be appreciated that any of the alicyclic or heterocyclic moieties described above and herein may comprise an aryl or heteroaryl moiety fused thereto. Additional examples of generally applicable substituents are illustrated by the specific embodiments shown in the Examples that are described herein. The terms “halo” and “halogen” as used herein refer to an atom selected from fluorine, chlorine, bromine and iodine.
[0028] The terms “halo” and “halogen” as used herein refer to an atom selected from fluorine, chlorine, bromine, and iodine.
[0029] The term “haloalkyl” denotes an alkyl group, as defined above, having one, two, or three halogen atoms attached thereto and is exemplified by such groups as chloromethyl, bromoethyl, trifluoromethyl, and the like.
[0030] The term “amino”, as used herein, refers to a primary (—NH 2 ), secondary (—NHR x ), tertiary (—NR x R y ) or quaternary (—N + R x R y R z ) amine, where R x , R y and R z are independently an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety, as defined herein. Examples of amino groups include, but are not limited to, methylamino, dimethylamino, ethylamino, diethylamino, diethylaminocarbonyl, methylethylamino, iso-propylamino, piperidino, trimethylamino, and propylamino.
[0031] The term “alkylidene”, as used herein, refers to a substituted or unsubstituted, linear or branched saturated divalent radical consisting solely of carbon and hydrogen atoms, having from one to n carbon atoms, having a free valence “-” at both ends of the radical.
[0032] The term “alkenylidene”, as used herein, refers to a substituted or unsubstituted, linear or branched unsaturated divalent radical consisting solely of carbon and hydrogen atoms, having from two to n carbon atoms, having a free valence “-” at both ends of the radical, and wherein the unsaturation is present only as double bonds and wherein a double bond can exist between the first carbon of the chain and the rest of the molecule.
[0033] The term “alkynylidene”, as used herein, refers to a substituted or unsubstituted, linear or branched unsaturated divalent radical consisting solely of carbon and hydrogen atoms, having from two to n carbon atoms, having a free valence “-” at both ends of the radical, and wherein the unsaturation is present only as triple bonds and wherein a triple bond can exist between the first carbon of the chain and the rest of the molecule.
[0034] Unless otherwise indicated, as used herein, the terms “alkyl”, “alkenyl”, “alkynyl”, “heteroalkyl”, “heteroalkenyl”, “heteroalkynyl”, “alkylidene”, alkenylidene”, -(alkyl)aryl, -(heteroalkyl)aryl, -(heteroalkyl)aryl, -(heteroalkyl)heteroaryl, and the like encompass substituted and unsubstituted, and linear and branched groups. Similarly, the terms “aliphatic”, “heteroaliphatic”, and the like encompass substituted and unsubstituted, saturated and unsaturated, and linear and branched groups. Similarly, the terms “cycloalkyl”, “heterocycle”, “heterocyclic”, and the like encompass substituted and unsubstituted, and saturated and unsaturated groups. Additionally, the terms “cycloalkenyl”, “cycloalkynyl”, “heterocycloalkenyl”, “heterocycloalkynyl”, “aromatic”, “heteroaromatic, “aryl”, “heteroaryl” and the like encompass both substituted and unsubstituted groups.
[0035] The phrase, “pharmaceutically acceptable derivative”, as used herein, denotes any pharmaceutically acceptable salt, ester, or salt of such ester, of such compound, or any other adduct or derivative which, upon administration to a patient, is capable of providing (directly or indirectly) a compound as otherwise described herein, or a metabolite or residue thereof. Pharmaceutically acceptable derivatives thus include among others pro-drugs. A pro-drug is a derivative of a compound, usually with significantly reduced pharmacological activity, which contains an additional moiety, which is susceptible to removal in vivo yielding the parent molecule as the pharmacologically active species. An example of a pro-drug is an ester, which is cleaved in vivo to yield a compound of interest. Pro-drugs of a variety of compounds, and materials and methods for derivatizing the parent compounds to create the pro-drugs, are known and may be adapted to the present invention. Pharmaceutically acceptable derivatives also include “reverse pro-drugs.” Reverse pro-drugs, rather than being activated, are inactivated upon absorption. For example, as discussed herein, many of the ester-containing compounds of the invention are biologically active but are inactivated upon exposure to certain physiological environments such as a blood, lymph, serum, extracellular fluid, etc. which contain esterase activity. The biological activity of reverse pro-drugs and pro-drugs may also be altered by appending a functionality onto the compound, which may be catalyzed by an enzyme. Also, included are oxidation and reduction reactions, including enzyme-catalyzed oxidation and reduction reactions. Certain exemplary pharmaceutical compositions and pharmaceutically acceptable derivatives will be discussed in more detail herein below.
[0036] The term “linker,” as used herein, refers to a chemical moiety utilized to attach one part of a compound of interest to another part of the compound. Exemplary linkers are described herein.
[0037] Unless indicated otherwise, the terms defined below have the following meanings:
[0038] “Compound”: The term “compound” or “chemical compound” as used herein can include organometallic compounds, organic compounds, metals, transitional metal complexes, and small molecules. In certain preferred embodiments, polynucleotides are excluded from the definition of compounds. In other preferred embodiments, polynucleotides and peptides are excluded from the definition of compounds. In a particularly preferred embodiment, the term compounds refers to small molecules (e.g., preferably, non-peptidic and non-oligomeric) and excludes peptides, polynucleotides, transition metal complexes, metals, and organometallic compounds.
[0039] “Small Molecule”: As used herein, the term “small molecule” refers to a non-peptidic, non-oligomeric organic compound either synthesized in the laboratory or found in nature. Small molecules, as used herein, can refer to compounds that are “natural product-like”, however, the term “small molecule” is not limited to “natural product-like” compounds. Rather, a small molecule is typically characterized in that it contains several carbon-carbon bonds, and has a molecular weight of less than 2000 g/mol, preferably less than 1500 g/mol, although this characterization is not intended to be limiting for the purposes of the present invention. Examples of “small molecules” that occur in nature include, but are not limited to, taxol, dynemicin, and rapamycin. Examples of “small molecules” that are synthesized in the laboratory include, but are not limited to, compounds described in Tan et al., (“Stereoselective Synthesis of over Two Million Compounds Having Structural Features Both Reminiscent of Natural Products and Compatible with Miniaturized Cell-Based Assays” J. Am. Chem. Soc. 120:8565, 1998; incorporated herein by reference). In certain other preferred embodiments, natural-product-like small molecules are utilized.
[0040] “Natural Product-Like Compound”: As used herein, the term “natural product-like compound” refers to compounds that are similar to complex natural products which nature has selected through evolution. Typically, these compounds contain one or more stereocenters, a high density and diversity of functionality, and a diverse selection of atoms within one structure. In this context, diversity of functionality can be defined as varying the topology, charge, size, hydrophilicity, hydrophobicity, and reactivity to name a few, of the functional groups present in the compounds. The term, “high density of functionality”, as used herein, can preferably be used to define any molecule that contains preferably three or more latent or active diversifiable functional moieties. These structural characteristics may additionally render the inventive compounds functionally reminiscent of complex natural products, in that they may interact specifically with a particular biological receptor, and thus may also be functionally natural product-like.
[0041] “Metal chelator”: As used herein, the term “metal chelator” refers to any molecule or moiety that is is capable of forming a complex (i.e., “chelates”) with a metal ion. In certain exemplary embodiments, a metal chelator refers to to any molecule or moiety that “binds” to a metal ion, in solution, making it unavailable for use in chemical/enzymatic reactions. In certain embodiments, the solution comprises aqueous environments under physiological conditions. Examples of metal ions include, but are not limited to, Ca 2+ , Fe 3+ , Zn 2+ , Na + , etc. In certain embodiments, the metal chelator binds Zn 2+ . In certain embodiments, molecules of moieties that precipitate metal ions are not considered to be metal chelators.
[0042] As used herein the term “biological sample” includes, without limitation, cell cultures or extracts thereof; biopsied material obtained from an animal (e.g., mammal) or extracts thereof; and blood, saliva, urine, feces, semen, tears, or other body fluids or extracts thereof. For example, the term “biological sample” refers to any solid or fluid sample obtained from, excreted by or secreted by any living organism, including single-celled micro-organisms (such as bacteria and yeasts) and multicellular organisms (such as plants and animals, for instance a vertebrate or a mammal, and in particular a healthy or apparently healthy human subject or a human patient affected by a condition or disease to be diagnosed or investigated). The biological sample can be in any form, including a solid material such as a tissue, cells, a cell pellet, a cell extract, cell homogenates, or cell fractions; or a biopsy, or a biological fluid. The biological fluid may be obtained from any site (e.g., blood, saliva (or a mouth wash containing buccal cells), tears, plasma, serum, urine, bile, cerebrospinal fluid, amniotic fluid, peritoneal fluid, and pleural fluid, or cells therefrom, aqueous or vitreous humor, or any bodily secretion), a transudate, an exudate (e.g. fluid obtained from an abscess or any other site of infection or inflammation), or fluid obtained from a joint (e.g. a normal joint or a joint affected by disease such as rheumatoid arthritis, osteoarthritis, gout or septic arthritis). The biological sample can be obtained from any organ or tissue (including a biopsy or autopsy specimen) or may comprise cells (whether primary cells or cultured cells) or medium conditioned by any cell, tissue or organ. Biological samples may also include sections of tissues such as frozen sections taken for histological purposes. Biological samples also include mixtures of biological molecules including proteins, lipids, carbohydrates and nucleic acids generated by partial or complete fractionation of cell or tissue homogenates. Although the sample is preferably taken from a human subject, biological samples may be from any animal, plant, bacteria, virus, yeast, etc. The term animal, as used herein, refers to humans as well as non-human animals, at any stage of development, including, for example, mammals, birds, reptiles, amphibians, fish, worms and single cells. Cell cultures and live tissue samples are considered to be pluralities of animals. In certain exemplary embodiments, the non-human animal is a mammal (e.g., a rodent, a mouse, a rat, a rabbit, a monkey, a dog, a cat, a sheep, cattle, a primate, or a pig). An animal may be a transgenic animal or a human clone. If desired, the biological sample may be subjected to preliminary processing, including preliminary separation techniques.
BRIEF DESCRIPTION OF THE DRAWING
[0043] FIG. 1 includes a table of esterases found in human and mouse plasma.
[0044] FIG. 2 shows the design of a reverse pro-drug version of SAHA-SAHP.
[0045] FIG. 3 illustrates the stability of SAHA (with an amide) in PBS.
[0046] FIG. 4 illustrates the stability of SAHA in serum.
[0047] FIG. 5 shows the stability of SAHP (ester instead of amdie) in PBS.
[0048] FIG. 6 shows the degradation of SAHP in serum. In less than 15 minutes, SAHP is completely degraded.
[0049] FIG. 7 shows a more detailed study of the degradation of SAHP in serum. In less than 2 minutes, SAHP is completely degraded into phenol and the corresponding carboxylic acid.
[0050] FIG. 8 shows the degradation of SAHP by human serum under various conditions.
[0051] FIG. 9 shows the degradation of SAHP by recombinant paraoxonase.
[0052] FIG. 10 shows the degradation of SAHP in RPMI media with 10% FBS.
[0053] FIG. 11 shows the effect of SAHA v. SAHP on lysine acetylation.
[0054] FIG. 12 shows the stability of SAHP in an olive oil/acetone formulation for murine model.
[0055] FIG. 13 is an exemplary synthetic scheme for preparing SAHP.
[0056] FIG. 14 . Interleukin-7 is a growth factor for T-cell development, in particular the gamma-delta subset. Transgenic mice overexpressing IL-7 in keratinocytes were developed by the laboratories of Thomas Kupper and Benjamin Rich, using a tissue-specific keratin-14 promoter element. These mice have been reported to develop a characteristic lymphoproliferative skin disease grossly and histologically similar to human cutaneous T-cell lymphoma (CTCL). Transformed lymphocytes derived from involved skin were passaged ex vivo and injected into syngeneic (non-transgenic) mice. After fourteen days, these mice develop a homogeneous lymphoproliferative disease. Two cohorts of five mice were included in a prospective study of topical, daily suberoyl hydroxamic acid phenyl ester (SAHP, also known as SHAPE) versus vehicle control. After fourteen days of therapy, mice were sacrificed and the treated region was dissected for histopathologic examination. In SHAPE-treated mice, hematoxylin-eosin staining demonstrates a marked reduction in lymphomatous infiltration within the treated window. Vehicle control mice failed to demonstrate a cytotoxic response.
[0057] FIG. 15 shows the pharmacodynamic effect of SAHP treatment as assessed using immunohistochemical staining for acetylated histones compared to vehicle treated controls. In SAHP-treated mice, AcH3K18 staining demonstrates hyperacetylated histone staining at the margin of compound treatment, with absent nuclear staining in the region of drug response. Vehicle control mice failed to demonstrate an increase in histone hyperacetylation.
DETAILED DESCRIPTION OF THE INVENTION
[0058] As discussed above, there remains a need for the development of novel histone deacetylase inhibitors. The present invention provides novel compounds of general formula (I), and methods for the synthesis thereof, which compounds are useful as inhibitors of histone deacetylases, and thus are useful for the treatment of proliferative diseases, particularly proliferative or other disorders associated with the skin and/or hair. In particular, the inventive compounds comprise an ester linkage. The ester linkage is preferably sensitive to esterase cleavage; therefore, when the compound is contacted with an esterase it is deactivated.
Compounds of the Invention
[0059] As discussed above, the present invention provides a novel class of compounds useful for the treatment of cancer and other proliferative conditions related thereto. In certain embodiments, the compounds of the present invention are useful as inhibitors of histone deacetylases and thus are useful as anticancer agents, and thus may be useful in the treatment of cancer, by effecting tumor cell death or inhibiting the growth of tumor cells. In certain exemplary embodiments, the inventive anticancer agents are useful in the treatment of cancers and other proliferative disorders, including, but not limited to breast cancer, cervical cancer, colon and rectal cancer, leukemia, lung cancer, melanoma, multiple myeloma, non-Hodgkin's lymphoma, ovarian cancer, pancreatic cancer, prostate cancer, and gastric cancer, to name a few. In certain embodiments, the inventive anticancer agents are active against leukemia cells and melanoma cells, and thus are useful for the treatment of leukemias (e.g., myeloid, lymphocytic, myelocytic and lymphoblastic leukemias) and malignant melanomas. In certain embodiments, the inventive compounds are active against cutaneous T-cell lymphoma. Additionally, as described above and in the exemplification, the inventive compounds may also be useful in the treatment of protozoal infections. In certain exemplary embodiments, the compounds of the invention are useful for disorders resulting from histone deacetylation activity. In certain embodiments, the compounds are useful for skin disorders. Exemplary skin disorders that may be treated using the inventive compounds include cutaneous T-cell lymphoma (CTCL), skin cancers (e.g., squamous cell carcinoma, basal cell carcinoma, malignant melanoma, etc.), psoriasis, hair loss, dermatitis, neurofibromatosis, disorders associated with skin hyperpigmentation, etc.
[0060] Compounds of this invention comprise those, as set forth above and described herein, and are illustrated in part by the various classes, subgenera and species disclosed elsewhere herein.
[0061] In general, the present invention provides compounds having the general structure (I):
[0000]
[0062] and pharmaceutically acceptable salts and derivatives thereof;
[0000] wherein
[0063] A comprises a functional group that inhibits histone deacetylase;
[0064] L is a linker moiety; and
[0065] Ar is a substituted or unsubstituted aryl or heteroaryl moiety; substituted or unsubstituted, branched or unbranched arylaliphatic or heteroarylaliphatic moiety; a substituted or unsubstituted cyclic or heterocyclic moiety; substituted or unsubstituted, branched or unbranched cyclicaliphatic or heterocyclicaliphatic moiety.
[0066] In certain embodiments, A comprises a metal chelating functional group. For example, A comprises a Zn 2+ chelating group. In certain embodiments, A comprises a functional group selected group consisting of:
[0000]
[0067] In certain embodiments, A comprises hydroxamic acid
[0000]
[0000] or a salt thereof. In other embodiments, A comprises the formula:
[0000]
[0068] In certain particular embodiments, A comprises the formula:
[0000]
[0069] In other embodiments, A comprises a carboxylic acid (—CO 2 H). In other embodiments, A comprises an o-aminoanilide
[0000]
[0000] In other embodiments, A comprises an o-hydroxyanilide
[0000]
[0000] In yet other embodiments, A comprises a thiol (—SH).
[0070] In certain embodiments, Ar is arylaliphatic. In other embodiments, Ar is heteroarylaliphatic. In certain embodiments, Ar is a substituted or unsubstituted aryl moiety. In certain embodiments, Ar is a monocyclic, substituted or unsubstituted aryl moiety, preferably a five- or six-membered aryl moiety. In other embodiments, Ar is a bicyclic, substituted or unsubstituted aryl moiety. In still other embodiments, Ar is a tricyclic, substituted or unsubstituted aryl moiety. In certain embodiments, Ar is a substituted or unsubstituted phenyl moiety. In certain embodiments, Ar is an unsubstituted phenyl moiety. In other embodiments, Ar is a substituted phenyl moiety. In certain embodiments, Ar is a monosubstituted phenyl moiety. In certain particular embodiments, Ar is an ortho-substituted Ar moiety. In certain particular embodiments, Ar is an meta-substituted Ar moiety. In certain particular embodiments, Ar is an para-substituted Ar moiety. In certain embodiments, Ar is a disubstituted phenyl moiety. In certain embodiments, Ar is a trisubstituted phenyl moiety. In certain embodiments, Ar is a tetrasubstituted phenyl moiety. In certain embodiments, Ar is a substituted or unsubstituted cyclic or heterocyclic.
[0071] In certain embodiments, Ar is a substituted or unsubstituted heteroaryl moiety. In certain embodiments, Ar is a monocyclic, substituted or unsubstituted heteroaryl moiety, preferably a five- or six-membered heteroaryl moiety. In other embodiments, Ar is a bicyclic, substituted or unsubstituted heteroaryl moiety. In still other embodiments, Ar is a tricyclic, substituted or unsubstituted heteroaryl moiety. In certain embodiments, Ar comprises N, S, or O. In certain embodiments, Ar comprises at least one N. In certain embodiments, Ar comprises at least two N.
[0072] In certain embodiments, Ar is:
[0000]
[0000] wherein
[0073] n is an integer between 1 and 5, inclusive; preferably, between 1 and 3, inclusive; more preferably, 1 or 2;
[0074] R 1 is is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ; —NHR A ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, Ar is
[0000]
[0000] In other embodiments, Ar is
[0000]
[0000] In yet other embodiments, Ar is
[0000]
[0000] In certain embodiments, R 1 is —N(R A ) 2 , wherein R A is hydrogen or C 1 -C 6 alkyl. In certain embodiments, R 1 is —OR A , wherein R A is hydrogen or C 1 -C 6 alkyl. In certain particular embodiments, R 1 is —OMe. In certain embodiments, R 1 is branched or unbranched acyl. In certain embodiments, R 1 is —O(═O)OR A . In certain embodiments, R 1 is —C(═O)OR A , wherein R A is hydrogen or C 1 -C 6 alkyl. In certain embodiments, R 1 is —C(═O)NH 2 . In certain embodiments, R 1 is —NHC(═O)R A . In certain embodiments, R 1 is —NHC(═O)R A , wherein R A is hydrogen or C 1 -C 6 alkyl. In certain embodiments, R 1 is halogen. In certain embodiments, R 1 is C 1 -C 6 alkyl.
[0075] In certain particular embodiments, Ar is a substituted phenyl moiety of formula:
[0000]
[0076] In certain embodiments, Ar is chosen from one of the following:
[0000]
[0000] wherein
[0077] n is an integer between 1 and 4, inclusive; preferably, between 1 and 3, inclusive; more preferably, 1 or 2;
[0078] R 1 is is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ; —NHR A ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0079] In certain embodiments, Ar is chosen from one of the following:
[0000]
[0000] Any of the above bicyclic ring system may be substituted with up to seven R 1 substituents as defined above.
[0080] In certain embodiments, L is a substituted or unsubstituted, cyclic or acyclic, branched or unbranched aliphatic moiety; a substituted or unsubstituted, cyclic or acyclic, branched or unbranched heteroaliphatic moiety; a substituted or unsubstituted aryl moiety; a substituted or unsubstituted heteroaryl moiety. In certain embodiments, L is a substituted or unsubstituted, cyclic or acyclic, branched or unbranched aliphatic moiety. In certain embodiments, L is C 1 -C 20 alkylidene, preferably C 1 to C 12 alkylidene, more preferably C 4 -C 7 alkylidene. In certain embodiments, L is C 1 -C 20 alkenylidene, preferably C 1 to C 12 alkenylidene, more preferably C 4 -C 7 alkenylidene. In certain embodiments, L is C 1 -C 20 alkynylidene, preferably C 1 to C 12 alkynylidene, more preferably C 4 -C 7 alkynylidene. In certain embodiments, L is a a substituted or unsubstituted, cyclic or acyclic, branched or unbranched heteroaliphatic moiety. In certain embodiments, L comprises a cyclic ring system, wherein the rings may be aryl, heteroaryl, non-aromatic carbocyclic, or non-aromatic heterocyclic. In still other embodiments, L comprises a substituted or unsubstituted heteroaryl moiety. In certain particular embodiments, L comprises a phenyl ring. In certain embodiments, L comprises multiple phenyl rings (e.g., one, two, three, or four phenyl rings).
[0081] In certain embodiments, L is
[0000]
[0000] wherein n is an integer between 1 and 4, inclusive; preferably, between 1 and 3, inclusive; more preferably, 1 or 2; and R 1 is is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ; —NHR A ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, L is
[0000]
[0082] In certain embodiments, L is
[0000]
[0083] In certain embodiments, L is an unbranched, unsubstituted, acyclic alkyl chain. In certain embodiments, L is
[0000]
[0000] In other embodiments, L is
[0000]
[0000] In certain other embodiments, L is
[0000]
[0000] In other embodiments, L is
[0000]
[0000] In yet other embodiments, L is
[0000]
[0084] In certain embodiments, L is a substituted, acyclic aliphatic chain. In certain embodiments, L is
[0000]
[0085] In certain embodiments, L is an unbranched, unsubstituted, acyclic heteroaliphatic chain. In certain particular embodiments, L is
[0000]
[0000] wherein n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; and m is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive. In certain particular embodiments, L is
[0000]
[0000] wherein n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; and m is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive. In certain particular embodiments, L is
[0000]
[0000] wherein n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; m is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; and R′ is hydrogen, C 1 -C 6 aliphatic, heteroaliphatic, aryl, heteroaryl, or acyl. In certain particular embodiments, L is
[0000]
[0000] wherein n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; and m is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive.
[0086] In certain embodiments of the invention, compounds of formula (I) have the following structure as shown in formula (Ia):
[0000]
[0000] wherein
[0087] n is an integer between 0 and 15, inclusive; preferably, between 0 and 10, inclusive; more preferably, between 1 and 8, inclusive; even more preferably, 4, 5, 6, 7, or 8; and
[0088] Ar is defined as above. In certain embodiments, n is 5. In other embodiments, n is 6. In still other embodiments, n is 7.
[0089] In certain embodiments of the invention, compounds of formula (I) have the following structure as shown in formula (Ib):
[0000]
[0000] wherein
[0090] n is an integer between 0 and 15, inclusive; preferably, between 0 and 10, inclusive; more preferably, between 1 and 8, inclusive; even more preferably, 4, 5, 6, 7, or 8;
[0091] m is an integer between 1 and 5, inclusive; preferably, m is 1, 2, or 3; and
[0092] R 1 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, R 1 is hydrogen, halogen, hydroxy, amino, alkylamino, dialkylamino, nitroso, acyl, or C 1 -C 6 alkyl. In certain embodiments, R 1 is aryl. In certain embodiments, R 1 is a multicyclic aryl moiety. In other embodiments, R 1 is heteroaryl. In certain embodiments, R 1 is carbocyclic. In other embodiments, R 1 is heterocyclic. In certain embodiments R 1 comprises a 1,3-dioxane ring optionally substituted. In certain embodiments, n is 5. In other embodiments, n is 6. In still other embodiments, n is 7. In certain embodiments, m is 0. In other embodiments, m is 1. In still other embodiments, m is 2.
[0093] In certain embodiments of the invention, compounds of formula (I) are of the formula (Ic):
[0000]
[0000] wherein
[0094] n is an integer between 0 and 15, inclusive; preferably, between 0 and 10, inclusive; more preferably, between 1 and 8, inclusive; even more preferably, 4, 5, 6, 7, or 8; and
[0095] R 1 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, R 1 is hydrogen, halogen, hydroxy, amino, alkylamino, dialkylamino, nitroso, acyl, or C 1 -C 6 alkyl. In certain embodiments, R 1 is aryl. In other embodiments, R 1 is heteroaryl. In certain embodiments, R 1 is carbocyclic. In other embodiments, R 1 is heterocyclic. In certain embodiments, n is 5. In other embodiments, n is 6. In still other embodiments, n is 7.
[0096] In certain embodiments of the invention, compounds of formula (I) are of the formula (Id):
[0000]
[0000] wherein
[0097] n is an integer between 1 and 5, inclusive; preferably, between 1 and 3; more preferably, 1 or 2; and
[0098] R 1 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR A ; —C(═O)R A ; —CO 2 R A ; —CN; —SCN; —SR A ; —SOR A ; —SO 2 R A ; —NO 2 ; —N(R A ) 2 ; —NHC(O)R A ; or —C(R A ) 3 ; wherein each occurrence of R A is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety. In certain embodiments, R 1 is hydrogen, halogen, hydroxy, amino, alkylamino, dialkylamino, nitroso, acyl, or C 1 -C 6 alkyl. In certain embodiments, R 1 is aryl. In other embodiments, R 1 is heteroaryl. In certain embodiments, R 1 is carbocyclic. In other embodiments, R 1 is heterocyclic. In certain embodiments, n is 1. In other embodiments, n is 2.
[0099] In certain embodiments of the invention, compounds of formula (I) are of the formula (Ie):
[0000]
[0000] wherein R1 is defined as above.
[0100] In certain embodiments of the invention, compounds of formula (I) have the following stereochemistry and structure as shown in formula (If):
[0000]
[0000] wherein A, L and Ar are defined as above; and
[0101] n is an integer between 0 and 10, inclusive; preferably, between 0 and 5, inclusive; even more preferably, 0, 1, 2, or 3. In certain embodiments, Ar is phenyl.
[0102] In certain embodiments, compounds of formula (I) are of the formula (Ig):
[0000]
[0000] wherein
[0103] A and L are defined as above;
[0104] R 2 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR B ; —C(═O)R B ; —CO 2 R B ; —CN; —SCN; —SR B ; —SOR B ; —SO 2 R B ; —NO 2 ; —N(R B ) 2 ; —NHC(O)R B ; or —C(R B ) 3 ; wherein each occurrence of R B is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety; and
[0105] R 3 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR C ; —C(═O)R C ; —CO 2 R C ; —CN; —SCN; —SR C ; —SOR C ; —SO 2 R C ; —NO 2 ; —N(R C ) 2 ; —NHC(O)R C ; or —C(R C ) 3 ; wherein each occurrence of R C is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0106] In certain embodiments, R 2 is hydrogen. In other embodiments, R 2 is hydroxyl or a protected hydroxyl group. In certain embodiments, R 2 is alkoxy. In yet other embodiments, R 2 is a lower alkyl, alkenyl, or alkynyl group. In certain embodiments, R 2 is —CH 2 —X(R B ) n , wherein X is O, S, N, or C, preferably O, S, or N; and n is 1, 2, or 3. In certain embodiments, R 2 is —CH 2 —OR B . In other embodiments, R 2 is —CH 2 —SR B . In yet other embodiments, R 2 is —CH 2 —R B . In other embodiments, R 2 is —CH 2 —N(R B ) 2 . In still other embodiments, R 2 is —CH 2 —NHR B . In certain embodiments of the invention, R B is one of:
[0000]
[0107] wherein m and p are each independently integers from 0 to 3; q 1 is an integer from 1 to 6; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety. In certain embodiments of the invention, R B is one of the structures:
[0000]
[0000] wherein m is an integer from 1 to 4; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety.
[0108] In certain embodiments, —X(R B ) n has one of the structures:
[0000]
[0109] In certain embodiments, R 2 is
[0000]
[0000] wherein X is N and Y is NH, S, or O. In other embodiments, R 2 is
[0000]
[0110] In certain embodiments, R 3 is substituted or unsubstituted aryl. In certain embodiments, R 3 is substituted or unsubstituted phenyl. In certain particular embodiments, R 3 is monosubstituted phenyl. In certain embodiments, R 3 is para-substituted phenyl. In certain embodiments, R 3 is
[0000]
[0000] wherein R 3 ′ is hydrogen, a protecting group, a solid support unit, an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R 3 is
[0000]
[0000] In other embodiments, R 3 is substituted or unsubstituted heteroaryl.
[0111] In certain embodiments, the stereochemistry of formula (Ig) is defined as follows:
[0000]
[0112] In certain embodiments of the invention, compounds of formula (I) are of the formula (Ih):
[0000]
[0000] wherein
[0113] A and L are defined as above;
[0114] n is an integer between 0 and 10, inclusive; preferably, between 1 and 6, inclusive; more preferably, between 1 and 3, inclusive; and even more preferably, 0, 1, 2, or 3;
[0115] R 2 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR B ; —C(═O)R B ; —CO 2 R B ; —CN; —SCN; —SR B ; —SOR B ; —SO 2 R B ; —NO 2 ; —N(R B ) 2 ; —NHC(O)R B ; or —C(R B ) 3 ; wherein each occurrence of R B is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety; and
[0116] R 3 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR C ; —C(═O)R C ; —CO 2 R C ; —CN; —SCN; —SR C ; —SOR C ; —SO 2 R C ; —NO 2 ; —N(R C ) 2 ; —NHC(O)R C ; or —C(R C ) 3 ; wherein each occurrence of R C is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0117] In certain embodiments, R 2 is hydrogen. In other embodiments, R 2 is hydroxyl or a protected hydroxyl group. In certain embodiments, R 2 is alkoxy. In yet other embodiments, R 2 is a lower alkyl, alkenyl, or alkynyl group. In certain embodiments, R 2 is —CH 2 —X(R B ) n ; wherein X is O, S, N, or C, preferably O, S, or N; and n is 1, 2, or 3. In certain embodiments, R 2 is —CH 2 —OR B . In other embodiments, R 2 is —CH 2 —SR B . In yet other embodiments, R 2 is —CH 2 —R B . In other embodiments, R 2 is —CH 2 —N(R B ) 2 . In still other embodiments, R 2 is —CH 2 —NHR B . In certain embodiments of the invention, R B is one of:
[0000]
[0118] wherein m and p are each independently integers from 0 to 3; q 1 is an integer from 1 to 6; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety. In certain embodiments of the invention, R B is one of the structures:
[0000]
[0000] wherein m is an integer from 1 to 4; R is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety.
[0119] In certain embodiments, —X(R B ) n has one of the structures:
[0000]
[0120] In certain embodiments, R 2 is
[0000]
[0000] wherein X is N and Y is NH, S, or O. In other embodiments, R 2 is
[0000]
[0121] In certain embodiments, R 3 is substituted or unsubstituted aryl. In certain embodiments, R 3 is substituted or unsubstituted phenyl. In certain particular embodiments, R 3 is monosubstituted phenyl. In certain embodiments, R 3 is para-substituted phenyl. In certain embodiments, R 3 is
[0000]
[0000] wherein R 3 ′ is hydrogen, a protecting group, a solid support unit, an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R 3 is
[0000]
[0000] In other embodiments, R 3 is substituted or unsubstituted heteroaryl.
[0122] In certain embodiments, the stereochemistry of formula (Ih) is defined as follows:
[0000]
[0123] In certain embodiments of the invention, compounds of formula (I) have structure as shown in formula (Ii):
[0000]
[0000] wherein
[0124] A and L are defined as above;
[0125] R 2 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR B ; —C(═O)R B ; —CO 2 R B ; —CN; —SCN; —SR B ; —SOR B ; —SO 2 R B ; —NO 2 ; —N(R B ) 2 ; —NHC(O)R B ; or —C(R B ) 3 ; wherein each occurrence of R B is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety; and
[0126] R 3 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR C ; —C(═O)R C ; —CO 2 R C ; —CN; —SCN; —SR C ; —SOR C ; —SO 2 R C ; —NO 2 ; —N(R C ) 2 ; —NHC(O)R C ; or —C(R C ) 3 ; wherein each occurrence of R C is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0127] In certain embodiments, R 2 is hydrogen. In other embodiments, R 2 is hydroxyl or a protected hydroxyl group. In certain embodiments, R 2 is alkoxy. In yet other embodiments, R 2 is a lower alkyl, alkenyl, or alkynyl group. In certain embodiments, R 2 is —CH 2 —X(R B ) n , wherein X is O, S, N, or C, preferably O, S, or N; and n is 1, 2, or 3. In certain embodiments, R 2 is —CH 2 —OR B . In other embodiments, R 2 is —CH 2 —SR B . In yet other embodiments, R 2 is —CH 2 —R B . In other embodiments, R 2 is —CH 2 —N(R B ) 2 . In still other embodiments, R 2 is —CH 2 —NHR B . In certain embodiments of the invention, R B is one of:
[0000]
[0128] wherein m and p are each independently integers from 0 to 3; q 1 is an integer from 1 to 6; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety. In certain embodiments of the invention, R B is one of the structures:
[0000]
[0000] wherein m is an integer from 1 to 4; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety.
[0129] In certain embodiments, —X(R B ) n has one of the structures:
[0000]
[0130] In certain embodiments, R 2 is
[0000]
[0000] wherein X is N and Y is NH, S, or O. In other embodiments, R 2 is
[0000]
[0131] In certain embodiments, R 3 is substituted or unsubstituted aryl. In certain embodiments, R 3 is substituted or unsubstituted phenyl. In certain particular embodiments, R 3 is monosubstituted phenyl. In certain embodiments, R 3 is para-substituted phenyl. In certain embodiments, R 3 is
[0000]
[0000] wherein R 3 ′ is hydrogen, a protecting group, a solid support unit, an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R 3 is
[0000]
[0000] In other embodiments, R 3 is substituted or unsubstituted heteroaryl.
[0132] In certain embodiments, the stereochemistry of formula (Ii) is defined as follows:
[0000]
[0133] In certain embodiments of the invention, compounds of formula (I) have the following stereochemistry and structure as shown in formula (Ij):
[0000]
[0000] wherein
[0134] R 2 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR B ; —C(═O)R B ; —CO 2 R B ; —CN; —SCN; —SR B ; —SOR B ; —SO 2 R B ; —NO 2 ; —N(R B ) 2 ; —NHC(O)R B ; or —C(R B ) 3 ; wherein each occurrence of R B is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety; and
[0135] R 3 is hydrogen; halogen; cyclic or acyclic, substituted or unsubstituted, branched or unbranched aliphatic; cyclic or acyclic, substituted or unsubstituted, branched or unbranched heteroaliphatic; substituted or unsubstituted, branched or unbranched acyl; substituted or unsubstituted, branched or unbranched aryl; substituted or unsubstituted, branched or unbranched heteroaryl; —OR C ; —C(═O)R C ; —CO 2 R C ; —CN; —SCN; —SR C ; —SOR C ; —SO 2 R C ; —NO 2 ; —N(R C ) 2 ; —NHC(O)R C ; or —C(R C ) 3 ; wherein each occurrence of R C is independently a hydrogen, a protecting group, an aliphatic moiety, a heteroaliphatic moiety, an acyl moiety; an aryl moiety; a heteroaryl moiety; alkoxy; aryloxy; alkylthio; arylthio; amino, alkylamino, dialkylamino, heteroaryloxy; or heteroarylthio moiety.
[0136] In certain embodiments, R 2 is hydrogen. In other embodiments, R 2 is hydroxyl or a protected hydroxyl group. In certain embodiments, R 2 is alkoxy. In yet other embodiments, R 2 is a lower alkyl, alkenyl, or alkynyl group. In certain embodiments, R 2 is —CH 2 —X(R B ) n ; wherein X is O, S, N, or C, preferably O, S, or N; and n is 1, 2, or 3. In certain embodiments, R 2 is —CH 2 —OR B . In other embodiments, R 2 is —CH 2 —SR B . In yet other embodiments, R 2 is —CH 2 —R B . In other embodiments, R 2 is —CH 2 —N(R B ) 2 . In still other embodiments, R 2 is —CH 2 —NHR B . In certain embodiments of the invention, R B is one of:
[0000]
[0137] wherein m and p are each independently integers from 0 to 3; q 1 is an integer from 1 to 6; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety. In certain embodiments of the invention, R B is one of the structures:
[0000]
[0000] wherein m is an integer from 1 to 4; R 2C is hydrogen, lower alkyl or a nitrogen protecting group; and each occurrence of R 2B is independently hydrogen, halogen, —CN, or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety.
[0138] In certain embodiments, —X(R B ) n has one of the structures:
[0000]
[0139] In certain embodiments, R 2 is
[0000]
[0000] wherein X is N and Y is NH, S, or O. In other embodiments, R 2 is
[0000]
[0140] In certain embodiments, R 3 is substituted or unsubstituted aryl. In certain embodiments, R 3 is substituted or unsubstituted phenyl. In certain particular embodiments, R 3 is monosubstituted phenyl. In certain embodiments, R 3 is para-substituted phenyl. In certain embodiments, R 3 is
[0000]
[0000] wherein R 3 ′ is hydrogen, a protecting group, a solid support unit, an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R 3 is
[0000]
[0000] In other embodiments, R 3 is substituted or unsubstituted heteroaryl.
[0141] Another class of compounds of special interest includes those compounds of the invention as described above and in certain subclasses herein, wherein R 3 is a substituted phenyl moiety and the compounds have the formula (II):
[0000]
[0000] wherein
[0142] L, A, X, and R B are defined as above;
[0143] n is an integer between 0 and 5, inclusive; preferably, between, 1 and 3; more preferably, 2; and
[0144] Z is hydrogen, —(CH 2 ) q OR Z , —(CH 2 ) q SR Z , —(CH 2 ) q N(R Z ) 2 , —C(═O)R Z , —C(═O)N(R Z ) 2 , or an alkyl, heteroalkyl, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety, wherein q is 0-4, and wherein each occurrence of R Z is independently hydrogen, a protecting group, a solid support unit, or an alkyl, acyl, cycloalkyl, heteroalkyl, heterocyclic, aryl, heteroaryl, -(alkyl)aryl, -(alkyl)heteroaryl, -(heteroalkyl)aryl, or -(heteroalkyl)heteroaryl moiety. In certain embodiments, R Z is hydrogen. In other embodiments, R Z is C 1 -C 6 alkyl. In certain embodiments, R Z is an oxygen-protecting group.
[0145] Another class of compounds includes those compounds of formula (II), wherein Z is —CH 2 OR Z , and the compounds have the general structure (Im):
[0000]
[0000] wherein
[0146] R B , R Z , X, L, n, and A are defined generally above and in classes and subclasses herein. In certain embodiments, X is S. In other embodiments, X is O.
[0147] Yet another class of compounds of particular interest includes those compounds of formula (Ii), wherein X is S and the compounds have the general structure (In):
[0000]
[0000] wherein
[0148] R B , X, L, n, and A are defined as above; and
[0149] R Z is as defined generally above and in classes and subclasses herein.
[0150] Yet another class of compounds of special interest includes those compounds of formula (Ii), wherein X is —NR 2A and the compounds have the general structure (Io):
[0000]
[0000] wherein
[0151] R B , R Z , X, L, n, and A are defined generally above and in classes and subclasses herein.
[0152] Yet another class of compounds of special interest includes those compounds of formula (Ii), wherein X is O and the compounds have the general structure (Ip):
[0000]
[0000] wherein
[0153] R B , R Z , X, L, n, and A are defined generally above and in classes and subclasses herein.
[0154] Exemplary compounds of the invention are shown:
[0000]
[0155] Some of the foregoing compounds can comprise one or more asymmetric centers, and thus can exist in various isomeric forms, e.g., stereoisomers and/or diastereomers. Thus, inventive compounds and pharmaceutical compositions thereof may be in the form of an individual enantiomer, diastereomer or geometric isomer, or may be in the form of a mixture of stereoisomers. In certain embodiments, the compounds of the invention are enantiopure compounds. In certain other embodiments, mixtures of stereoisomers or diastereomers are provided.
[0156] Furthermore, certain compounds, as described herein may have one or more double bonds that can exist as either the Z or E isomer, unless otherwise indicated. The invention additionally encompasses the compounds as individual isomers substantially free of other isomers and alternatively, as mixtures of various isomers, e.g., racemic mixtures of stereoisomers. In addition to the above-mentioned compounds per se, this invention also encompasses pharmaceutically acceptable derivatives of these compounds and compositions comprising one or more compounds of the invention and one or more pharmaceutically acceptable excipients or additives.
[0157] Compounds of the invention may be prepared by crystallization of the compound under different conditions and may exist as one or a combination of polymorphs of the compound forming part of this invention. For example, different polymorphs may be identified and/or prepared using different solvents, or different mixtures of solvents for recrystallization; by performing crystallizations at different temperatures; or by using various modes of cooling, ranging from very fast to very slow cooling during crystallizations. Polymorphs may also be obtained by heating or melting the compound followed by gradual or fast cooling. The presence of polymorphs may be determined by solid probe NMR spectroscopy, IR spectroscopy, differential scanning calorimetry, powder X-ray diffractogram and/or other techniques. Thus, the present invention encompasses inventive compounds, their derivatives, their tautomeric forms, their stereoisomers, their polymorphs, their pharmaceutically acceptable salts their pharmaceutically acceptable solvates and pharmaceutically acceptable compositions containing them.
Synthetic Overview
[0158] The synthesis of the various monomeric compounds used to prepare the dimeric, multimeric, and polymeric compounds of the invention are known in the art. These published syntheses may be utilized to prepare the compounds of the invention. Exemplary synthetic methods for preparing compounds of the invention are described in U.S. Pat. No. 6,960,685; U.S. Pat. No. 6,897,220; U.S. Pat. No. 6,541,661; U.S. Pat. No. 6,512,123; U.S. Pat. No. 6,495,719; US 2006/0020131; US 2004/087631; US 2004/127522; US 2004/0072849; US 2003/0187027; WO 2005/018578; WO 2005/007091; WO 2005/007091; WO 2005/018578; WO 2004/046104; WO 2002/89782; each of which is incorporated herein by reference. In many cases, an amide moiety is changed to an ester moiety to prepare the inventive compounds.
[0159] An exemplary synthetic scheme for preparing SAHP is shown in FIG. 13 . Those of skill in the art will realize that based on this teaching and those in the art as referenced above one could prepare any of the esterase-sensitive compounds of the invention.
[0160] In yet another aspect of the invention, methods for producing intermediates useful for the preparation of certain compounds of the invention are provided.
[0161] In one aspect of the invention, a method for the synthesis of the core structure of certain compounds is provided, one method comprising steps of:
[0162] providing an epoxy alcohol having the structure:
[0000]
[0163] reacting the epoxy alcohol with a reagent having the structure R 2 XH under suitable conditions to generate a diol having the core structure:
[0000]
[0164] reacting the diol with a reagent having the structure R 3 CH(OMe) 2 under suitable conditions to generate a scaffold having the core structure:
[0000]
[0165] wherein R 1 is hydrogen, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0166] R 2 is hydrogen, a protecting group, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0167] X is −O—, —C(R 2A ) 2 —, —S—, or —NR 2A —, wherein R 2A is hydrogen, a protecting group, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0168] or wherein two or more occurrences of R 2 and R 2A , taken together, form an alicyclic or heterocyclic moiety, or an aryl or heteroaryl moiety;
[0169] R 3 is an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety; and
[0170] R Z is an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety and is optionally attached to a solid support.
[0171] In certain exemplary embodiments, the epoxy alcohol has the structure:
[0000]
[0172] the diol has the structure:
[0000]
[0173] and the core scaffold has the structure:
[0000]
[0174] In certain other exemplary embodiments, the epoxy alcohol has the structure:
[0000]
[0175] the diol has the structure:
[0000]
[0176] and the the core scaffold has the structure:
[0000]
[0177] In certain embodiments, R 3 has the following structure:
[0000]
and the method described above generates the structure:
[0000]
[0179] In another aspect of the invention, a method for the synthesis of the core structure of certain compounds of the invention is provided, one method comprising steps of:
[0180] providing an epoxy alcohol having the structure:
[0000]
[0181] reacting the epoxy alcohol with a reagent having the structure R 2 XH under suitable conditions to generate a diol having the core structure:
[0000]
[0182] subjecting the diol to a reagent having the structure:
[0000]
[0000] wherein R 4C is a nitrogen protecting group; to suitable conditions to generate an amine having the structure:
[0000]
reacting the amine with a reagent having the structure:
[0000]
[0000] under suitable conditions to generate a scaffold having the core structure:
[0000]
[0184] wherein R 1 is hydrogen, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0185] R 2 is hydrogen, a protecting group, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0186] X is −O—, —C(R 2A ) 2 —, —S—, or —NR 2A —, wherein R 2A is hydrogen, a protecting group, or an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety;
[0187] or wherein two or more occurrences of R 2 and R 2A , taken together, form an alicyclic or heterocyclic moiety, or an aryl or heteroaryl moiety;
[0188] r is 0 or 1;
[0189] s is an integer from 2-5;
[0190] w is an integer from 0-4;
[0191] R 4A comprises a metal chelator;
[0192] each occurrence of R 4D is independently hydrogen, alkyl, heteroalkyl, cycloalkyl, heterocyclic, alkenyl, alkynyl, aryl, heteroaryl, halogen, CN, NO 2 , or WR W1 wherein W is O, S, NR W2 , —C(═O), —S(═O), —SO 2 , —C(═O)O—, —OC(═O), —C(═O)NR W2 , —NR W2 C(═O); wherein each occurrence of R W1 and R W2 is independently hydrogen, a protecting group, a prodrug moiety or an alkyl, cycloalkyl, heteroalkyl, heterocyclic, aryl or heteroaryl moiety, or, when W is NR W2 , R W1 and R W2 , taken together with the nitrogen atom to which they are attached, form a heterocyclic or heteroaryl moiety; or any two adjacent occurrences of R 2B , taken together with the atoms to which they are attached, form a substituted or unsubstituted, saturated or unsaturated alicyclic or heterocyclic moiety, or a substituted or unsubstituted aryl or heteroaryl moiety; and
[0193] R Z is an aliphatic, alicyclic, heteroaliphatic, heterocyclic, aromatic or heteroaromatic moiety and is optionally attached to a solid support.
[0194] In certain exemplary embodiments, the epoxy alcohol has the structure:
[0000]
[0195] the diol has the structure:
[0000]
[0196] the amine has the structure:
[0000]
[0197] and the core scaffold has the structure:
[0000]
[0198] In certain exemplary embodiments, the epoxy alcohol has the structure:
[0000]
[0199] the diol has the structure:
[0000]
[0200] the amine has the structure:
[0000]
[0201] and the core scaffold has the structure:
[0000]
[0202] In certain embodiments, the methods described above are carried out in solution phase. In certain other embodiments, the methods described above are carried out on a solid phase. In certain embodiments, the synthetic method is amenable to high-throughput techniques or to techniques commonly used in combinatorial chemistry.
Pharmaceutical Compositions
[0203] As discussed above, the present invention provides novel compounds having antitumor and antiproliferative activity, and thus the inventive compounds are useful for the treatment of cancer (e.g., cutaneous T-cell lymphoma). Benign proliferative diseases may also be treated using the inventive compounds. The compounds are also useful in the treatment of other diseases or condition that benefit from inhibition of deacetylation activity (e.g. HDAC inhibition). In certain embodiments, the compounds are useful in the treatment of baldness based on the discovery that HDAC inhibition (particularly, HDAC6 inhibition) blocks androgen signaling vis hsp90. HDAC inhibition has also been shown to inhibit estrogen signaling. In certain embodiments, the compounds are useful in blocking the hyperpigmentation of skin by HDAC inhibition.
[0204] Accordingly, in another aspect of the present invention, pharmaceutical compositions are provided, which comprise any one of the compounds described herein (or a prodrug, pharmaceutically acceptable salt or other pharmaceutically acceptable derivative thereof), and optionally comprise a pharmaceutically acceptable carrier. In certain embodiments, these compositions optionally further comprise one or more additional therapeutic agents. Alternatively, a compound of this invention may be administered to a patient in need thereof in combination with the administration of one or more other therapeutic agents. For example, additional therapeutic agents for conjoint administration or inclusion in a pharmaceutical composition with a compound of this invention may be an approved chemotherapeutic agent, or it may be any one of a number of agents undergoing approval in the Food and Drug Administration that ultimately obtain approval for the treatment of hair loss, skin hyperpigmentation, protozoal infections, and/or any disorder associated with cellular hyperproliferation. In certain other embodiments, the additional therapeutic agent is an anticancer agent, as discussed in more detail herein. In certain other embodiments, the compositions of the invention are useful for the treatment of protozoal infections.
[0205] It will also be appreciated that certain of the compounds of present invention can exist in free form for treatment, or where appropriate, as a pharmaceutically acceptable derivative thereof. According to the present invention, a pharmaceutically acceptable derivative includes, but is not limited to, pharmaceutically acceptable salts, esters, salts of such esters, or a pro-drug or other adduct or derivative of a compound of this invention which upon administration to a patient in need is capable of providing, directly or indirectly, a compound as otherwise described herein, or a metabolite or residue thereof.
[0206] As used herein, the term “pharmaceutically acceptable salt” refers to those salts which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of humans and lower animals without undue toxicity, irritation, allergic response and the like, and are commensurate with a reasonable benefit/risk ratio. Pharmaceutically acceptable salts of amines, carboxylic acids, and other types of compounds, are well known in the art. For example, S. M. Berge, et al. describe pharmaceutically acceptable salts in detail in J. Pharmaceutical Sciences, 66: 1-19 (1977), incorporated herein by reference. The salts can be prepared in situ during the final isolation and purification of the compounds of the invention, or separately by reacting a free base or free acid function with a suitable reagent, as described generally below. For example, a free base function can be reacted with a suitable acid. Furthermore, where the compounds of the invention carry an acidic moiety, suitable pharmaceutically acceptable salts thereof may, include metal salts such as alkali metal salts, e.g. sodium or potassium salts; and alkaline earth metal salts, e.g. calcium or magnesium salts. Examples of pharmaceutically acceptable, nontoxic acid addition salts are salts of an amino group formed with inorganic acids such as hydrochloric acid, hydrobromic acid, phosphoric acid, sulfuric acid and perchloric acid or with organic acids such as acetic acid, oxalic acid, maleic acid, tartaric acid, citric acid, succinic acid or malonic acid or by using other methods used in the art such as ion exchange. Other pharmaceutically acceptable salts include adipate, alginate, ascorbate, aspartate, benzenesulfonate, benzoate, bisulfate, borate, butyrate, camphorate, camphorsulfonate, citrate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, formate, fumarate, glucoheptonate, glycerophosphate, gluconate, hernisulfate, heptanoate, hexanoate, hydroiodide, 2-hydroxy-ethanesulfonate, lactobionate, lactate, laurate, lauryl sulfate, malate, maleate, malonate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, nitrate, oleate, oxalate, palmitate, pamoate, pectinate, persulfate, 3-phenylpropionate, phosphate, picrate, pivalate, propionate, stearate, succinate, sulfate, tartrate, thiocyanate, p-toluenesulfonate, undecanoate, valerate salts, and the like. Representative alkali or alkaline earth metal salts include sodium, lithium, potassium, calcium, magnesium, and the like. Further pharmaceutically acceptable salts include, when appropriate, nontoxic ammonium, quaternary ammonium, and amine cations formed using counterions such as halide, hydroxide, carboxylate, sulfate, phosphate, nitrate, lower alkyl sulfonate and aryl sulfonate.
[0207] Additionally, as used herein, the term “pharmaceutically acceptable ester” refers to esters that hydrolyze in vivo and include those that break down readily in the human body to leave the parent compound or a salt thereof. Suitable ester groups include, for example, those derived from pharmaceutically acceptable aliphatic carboxylic acids, particularly alkanoic, alkenoic, cycloalkanoic and alkanedioic acids, in which each alkyl or alkenyl moeity advantageously has not more than 6 carbon atoms. Examples of particular esters include formates, acetates, propionates, butyrates, acrylates and ethylsuccinates.
[0208] Furthermore, the term “pharmaceutically acceptable prodrugs” as used herein refers to those prodrugs of the compounds of the present invention which are, within the scope of sound medical judgment, suitable for use in contact with the issues of humans and lower animals with undue toxicity, irritation, allergic response, and the like, commensurate with a reasonable benefit/risk ratio, and effective for their intended use, as well as the zwitterionic forms, where possible, of the compounds of the invention. The term “prodrug” refers to compounds that are rapidly transformed in vivo to yield the parent compound of the above formula, for example by hydrolysis in blood. A thorough discussion is provided in T. Higuchi and V. Stella, Pro-drugs as Novel Delivery Systems, Vol. 14 of the A.C.S. Symposium Series, and in Edward B. Roche, ed., Bioreversible Carriers in Drug Design, American Pharmaceutical Association and Pergamon Press, 1987, both of which are incorporated herein by reference.
[0209] As described above, the pharmaceutical compositions of the present invention additionally comprise a pharmaceutically acceptable carrier, which, as used herein, includes any and all solvents, diluents, or other liquid vehicle, dispersion or suspension aids, surface active agents, isotonic agents, thickening or emulsifying agents, preservatives, solid binders, lubricants and the like, as suited to the particular dosage form desired. Remington's Pharmaceutical Sciences, Sixteenth Edition, E. W. Martin (Mack Publishing Co., Easton, Pa., 1980) discloses various carriers used in formulating pharmaceutical compositions and known techniques for the preparation thereof. Except insofar as any conventional carrier medium is incompatible with the compounds of the invention, such as by producing any undesirable biological effect or otherwise interacting in a deleterious manner with any other component(s) of the pharmaceutical composition, its use is contemplated to be within the scope of this invention. Some examples of materials which can serve as pharmaceutically acceptable carriers include, but are not limited to, sugars such as lactose, glucose and sucrose; starches such as corn starch and potato starch; cellulose and its derivatives such as sodium carboxymethyl cellulose, ethyl cellulose and cellulose acetate; powdered tragacanth; malt; gelatine; talc; excipients such as cocoa butter and suppository waxes; oils such as peanut oil, cottonseed oil; safflower oil, sesame oil; olive oil; corn oil and soybean oil; glycols; such as propylene glycol; esters such as ethyl oleate and ethyl laurate; agar; buffering agents such as magnesium hydroxide and aluminum hydroxide; alginic acid; pyrogen free water; isotonic saline; Ringer's solution; ethyl alcohol, and phosphate buffer solutions, as well as other non-toxic compatible lubricants such as sodium lauryl sulfate and magnesium stearate, as well as coloring agents, releasing agents, coating agents, sweetening, flavoring and perfuming agents, preservatives and antioxidants can also be present in the composition, according to the judgment of the formulator.
[0210] Liquid dosage forms for oral administration include, but are not limited to, pharmaceutically acceptable emulsions, microemulsions, solutions, suspensions, syrups and elixirs. In addition to the active compounds, the liquid dosage forms may contain inert diluents commonly used in the art such as, for example, water or other solvents, solubilizing agents and emulsifiers such as ethyl alcohol, isopropyl alcohol, ethyl carbonate, ethyl acetate, benzyl alcohol, benzyl benzoate, propylene glycol, 1,3-butylene glycol, dimethylformamide, oils (in particular, cottonseed, groundnut, corn, germ, olive, castor, and sesame oils), glycerol, tetrahydrofurfuryl alcohol, polyethylene glycols and fatty acid esters of sorbitan, and mixtures thereof. Besides inert diluents, the oral compositions can also include adjuvants such as wetting agents, emulsifying and suspending agents, sweetening, flavoring, and perfuming agents.
[0211] Injectable preparations, for example, sterile injectable aqueous or oleaginous suspensions may be formulated according to the known art using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution, suspension or emulsion in a nontoxic parenterally acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution, U.S.P. and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil can be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid are used in the preparation of injectables.
[0212] The injectable formulations can be sterilized, for example, by filtration through a bacterial-retaining filter, or by incorporating sterilizing agents in the form of sterile solid compositions which can be dissolved or dispersed in sterile water or other sterile injectable medium prior to use.
[0213] In order to prolong the effect of a drug, it is often desirable to slow the absorption of the drug from subcutaneous or intramuscular injection. This may be accomplished by the use of a liquid suspension or crystalline or amorphous material with poor water solubility. The rate of absorption of the drug then depends upon its rate of dissolution that, in turn, may depend upon crystal size and crystalline form. Alternatively, delayed absorption of a parenterally administered drug form is accomplished by dissolving or suspending the drug in an oil vehicle. Injectable depot forms are made by forming microencapsule matrices of the drug in biodegradable polymers such as polylactide-polyglycolide. Depending upon the ratio of drug to polymer and the nature of the particular polymer employed, the rate of drug release can be controlled. Examples of other biodegradable polymers include (poly(orthoesters) and poly(anhydrides). Depot injectable formulations are also prepared by entrapping the drug in liposomes or microemulsions which are compatible with body tissues.
[0214] Compositions for rectal or vaginal administration are preferably suppositories which can be prepared by mixing the compounds of this invention with suitable non-irritating excipients or carriers such as cocoa butter, polyethylene glycol or a suppository wax which are solid at ambient temperature but liquid at body temperature and therefore melt in the rectum or vaginal cavity and release the active compound.
[0215] Solid dosage forms for oral administration include capsules, tablets, pills, powders, and granules. In such solid dosage forms, the active compound is mixed with at least one inert, pharmaceutically acceptable excipient or carrier such as sodium citrate or dicalcium phosphate and/or a) fillers or extenders such as starches, lactose, sucrose, glucose, mannitol, and silicic acid, b) binders such as, for example, carboxymethylcellulose, alginates, gelatin, polyvinylpyrrolidinone, sucrose, and acacia, c) humectants such as glycerol, d) disintegrating agents such as agar-agar, calcium carbonate, potato or tapioca starch, alginic acid, certain silicates, and sodium carbonate, e) solution retarding agents such as paraffin, absorption accelerators such as quaternary ammonium compounds, g) wetting agents such as, for example, cetyl alcohol and glycerol monostearate, h) absorbents such as kaolin and bentonite clay, and i) lubricants such as talc, calcium stearate, magnesium stearate, solid polyethylene glycols, sodium lauryl sulfate, and mixtures thereof. In the case of capsules, tablets and pills, the dosage form may also comprise buffering agents.
[0216] Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules using such excipients as lactose or milk sugar as well as high molecular weight polyethylene glycols and the like. The solid dosage forms of tablets, dragees, capsules, pills, and granules can be prepared with coatings and shells such as enteric coatings and other coatings well known in the pharmaceutical formulating art. They may optionally contain opacifying agents and can also be of a composition that they release the active ingredient(s) only, or preferentially, in a certain part of the intestinal tract, optionally, in a delayed manner Examples of embedding compositions that can be used include polymeric substances and waxes. Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules using such excipients as lactose or milk sugar as well as high molecular weight polyethylene glycols and the like.
[0217] The active compounds can also be in micro-encapsulated form with one or more excipients as noted above. The solid dosage forms of tablets, dragees, capsules, pills, and granules can be prepared with coatings and shells such as enteric coatings, release controlling coatings and other coatings well known in the pharmaceutical formulating art. In such solid dosage forms the active compound may be admixed with at least one inert diluent such as sucrose, lactose and starch. Such dosage forms may also comprise, as in normal practice, additional substances other than inert diluents, e.g., tableting lubricants and other tableting aids such as magnesium stearate and microcrystalline cellulose. In the case of capsules, tablets and pills, the dosage forms may also comprise buffering agents. They may optionally contain opacifying agents and can also be of a composition that they release the active ingredient(s) only, or preferentially, in a certain part of the intestinal tract, optionally, in a delayed manner Examples of embedding compositions which can be used include polymeric substances and waxes.
[0218] The present invention encompasses pharmaceutically acceptable topical formulations of inventive compounds. The term “pharmaceutically acceptable topical formulation”, as used herein, means any formulation which is pharmaceutically acceptable for intradermal administration of a compound of the invention by application of the formulation to the epidermis. In certain embodiments of the invention, the topical formulation comprises a carrier system. Pharmaceutically effective carriers include, but are not limited to, solvents (e.g., alcohols, poly alcohols, water), creams, lotions, ointments, oils, plasters, liposomes, powders, emulsions, microemulsions, and buffered solutions (e.g., hypotonic or buffered saline) or any other carrier known in the art for topically administering pharmaceuticals. A more complete listing of art-known carriers is provided by reference texts that are standard in the art, for example, Remington's Pharmaceutical Sciences, 16th Edition, 1980 and 17th Edition, 1985, both published by Mack Publishing Company, Easton, Pa., the disclosures of which are incorporated herein by reference in their entireties. In certain other embodiments, the topical formulations of the invention may comprise excipients. Any pharmaceutically acceptable excipient known in the art may be used to prepare the inventive pharmaceutically acceptable topical formulations. Examples of excipients that can be included in the topical formulations of the invention include, but are not limited to, preservatives, antioxidants, moisturizers, emollients, buffering agents, solubilizing agents, other penetration agents, skin protectants, surfactants, and propellants, and/or additional therapeutic agents used in combination to the inventive compound. Suitable preservatives include, but are not limited to, alcohols, quaternary amines, organic acids, parabens, and phenols. Suitable antioxidants include, but are not limited to, ascorbic acid and its esters, sodium bisulfite, butylated hydroxytoluene, butylated hydroxyanisole, tocopherols, and chelating agents like EDTA and citric acid. Suitable moisturizers include, but are not limited to, glycerine, sorbitol, polyethylene glycols, urea, and propylene glycol. Suitable buffering agents for use with the invention include, but are not limited to, citric, hydrochloric, and lactic acid buffers. Suitable solubilizing agents include, but are not limited to, quaternary ammonium chlorides, cyclodextrins, benzyl benzoate, lecithin, and polysorbates. Suitable skin protectants that can be used in the topical formulations of the invention include, but are not limited to, vitamin E oil, allatoin, dimethicone, glycerin, petrolatum, and zinc oxide.
[0219] In certain embodiments, the pharmaceutically acceptable topical formulations of the invention comprise at least a compound of the invention and a penetration enhancing agent. The choice of topical formulation will depend or several factors, including the condition to be treated, the physicochemical characteristics of the inventive compound and other excipients present, their stability in the formulation, available manufacturing equipment, and costs constraints. As used herein the term “penetration enhancing agent” means an agent capable of transporting a pharmacologically active compound through the stratum corneum and into the epidermis or dermis, preferably, with little or no systemic absorption. A wide variety of compounds have been evaluated as to their effectiveness in enhancing the rate of penetration of drugs through the skin. See, for example, Percutaneous Penetration Enhancers , Maibach H. I. and Smith H. E. (eds.), CRC Press, Inc., Boca Raton, Fla. (1995), which surveys the use and testing of various skin penetration enhancers, and Buyuktimkin et al., Chemical Means of Transdermal Drug Permeation Enhancement in Transdermal and Topical Drug Delivery Systems, Gosh T. K., Pfister W. R., Yum S. I. (Eds.), Interpharm Press Inc., Buffalo Grove, Ill. (1997). In certain exemplary embodiments, penetration agents for use with the invention include, but are not limited to, triglycerides (e.g., soybean oil), aloe compositions (e.g., aloe-vera gel), ethyl alcohol, isopropyl alcohol, octolyphenylpolyethylene glycol, oleic acid, polyethylene glycol 400, propylene glycol, N-decylmethylsulfoxide, fatty acid esters (e.g., isopropyl myristate, methyl laurate, glycerol monooleate, and propylene glycol monooleate), and N-methyl pyrrolidone.
[0220] In certain embodiments, the compositions may be in the form of ointments, pastes, creams, lotions, gels, powders, solutions, sprays, inhalants or patches. In certain exemplary embodiments, formulations of the compositions according to the invention are creams, which may further contain saturated or unsaturated fatty acids such as stearic acid, palmitic acid, oleic acid, palmito-oleic acid, cetyl or oleyl alcohols, stearic acid being particularly preferred. Creams of the invention may also contain a non-ionic surfactant, for example, polyoxy-40-stearate. In certain embodiments, the active component is admixed under sterile conditions with a pharmaceutically acceptable carrier and any needed preservatives or buffers as may be required. Ophthalmic formulation, eardrops, and eye drops are also contemplated as being within the scope of this invention. Additionally, the present invention contemplates the use of transdermal patches, which have the added advantage of providing controlled delivery of a compound to the body. Such dosage forms are made by dissolving or dispensing the compound in the proper medium. As discussed above, penetration enhancing agents can also be used to increase the flux of the compound across the skin. The rate can be controlled by either providing a rate controlling membrane or by dispersing the compound in a polymer matrix or gel.
[0221] It will also be appreciated that the compounds and pharmaceutical compositions of the present invention can be formulated and employed in combination therapies, that is, the compounds and pharmaceutical compositions can be formulated with or administered concurrently with, prior to, or subsequent to, one or more other desired therapeutics or medical procedures. The particular combination of therapies (therapeutics or procedures) to employ in a combination regimen will take into account compatibility of the desired therapeutics and/or procedures and the desired therapeutic effect to be achieved. It will also be appreciated that the therapies employed may achieve a desired effect for the same disorder (for example, an inventive compound may be administered concurrently with another immunomodulatory agent, anticancer agent or agent useful for the treatment of psoriasis), or they may achieve different effects (e.g., control of any adverse effects).
[0222] For example, other therapies or anticancer agents that may be used in combination with the inventive compounds of the present invention include surgery, radiotherapy (in but a few examples, γ-radiation, neutron beam radiotherapy, electron beam radiotherapy, proton therapy, brachytherapy, and systemic radioactive isotopes, to name a few), endocrine therapy, biologic response modifiers (interferons, interleukins, and tumor necrosis factor (TNF) to name a few), hyperthermia and cryotherapy, agents to attenuate any adverse effects (e.g., antiemetics), and other approved chemotherapeutic drugs, including, but not limited to, alkylating drugs (mechlorethamine, chlorambucil, Cyclophosphamide, Melphalan, Ifosfamide), antimetabolites (Methotrexate), purine antagonists and pyrimidine antagonists (6-Mercaptopurine, 5-Fluorouracil, Cytarabile, Gemcitabine), spindle poisons (Vinblastine, Vincristine, Vinorelbine, Paclitaxel), podophyllotoxins (Etoposide, Irinotecan, Topotecan), antibiotics (Doxorubicin, Bleomycin, Mitomycin), nitrosoureas (Carmustine, Lomustine), inorganic ions (Cisplatin, Carboplatin), enzymes (Asparaginase), and hormones (Tamoxifen, Leuprolide, Flutamide, and Megestrol), to name a few. For a more comprehensive discussion of updated cancer therapies see, The Merck Manual , Seventeenth Ed. 1999, the entire contents of which are hereby incorporated by reference. See also the National Cancer Institute (CNI) website (www.nci nih gov) and the Food and Drug Administration (FDA) website for a list of the FDA approved oncology drugs (www.fda.gov/cder/cancer/druglistframe).
[0223] In certain embodiments, the pharmaceutical compositions of the present invention further comprise one or more additional therapeutically active ingredients (e.g., chemotherapeutic and/or palliative). For purposes of the invention, the term “palliative” refers to treatment that is focused on the relief of symptoms of a disease and/or side effects of a therapeutic regimen, but is not curative. For example, palliative treatment encompasses painkillers, antinausea medications and anti-sickness drugs. In addition, chemotherapy, radiotherapy and surgery can all be used palliatively (that is, to reduce symptoms without going for cure; e.g., for shrinking tumors and reducing pressure, bleeding, pain and other symptoms of cancer).
[0224] Additionally, the present invention provides pharmaceutically acceptable derivatives of the inventive compounds, and methods of treating a subject using these compounds, pharmaceutical compositions thereof, or either of these in combination with one or more additional therapeutic agents.
[0225] It will also be appreciated that certain of the compounds of present invention can exist in free form for treatment, or where appropriate, as a pharmaceutically acceptable derivative thereof. According to the present invention, a pharmaceutically acceptable derivative includes, but is not limited to, pharmaceutically acceptable salts, esters, salts of such esters, or a prodrug or other adduct or derivative of a compound of this invention which upon administration to a patient in need is capable of providing, directly or indirectly, a compound as otherwise described herein, or a metabolite or residue thereof.
Research Uses, Pharmaceutical Uses and Methods of Treatment
Research Uses
[0226] According to the present invention, the inventive compounds may be assayed in any of the available assays known in the art for identifying compounds having antiprotozoal, HDAC inhibitory, hair growth, androgen signalling inhibitory, estrogen signaling inhibitory, and/or antiproliferative activity. For example, the assay may be cellular or non-cellular, in vivo or in vitro, high- or low-throughput format, etc.
[0227] Thus, in one aspect, compounds of this invention which are of particular interest include those which:
exhibit HDAC-inhibitory activity; exhibit HDAC Class I inhibitory activity (e.g., HDAC1, HDAC2, HDAC3, HDAC8); exhibit HDAC Class II inhibitory activity (e.g., HDAC4, HDAC5, HDAC6, HDAC7, HDAC9a, HDAC9b, HDRP/HDAC9c, HDAC10); exhibit the ability to inhibit HDAC1 (Genbank Accession No. NP_004955, incorporated herein by reference); exhibit the ability to inhibit HDAC2 (Genbank Accession No. NP_001518, incorporated herein by reference); exhibit the ability to inhibit HDAC3 (Genbank Accession No. O15739, incorporated herein by reference); exhibit the ability to inhibit HDAC4 (Genbank Accession No. AAD29046, incorporated herein by reference); exhibit the ability to inhibit HDAC5 (Genbank Accession No. NP_005465, incorporated herein by reference); exhibit the ability to inhibit HDAC6 (Genbank Accession No. NP_006035, incorporated herein by reference); exhibit the ability to inhibit HDAC7 (Genbank Accession No. AAP63491, incorporated herein by reference); exhibit the ability to inhibit HDAC8 (Genbank Accession No. AAF73428, NM_018486, AF245664, AF230097, each of which is incorporated herein by reference); exhibit the ability to inhibit HDAC9 (Genbank Accession No. NM_178425, NM_178423, NM_058176, NM_014707, BC111735, NM_058177, each of which is incorporated herein by reference) exhibit the ability to inhibit HDAC10 (Genbank Accession No. NM_032019, incorporated herein by reference) exhibit the ability to inhibit HDAC11 (Genbank Accession No. BC009676, incorporated herein by reference); exhibit the ability to inhibit tubulin deactetylation (TDAC); exhibit the ability to modulate the glucose-sensitive subset of genes downstream of Ure2p; exhibit cytotoxic or growth inhibitory effect on cancer cell lines maintained in vitro or in animal studies using a scientifically acceptable cancer cell xenograft model; and/or exhibit a therapeutic profile (e.g., optimum safety and curative effect) that is superior to existing chemotherapeutic agents.
[0246] As detailed in the exemplification herein, in assays to determine the ability of compounds to inhibit cancer cell growth certain inventive compounds may exhibit IC 50 values ≦100 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦50 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦40 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦30 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦20 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦10 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦7.5 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦5 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦2.5 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦1 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦0.75 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦0.5 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦0.25 μM. In certain embodiments, inventive compounds exhibit IC 50 values ≦0.1 μM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦75 nM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦50 nM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦25 nM. In certain other embodiments, inventive compounds exhibit IC 50 values ≦10 nM. In other embodiments, exemplary compounds exhibited IC 50 values ≦7.5 nM. In other embodiments, exemplary compounds exhibited IC 50 values ≦5 nM.
Pharmaceutical Uses and Methods of Treatment
[0247] In general, methods of using the compounds of the present invention comprise administering to a subject in need thereof a therapeutically effective amount of a compound of the present invention. The compounds of the invention are generally inhibitors of deacetyalse activity. As discussed above, the compounds of the invention are typically inhibitors of histone deacetylases and, as such, are useful in the treatment of disorders modulated by histone deacetylases. Other deacetylase such as tubulin deacetylases may also be inhibited by the inventive compounds.
[0248] In certain embodiments, compounds of the invention are useful in the treatment of proliferative diseases (e.g., cancer, benign neoplasms, inflammatory disease, autoimmune diseases). In certain embodiments, given the esterase sensitive ester linkage in the compounds of the invention, they are particularly useful in treating skin disorders modulated by histone deacetyalses where systemic effects of the drug are to be avoided or at least minimized. This feature of the inventive compounds may allow the use of compounds normally too toxic for administration to a subject systemically. In certain embodiments, these skin disorders are proliferative disorders. For example, the inventive compounds are particularly useful in the treatment of skin cancer and benign skin tumors. In certain embodiments, the compounds are useful in the treatment of cutaneous T-cell lymphoma. In certain embodiments, the compounds are useful in the treatment of neurofibromatosis. Accordingly, in yet another aspect, according to the methods of treatment of the present invention, tumor cells are killed, or their growth is inhibited by contacting said tumor cells with an inventive compound or composition, as described herein. In other embodiments, the compounds are useful in treating inflammatory diseases of the skin such as psoriasis or dermatitis. In other embodiments, the compounds are useful in the treatment or prevention of hair loss. In certain embodiments, the compounds are useful in the treatment of diseases associated with skin pigmentation. For example, the compounds may be used to prevent the hyperpigmentation of skin.
[0249] Thus, in another aspect of the invention, methods for the treatment of cancer are provided comprising administering a therapeutically effective amount of an inventive compound, as described herein, to a subject in need thereof. In certain embodiments, a method for the treatment of cancer is provided comprising administering a therapeutically effective amount of an inventive compound, or a pharmaceutical composition comprising an inventive compound to a subject in need thereof, in such amounts and for such time as is necessary to achieve the desired result. Preferably, the inventive compounds is administered topically. In certain embodiments of the present invention a “therapeutically effective amount” of the inventive compound or pharmaceutical composition is that amount effective for killing or inhibiting the growth of tumor cells. The compounds and compositions, according to the method of the present invention, may be administered using any amount and any route of administration effective for killing or inhibiting the growth of tumor cells. Thus, the expression “amount effective to kill or inhibit the growth of tumor cells,” as used herein, refers to a sufficient amount of agent to kill or inhibit the growth of tumor cells. The exact amount required will vary from subject to subject, depending on the species, age, and general condition of the subject, the severity of the infection, the particular anticancer agent, its mode of administration, and the like. In certain embodiments of the present invention a “therapeutically effective amount” of the inventive compound or pharmaceutical composition is that amount effective for inhibiting deacetylase activity (in particular, HDAC activity) in skin cells. In certain embodiments of the present invention a “therapeutically effective amount” of the inventive compound or pharmaceutical composition is that amount effective to kill or inhibit the growth of skin cells.
[0250] In certain embodiments, the method involves the administration of a therapeutically effective amount of the compound or a pharmaceutically acceptable derivative thereof to a subject (including, but not limited to a human or animal) in need of it. In certain embodiments, the inventive compounds as useful for the treatment of cancer (including, but not limited to, glioblastoma, retinoblastoma, breast cancer, cervical cancer, colon and rectal cancer, leukemia, lymphoma, lung cancer (including, but not limited to small cell lung cancer), melanoma and/or skin cancer, multiple myeloma, non-Hodgkin's lymphoma, ovarian cancer, pancreatic cancer, prostate cancer and gastric cancer, bladder cancer, uterine cancer, kidney cancer, testicular cancer, stomach cancer, brain cancer, liver cancer, or esophageal cancer).
[0251] In certain embodiments, the inventive anticancer agents are useful in the treatment of cancers and other proliferative disorders, including, but not limited to breast cancer, cervical cancer, colon and rectal cancer, leukemia, lung cancer, melanoma, multiple myeloma, non-Hodgkin's lymphoma, ovarian cancer, pancreatic cancer, prostate cancer, and gastric cancer, to name a few. In certain embodiments, the inventive anticancer agents are active against leukemia cells and melanoma cells, and thus are useful for the treatment of leukemias (e.g., myeloid, lymphocytic, myelocytic and lymphoblastic leukemias) and malignant melanomas. In still other embodiments, the inventive anticancer agents are active against solid tumors.
[0252] In certain embodiments, the inventive compounds also find use in the prevention of restenosis of blood vessels subject to traumas such as angioplasty and stenting. For example, it is contemplated that the compounds of the invention will be useful as a coating for implanted medical devices, such as tubings, shunts, catheters, artificial implants, pins, electrical implants such as pacemakers, and especially for arterial or venous stents, including balloon-expandable stents. In certain embodiments inventive compounds may be bound to an implantable medical device, or alternatively, may be passively adsorbed to the surface of the implantable device. In certain other embodiments, the inventive compounds may be formulated to be contained within, or, adapted to release by a surgical or medical device or implant, such as, for example, stents, sutures, indwelling catheters, prosthesis, and the like. For example, drugs having antiproliferative and anti-inflammatory activities have been evaluated as stent coatings, and have shown promise in preventing restenosis (See, for example, Presbitero P. et al., “Drug eluting stents do they make the difference?”, Minerva Cardioangiol, 2002, 50(5):431-442; Ruygrok P. N. et al., “Rapamycin in cardiovascular medicine”, Intern. Med. J., 2003, 33(3):103-109; and Marx S. O. et al., “Bench to bedside: the development of rapamycin and its application to stent restenosis”, Circulation, 2001, 104(8):852-855, each of these references is incorporated herein by reference in its entirety). Accordingly, without wishing to be bound to any particular theory, Applicant proposes that inventive compounds having antiproliferative effects can be used as stent coatings and/or in stent drug delivery devices, inter alia for the prevention of restenosis or reduction of restenosis rate. Suitable coatings and the general preparation of coated implantable devices are described in U.S. Pat. Nos. 6,099,562; 5,886,026; and 5,304,121. The coatings are typically biocompatible polymeric materials such as a hydrogel polymer, polymethyldisiloxane, polycaprolactone, polyethylene glycol, polylactic acid, ethylene vinyl acetate, and mixtures thereof. The coatings may optionally be further covered by a suitable topcoat of fluorosilicone, polysaccarides, polyethylene glycol, phospholipids or combinations thereof to impart controlled release characteristics in the composition. A variety of compositions and methods related to stent coating and/or local stent drug delivery for preventing restenosis are known in the art (see, for example, U.S. Pat. Nos. 6,517,889; 6,273,913; 6,258,121; 6,251,136; 6,248,127; 6,231,600; 6,203,551; 6,153,252; 6,071,305; 5,891,507; 5,837,313 and published U.S. patent application No.: US2001/0027340, each of which is incorporated herein by reference in its entirety). For example, stents may be coated with polymer-drug conjugates by dipping the stent in polymer-drug solution or spraying the stent with such a solution. In certain embodiment, suitable materials for the implantable device include biocompatible and nontoxic materials, and may be chosen from the metals such as nickel-titanium alloys, steel, or biocompatible polymers, hydrogels, polyurethanes, polyethylenes, ethylenevinyl acetate copolymers, etc. In certain embodiments, the inventive compound is coated onto a stent for insertion into an artery or vein following balloon angioplasty.
[0253] The compounds of this invention or pharmaceutically acceptable compositions thereof may also be incorporated into compositions for coating implantable medical devices, such as prostheses, artificial valves, vascular grafts, stents and catheters. Accordingly, the present invention, in another aspect, includes a composition for coating an implantable device comprising a compound of the present invention as described generally above, and in classes and subclasses herein, and a carrier suitable for coating said implantable device. In still another aspect, the present invention includes an implantable device coated with a composition comprising a compound of the present invention as described generally above, and in classes and subclasses herein, and a carrier suitable for coating said implantable device.
[0254] Within other aspects of the present invention, methods are provided for expanding the lumen of a body passageway, comprising inserting a stent into the passageway, the stent having a generally tubular structure, the surface of the structure being coated with (or otherwise adapted to release) an inventive compound or composition, such that the passageway is expanded. In certain embodiments, the lumen of a body passageway is expanded in order to eliminate a biliary, gastrointestinal, esophageal, tracheal/bronchial, urethral and/or vascular obstruction.
[0255] Methods for eliminating biliary, gastrointestinal, esophageal, tracheal/bronchial, urethral and/or vascular obstructions using stents are known in the art. The skilled practitioner will know how to adapt these methods in practicing the present invention. For example, guidance can be found in U.S. Patent Application Publication No.: 2003/0004209 in paragraphs [0146]-[0155], which paragraphs are hereby incorporated herein by reference.
[0256] Another aspect of the invention relates to a method for inhibiting the growth of multidrug resistant cells in a biological sample or a patient, which method comprises administering to the patient, or contacting said biological sample with a compound of formula I or a composition comprising said compound.
[0257] Additionally, the present invention provides pharmaceutically acceptable derivatives of the inventive compounds, and methods of treating a subject using these compounds, pharmaceutical compositions thereof, or either of these in combination with one or more additional therapeutic agents.
[0258] Another aspect of the invention relates to a method of treating or lessening the severity of a disease or condition associated with a proliferation disorder in a patient, said method comprising a step of administering to said patient, a compound of formula I or a composition comprising said compound.
[0259] It will be appreciated that the compounds and compositions, according to the method of the present invention, may be administered using any amount and any route of administration effective for the treatment of cancer and/or disorders associated with cell hyperproliferation. For example, when using the inventive compounds for the treatment of cancer, the expression “effective amount” as used herein, refers to a sufficient amount of agent to inhibit cell proliferation, or refers to a sufficient amount to reduce the effects of cancer. The exact amount required will vary from subject to subject, depending on the species, age, and general condition of the subject, the severity of the diseases, the particular anticancer agent, its mode of administration, and the like.
[0260] The compounds of the invention are preferably formulated in dosage unit form for ease of administration and uniformity of dosage. The expression “dosage unit form” as used herein refers to a physically discrete unit of therapeutic agent appropriate for the patient to be treated. It will be understood, however, that the total daily usage of the compounds and compositions of the present invention will be decided by the attending physician within the scope of sound medical judgment. The specific therapeutically effective dose level for any particular patient or organism will depend upon a variety of factors including the disorder being treated and the severity of the disorder; the activity of the specific compound employed; the specific composition employed; the age, body weight, general health, sex and diet of the patient; the time of administration, route of administration, and rate of excretion of the specific compound employed; the duration of the treatment; drugs used in combination or coincidental with the specific compound employed; and like factors well known in the medical arts (see, for example, Goodman and Gilman's, “The Pharmacological Basis of Therapeutics”, Tenth Edition, A. Gilman, J. Hardman and L. Limbird, eds., McGraw-Hill Press, 155-173, 2001, which is incorporated herein by reference in its entirety).
[0261] Another aspect of the invention relates to a method for inhibiting histone deacetylase activity in a biological sample or a patient, which method comprises administering to the patient, or contacting said biological sample with an inventive compound or a composition comprising said compound.
[0262] Furthermore, after formulation with an appropriate pharmaceutically acceptable carrier in a desired dosage, the pharmaceutical compositions of this invention can be administered to humans and other animals orally, rectally, parenterally, intracisternally, intravaginally, intraperitoneally, topically (as by powders, ointments, creams or drops), bucally, as an oral or nasal spray, or the like, depending on the severity of the infection being treated. In certain embodiments, the compounds of the invention may be administered at dosage levels of about 0.001 mg/kg to about 50 mg/kg, from about 0.01 mg/kg to about 25 mg/kg, or from about 0.1 mg/kg to about 10 mg/kg of subject body weight per day, one or more times a day, to obtain the desired therapeutic effect. It will also be appreciated that dosages smaller than 0.001 mg/kg or greater than 50 mg/kg (for example 50-100 mg/kg) can be administered to a subject. In certain embodiments, compounds are administered orally or parenterally.
Treatment Kit
[0263] In other embodiments, the present invention relates to a kit for conveniently and effectively carrying out the methods in accordance with the present invention. In general, the pharmaceutical pack or kit comprises one or more containers filled with one or more of the ingredients of the pharmaceutical compositions of the invention. Such kits are especially suited for the topical delivery of the inventive compounds. Optionally associated with such container(s) can be a notice in the form prescribed by a governmental agency regulating the manufacture, use or sale of pharmaceutical products, which notice reflects approval by the agency of manufacture, use or sale for human administration.
EQUIVALENTS
[0264] The representative examples which follow are intended to help illustrate the invention, and are not intended to, nor should they be construed to, limit the scope of the invention. Indeed, various modifications of the invention and many further embodiments thereof, in addition to those shown and described herein, will become apparent to those skilled in the art from the full contents of this document, including the examples which follow and the references to the scientific and patent literature cited herein. It should further be appreciated that, unless otherwise indicated, the entire contents of each of the references cited herein are incorporated herein by reference to help illustrate the state of the art. The following examples contain important additional information, exemplification and guidance which can be adapted to the practice of this invention in its various embodiments and the equivalents thereof.
[0265] These and other aspects of the present invention will be further appreciated upon consideration of the following Examples, which are intended to illustrate certain particular embodiments of the invention but are not intended to limit its scope, as defined by the claims.
Examples
[0266] The compounds of this invention and their preparation can be understood further by the examples that illustrate some of the processes by which these compounds are prepared or used. It will be appreciated, however, that these examples do not limit the invention. Variations of the invention, now known or further developed, are considered to fall within the scope of the present invention as described herein and as hereinafter claimed.
General Description of Synthetic Methods
[0267] The various references cited herein provide helpful background information on preparing compounds similar to the inventive compounds described herein or relevant intermediates, as well as information on formulation, uses, and administration of such compounds which may be of interest.
[0268] Moreover, the practitioner is directed to the specific guidance and examples provided in this document relating to various exemplary compounds and intermediates thereof.
[0269] The compounds of this invention and their preparation can be understood further by the examples that illustrate some of the processes by which these compounds are prepared or used. It will be appreciated, however, that these examples do not limit the invention. Variations of the invention, now known or further developed, are considered to fall within the scope of the present invention as described herein and as hereinafter claimed.
[0270] According to the present invention, any available techniques can be used to make or prepare the inventive compounds or compositions including them. For example, a variety of a variety combinatorial techniques, parallel synthesis and/or solid phase synthetic methods such as those discussed in detail below may be used. Alternatively or additionally, the inventive compounds may be prepared using any of a variety of solution phase synthetic methods known in the art.
[0271] It will be appreciated as described below, that a variety of inventive compounds can be synthesized according to the methods described herein. The starting materials and reagents used in preparing these compounds are either available from commercial suppliers such as Aldrich Chemical Company (Milwaukee, Wis.), Bachem (Torrance, Calif.), Sigma (St. Louis, Mo.), or are prepared by methods well known to a person of ordinary skill in the art following procedures described in such references as Fieser and Fieser 1991, “Reagents for Organic Synthesis”, vols 1-17, John Wiley and Sons, New York, N.Y., 1991; Rodd 1989 “Chemistry of Carbon Compounds”, vols. 1-5 and supps, Elsevier Science Publishers, 1989; “Organic Reactions”, vols 1-40, John Wiley and Sons, New York, N.Y., 1991; March 2001, “Advanced Organic Chemistry”, 5th ed. John Wiley and Sons, New York, N.Y.; and Larock 1990, “Comprehensive Organic Transformations: A Guide to Functional Group Preparations”, 2 nd ed. VCH Publishers. These schemes are merely illustrative of some methods by which the compounds of this invention can be synthesized, and various modifications to these schemes can be made and will be suggested to a person of ordinary skill in the art having regard to this disclosure.
[0272] The starting materials, intermediates, and compounds of this invention may be isolated and purified using conventional techniques, including filtration, distillation, crystallization, chromatography, and the like. They may be characterized using conventional methods, including physical constants and spectral data.
Synthesis of Exemplary Compounds
[0273] Unless otherwise indicated, starting materials are either commercially available or readily accessibly through laboratory synthesis by anyone reasonably familiar with the art. Described generally below, are procedures and general guidance for the synthesis of compounds as described generally and in subclasses and species herein.
Example 1: Synthesis of SAHP for Use as HDAC Inhibitors
[0274]
[0275] Described below is the synthesis of a SAHP, an ester-containing analog of SAHA (as shown in FIG. 12 ).
[0276] 3.86 g (24.2 mmol) O-benzylhydroxylamine hydrochloride and 13 mL (75 mmol) diisopropylethylamine were dissolved in 100 mL methylene chloride and cooled to 0° C. 5.00 g (24.2 mmol) methyl 8-chloro-8-oxooctanoate were dissolved in 10 mL methylene chloride and slowly added to the reaction mixture. The reaction mixture was stirred for 1 h at 0° C. and warmed to room temperature. After stirring for additional 12 h, 300 mL 0.5N HCl were added. The organic layer was separated and washed with brine and sat. bicarb. After drying over sodium sulfate, the organic solvent was removed under reduced pressure and the crude product was purified on silica (methylene chloride/methanol 12:1, rf=0.7) to yield the desired compound 1 as white solid (6.3 g, 89%).
[0277] 6.3 g (21.5 mmol) methyl ester 1 were dissolved in 200 mL methanol, followed by the addition of 50 mL 2N LiOH. The reaction mixture was heated to reflux for 1 h and cooled to room temperature. After addition of 100 mL 1N HCl and 200 mL water, the reaction mixture was extracted three times with 150 mL ethyl acetate. The combined organic layers were dried over sodium sulfate and the solvent was removed under reduced pressure to afford the carboxylic acid 2 pure and in quantitative yields as white solid
[0278] 140 mg carboxylic acid 2 (5 mmol), 56.5 mg phenol (6 mmol) and 113 mg dicyclohexylcarbodiimide (5.5 mmol) are mixed followed by the addition of 10 mL methylene chloride and 30 mg 4-Dimethylaminopyridine. The reaction mixture was stirred for 2 h and applied crude on a silica column followed by elution with haxanes/ethyl acetate (10-100% ethyl acetate). The desired phenol ester 3 was obtained as a white solid in 87% yield (155 mg).
[0279] 80 mg phenol ester 3 (0.225 mmol) are dissolved in methanol. A catalytical amount of palladium on charcoal (10%) was as added and hydrogen was bubbled through the reaction mixture. After 1 h hour no starting material was detectable by TLC. The reaction mixture was filtered through Celite and the solvent was removed under reduced pressure to yield the free hydroxamte SAHP as brownish solid in quantitative yields (59 mg). The crude product did not show any impurities as judged by LCMS and NMR.
Example 2: Biological Assay Procedures
[0280] Cell culture and Transfections.
[0281] TAg-Jurkat cells were transfected by electroporation with 5 μg of FLAG-epitope-tagged pBJ5 constructs for expression of recombinant proteins. Cells were harvested 48 h posttransfection.
[0282] HDAC assays.
[0283] [ 3 H]Acetate-incorporated histones were isolated from butyrate-treated HeLa cells by hydroxyapatite chromatography (as described in Tong, et al. Nature 1997, 395, 917-921.) Immunoprecipitates were incubated with 1.4 μg (10,000 dpm) histones for 3 h at 37° C. HDAC activity was determined by scintillation counting of the ethyl acetate-soluble [ 3 H]acetic acid (as described in Taunton, et al., Science 1996, 272, 408-411). Compounds were added in DMSO such that final assay concentrations were 1% DMSO. IC50s were calculated using Prism 3.0 software. Curve fitting was done without constraints using the program's Sigmoidal-Dose Response parameters. All data points were acquired in duplicate and IC50s are calculated from the composite results of at least two separate experiments.
Example 3: In Vivo Activity
[0284] Although a variety of methods can be utilized, one exemplary method by which the in vivo activity of the inventive compounds is determined is by subcutaneously transplanting a desired tumor mass in mice. Drug treatment is then initiated when tumor mass reaches approximately 100 mm 3 after transplantation of the tumor mass. A suitable composition, as described in more detail above, is then administered to the mice, preferably in saline and also preferably administered once a day at doses of 5, 10 and 25 mg/kg, although it will be appreciated that other doses can also be administered. Body weight and tumor size are then measured daily and changes in percent ratio to initial values are plotted. In cases where the transplanted tumor ulcerates, the weight loss exceeds 25-30% of control weight loss, the tumor weight reaches 10% of the body weight of the cancer-bearing mouse, or the cancer-bearing mouse is dying, the animal is sacrificed in accordance with guidelines for animal welfare.
Example 4: Assays to Identify Potential Antiprotozoal Compounds by Inhibition of Histone Deacetylase
[0285] As detailed in U.S. Pat. No. 6,068,987, inhibitors of histone deacetylases may also be useful as antiprotozoal agents. Described therein are assays for histone deacetylase activity and inhibition and describe a variety of known protozoal diseases. The entire contents of 6,068,987 are hereby incorporated by reference. | In recognition of the need to develop novel therapeutic agents, the present invention provides novel histone deacetylase inhibitors. These compounds include an ester bond making them sensitive to deactivation by esterases. Therefore, these compounds are particularly useful in the treatment of skin disorders. When the compounds reaches the bloodstream, an esterase or an enzyme with esterase activity cleaves the compound into biologically inactive fragments or fragments with greatly reduced activity Ideally these degradation products exhibit a short serum and/or systemic half-life and are eliminated rapidly. These compounds and pharmaceutical compositions thereof are particularly useful in treating cutaneous T-cell lymphoma, neurofibromatosis, psoriasis, hair loss, skin pigmentation, and dermatitis, for example. The present invention also provides methods for preparing compounds of the invention and intermediates thereto. | 2 |
BACKGROUND OF THE INVENTION
The phosphate rock industry is an outstanding example of industrial and ecological achievement through the use of modern mining techniques, improved ore dressing methods and novel ecologically oriented practices.
New developments in each of these areas has resulted in increased output and recovery of the vital mineral product from the mineral deposit, marked extension of the life of the phosphate fields and conservation of water resources through recycle. The improved practices have also resulted in elimination or minimization of land and water pollution hazards normally associated with disposal of waste slimes produced in ore processing plants and in the reclamation of otherwise useless land by formulating waste slimes and tails into a reconstituted fertile soil having acceptable bearing strength. Processes for achieving these desirable results are described in U.S. Pat. to C. C. Cook and E. M. Haynsworth, No. 3,718,003; No. 3,763,041 and No. 3,761,239, issued Feb. 27, Oct. 2 and Sep. 25, 1973, respectively, and M. L. Lassiter, No. 3,940,071, issued Feb. 24, 1976.
The benefits derived from these improved practices are dramatic and accrue to both the industry and the public alike. However, these benefits are not derived without (a) utilization of additional equipment, (b) an increase in the labor force required to install, operate and maintain said equipment, and (c) a marked increase in power consumption.
Now, in light of diminishing fuel reserves, skyrocketing costs for electrical energy and significantly increasing equipment costs, especially for large diameter steel pipe required by the modern practices for moving high pressure water, tailing, slimes and matrix between the mine, the phosphate recovery plant and the waste disposal area, it becomes exceedingly apparent that still further technological advances are required to achieve the desirable results afforded by the above-mentioned practices; but, to achieve such results with greatly reduced power consumption and minimized equipment and labor costs.
The magnitude of the problems confronting the industry, as regards increasing energy costs and usage of large diameter steel pipe is evidenced by the fact that energy costs for a typical modern phosphate mining operation have nearly quadrupled in the past five years; and further, by the fact that such an operation will normally require replacement of approximately 20,000 to 30,000 feet of large diameter, i.e. 16 to 20 inches, steel pipe annually.
It is, therefore, an object of the present invention to provide an improved method and apparatus for processing hydraulically mined ore slurries, particularly phosphatic ore slurries, whereby power consumption per ton of ore processed is markedly reduced.
It is also an object of this invention to eliminate or minimize pipe errosion and maintenance problems encountered in the conventional processing of hydraulically mined ore slurries by replacing the slurry pump transport of matrix and plant tailings with an endless belt conveyor system.
It is a further object of this invention to provide a method for processing matrix slurries, wherein said matrix slurries are dewatered and deslimed at or near the active mining operation such that pumping of the matrix slurry over extended distances is eliminated.
It is a still further object of this invention to provide a method for transporting wet, deslimed, phosphate matrix from an active mining operation to an ore dressing plant via a continuous belt, while simultaneously transporting tailings from the ore dressing plant for use at a land reclamation excavation, near or adjacent the active mining operation, using the same said continuous belt.
SUMMARY OF THE INVENTION
This invention relates to a method of processing hydraulically mined ore slurries, containing in addition to the mineral values, substantial quantities of contaminating argillaceous material (clay) and silica.
Among the ores which can be processed in accordance with the method of the present invention are non-metallic ores such as phosphate, potash, feldspar, clays and fluorspar, and metallic ores such as titanium and rutile. For the purpose of clarity, it is most convenient to describe this invention in terms of a particular ore processing industry, such as the phosphate industry, although the present process is not necessarily limited to the processing of phosphate ore.
In the surface mining of phosphate ores over-burden covering the phosphate rock is removed by any convenient means, as for example with a dragline, bulldozer, steamshovel, or the like. The phosphate bearing ore comprising, argillaceous material (clay), quartz or silica, mineral values and extraneous gangue, is then dug from the deposit, generally with a dragline, and deposited as a mound of loosely consolidated ore matrix in front of a pit gun car. Hydraulic pit guns, mounted on the car, are used to direct streams of high pressure water at the matrix forming it into a slurry.
According to the invention, this matrix slurry is pumped to slurry treatment apparatus at an intermediate station where it is sized, deslimed, dewatered and deposited on an endless belt for transport to the phosphate ore dressing plant for further refining.
In contrast to the typical phosphate mining operation, desliming at a station near the pits can reduce the volume of materials handling by as much as 100 to 300 tons per hour.
The term, intermediate station, as used herein, is intended to mean those parts of the treating and transport apparatus located in the vicinity of the active mining pits for concentrating solids from the matrix slurry for transport by conveyor belt to a more remote processing plant, and for reslurrying the return tailings. This arrangement is a total departure from conventional practices. Similarly, the location of waste disposal areas near or adjacent the active mining operation is another recent departure from conventional phosphate mining practices. This latter arrangement is particularly advantageous in conjunction with the present invention, since it provides for waste disposal of slimes with minimized transport and requires little, if any, additional electric power.
In a preferred operation, the intermediate station is situated where the slimes can be delivered from the intermediate station to the disposal area by gravitational flow. Depending on the terrain in which the mining is carried out, in some cases some pumping facilities may be required for moving slimes to the waste disposal area.
Yet another departure from conventional phosphate mining practices is the use of an endless belt to convey dewatered and deslimed matrix over a long distance from the intermediate station to the phosphate recovery plant. This arrangement reduces power consumption and eliminates many problems formerly associated with the maintenance and replacement of the slurry pumps and the long distance, large diameter pipelines used to deliver matrix slurry from the mines directly to the ore dressing plant. In addition, in a preferred practice of the present invention, dewatered sand tailings from the ore dressing plant are deposited on the returning strand of the continuous belt and carried to the intermediate station near the disposal area where the tailings are slurried and transported by a slurry pipeline over the short distance to the disposal area. The sand tailings slurry is sprayed over thickened slimes in the disposal area.
The invention in some preferred embodiments thus combines an improved method for transporting and processing the ore matrix with improvements in a continuous land reclamation method.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a diagrammatic sketch of a preferred process of this invention.
FIG. 2 is a diagrammatic sketch of a preferred process of this invention especially designed for the treatment of phosphate ores which contain substantial quantities of compacted clays (mudballs) in which phosphate values are entrapped.
FIG. 3 is a cross-sectional view of the idler support system for the continuous belt.
FIG. 4 is a side view of the continuous belt drive module; and
FIG. 5 is a cross-section of the continuous belt drive module.
FIG. 6 is a graphic presentation of data tabulated in Table 1.
Now referring to FIG. 1, a stream of high pressure water is directed at a loosely consolidated mound of phosphate matrix. The stream washes the matrix into a sump 1 from which the slurried matrix, containing approximately 35% solids, is withdrawn by means of pit pumps 2.
The slurry is pumped over a short distance under high pressure through a large diameter pipe 3 to an intermediate station which is relatively nearer to the mine than the ore processing plant. The slurry is delivered first to a grizzly 4 where plus 3-inch materials such as rocks, mudballs and extraneous gangue, are removed. The plus 3-inch waste from the grizzly is deposited on a waste conveyor 5 and sent to a waste disposal area where it becomes a constituent in the continuous land reclamation process.
Alternatively, where the plus 3-inch material from the grizzly 4 is primarily compacted clay (mudballs) containing entrapped phosphate values, said mudballs can be slurried in water to about 60% to 80% solids by weight and subjected to jets or streams of high pressure water, preferably in the 125 to 175 psig. range. The mudballs are disintegrated by the high velocity jets, not shown, and the slurry is recycled to the grizzly for further treatment.
Another alternative to the disposal of plus 3-inch mudballs is the use of ultrasonic waves to disintegrate the mudballs (not shown). In this alternative method of treatment, the mudballs from grizzly 4 are slurried to about 20% to 40% solids by weight and the slurry is subjected to sonic waves in a frequency range of about 75 to 100 cycles per second. The thus-treated slurry is then recycled to the grizzly 4 for further treatment.
Minus 3-inch material passing the grizzly 4 is deposited on a 3/4-inch screen 6 to separate minus 3-inch plus 3/4-inch matrix from the minus 3/4-inch matrix slurry which is used as cyclone feed.
The minus 3-inch plus 3/4-inch matrix from screen 6 is then crushed to pass through the 3/4-inch screens. While the crusher 7 is shown as an impactor, other types of crushers, such as hammer or rodmills, can be used to reduce this minus 3-inch plus 3/4-inch matrix fraction to the desired minus 3/4-inch particle size.
Crushed product from the impactor 7 is deposited in a slurry holding tank 8, equipped with an agitator, not shown, for dispersing and maintaining the crushed product in a slurry. This slurry is recycled by pump means 9 to the 3-inch grizzly 4.
The minus 3/4-inch slurry which passes the screen 6 is sent to a matrix slurry holding tank 10, where the solids concentration of the matrix slurry is adjusted to about 20% to 30% solid, and preferably to about 25% solids. In practice, we have found that slurries having a solids concentration below about 20% generally result in excessive deposition of water on the belt due to inadequate cyclone separation. Likewise, slurries having more than about 30% solids concentration do not lend themselves to cyclone desliming, but rather, yield a matrix contaminated with excessive slimes.
The term, "slimes," as used herein, refers to aqueous suspensions or dispersions of ultrafine solid wastes most of which are ordinarily separated from the ore feed stream prior to the flotation step. More particularly, slimes are the ultrafine soil solids associated with the ore such as; for example, clays, quartz, and mineral values, the solid particles of which are of sufficiently small particle size so that at least about 99% by weight of the solids (dry basis) passes through a 150-mesh screen.
The matrix slurry containing 20% to 30% solids is withdrawn from holding tank (10), where solids are kept in suspension by constant agitation, and pumped by pump means 11 through conduit 12 to a high pressure super cyclone 14. The super cyclone is a 48-inch cyclone which is operated at feed pressures in the range of from 50 psig. to 80 psig., to prevent or inhibit losses of 150-mesh phosphate particles and maintain the percent solids in the overflow from said cyclones below 10% solids at about 50 psig. or below about 12% at 70 psig.
In the present process, overflow from cyclone 14 is generally discharged under pressure which may be sufficient to move the slimes through pipeline to the settling area without additional pump support. Location of the waste disposal area adjacent to or near the active mining operation and the use of piping arrangements which utilize gravitational forces help to achieve disposal of the slimes with minimum equipment and little, if any, additional electrical power.
The underflow from cyclone 14 is a dewatered-deslimed matrix having a solids concentration in excess of 65%. This dewatered-deslimed matrix is deposited wet upon a continuous belt 21 and transported on the belt to a matrix reslurry tank 22 located in the immediate vicinity of the ore dressing plant.
When the continuous belt is operated over extended distances and over terrain wherein the belt 21 is necessarily inclined or declined about 2° or more from level for a distance of several hundred feet or more, it is critical to dewater the matrix to at least 65% solids, and preferably to 75% solids concentration. It has been found that matrix having 65% or more solids can be successfully carried up to 2° to 3° grades for extended distances. However, when the solids content is reduced below about 65% and the wet matrix is transported under the stated conditions, washouts of the matrix on the belt can occur. Lower solids concentration in the wet matrix might be tolerated when the belt is operated over level terrain.
To deal with dewatering of the deslimed matrix on the belt 21, we have found it advantageous to flatten the belt at several locations, preferably on level terrain, along the transport route. This procedure permits any accumulation of water separated from the matrix to drain from the belt at sites where said belt is flattened.
Reslurried matrix from holding tank 22 is pumped by pump means 23 to the washer 24, the first stage of a conventional ore dressing process in which the deslimed matrix is washed, sized by screening, scrubbed, dewatered, conditioned and subjected to a flotation treatment where sand tailings are separated from the mineral values.
in accordance with the present process, a slurry of tailings 25 from the flotation treatment, is pumped by pump means 26 to a cyclone 27 where water is removed and recycled to the plant water holding pond. Dewatered tailings 28 from cyclone 27 are deposited on the returning strand of the continuous belt 21 and transported by belt 21 to a tails reslurry tank 29 at the intermediate station.
This arrangement reduces horsepower requirements for transport of both ore and tailings by a more efficient system and combines tails and matrix conveying into one unit. Reslurried tails from holding tank 29 are pumped by pump means to the waste disposal area where the slurry is sprayed over slimes which have settled to a solids concentration of from 10% to 25% solids.
Continuous land reclamation is thus achieved in accordance with the processes of the above-mentioned Cook et al. and Lassiter Patents.
FIG. 2 illustrates a variation of the ore processing method which is especially designed for the treatment of ores found to contain a high percentage of mudballs. This method involves mining and treatment of the matrix in about the same manner as described for the process of FIG. 1. The process differs in one material way, and that is installation of a sonic mudball disintegrator in the matrix slurry delivery system, between the pit pump 2 and the grizzly 4. In this process, the matrix slurry 3 from pumps 2 is introduced into a vessel equipped with transducers for generating sonic vibrations at frequencies as high as 100 cycles per second in the slurry to cause compacted clays or mudballs to be broken up or disintegrated, thus freeing entrapped phosphate particles.
Apparatus for generating and transmitting sonic vibrations in liquids, slurries, and the like, are described for example in U.S. Pat. to A. G. Bodine (No. 3,153,530; No. 2,960,317 and No. 3,682,511) and R. O. Speer (No. 3,811,623).
After subjecting the slurry 3 to sonic vibration treatment, the slurry is deposited on the grizzly 4 for scalping off any plus 3-inch material which remains in the slurry; as for example, rocks, wook, and the like. Treatment of the underflow from grizzly 4 is as described with reference to the process of FIG. 1.
While the continuous belt 21 is shown only schematically in FIGS. 1 and 2, FIGS. 3, 4 and 5 are provided to illustrate some details of a continuous belt system preferred in the practice of the present invention.
The system transport between the intermediate station and the ore processing plant comprises a flexible radial steel belt, reinforced longitudinally by steel cables embedded in the edges thereof. Power is transmitted to the belt by pneumatic tires working in pairs at the drive modules. Each drive module employs two pairs of drive wheels 31, one pair disposed at either edge of the radial steel belt, two pairs of free-wheeling pressure tires 32 disposed above said drive wheels on the opposite side of the upper strand of the belt, and two pairs of rubber-covered pressure rolls 33 disposed under said drive wheels, below the lower strand of the belt. The tires squeeze the edges of the belt, and as they turn the belt moves forward. The return strand of the belt is similarly powered as it is squeezed between the drive tires and the rubber-covered pressure rolls. Thus, the driving force applied at each module to both the primary belt and the return strand is uniform and synchronized.
Drive modules are spaced, as needed, along the length of the belt, and power for operating each drive module is furnished by a relatively low horsepower electric motor 34 at each module.
Between the drive modules, the belt is supported by several suspended idler support units (FIG. 3), spaced as needed along the length of the belt. Each idler unit comprises rollers 36 mounted in a frame 37 which is suspended at either end by cable means 38 mounted on adjustable supports 39. Each idler unit is equipped with a central support roller which supports the center of the belt and with two adjustable side or trough rollers which can be elevated as shown in FIG. 3 to support the sides of the belt and to form the belt into a "U"-shaped trough. The adjustable side rollers lend flexibility to the conveyor system. They can be lowered to permit flattening of the belt at selected locations. As indicated previously this arrangement is particularly advantageous for handling wet matrix, since it permits water which separates from the matrix while in transit to be drained from the belt.
In practice, the return strand of the belt is carried by similar idler supports, and when it is used to return wet tailings the same technique of flattening the lower section of the belt can be used to drain excess water which separates from wet trailings on the belt.
Also, in practice we have found it essential when using the intermediate conveyor system for the simultaneous transport of both matrix and tailings, to use the same surface of the belt in contact with both materials. This is achieved by providing means for twisting the return strand at each end of the conveyor system. The flexible belt is passed downward around horizontal rolls at the matrix discharge end of the system to reverse the direction of the belt. Before the lower section reaches the point for loading on tailings, the belt is twisted 90° onto vertical rolls, and then twisted another 90° onto horizontal rolls to complete a 180° twist at the beginning of the lower section. This procedure is reversed at the beginning of the upper section before the upper section reaches the matrix loading point at the mine area.
EXAMPLE 1
Two 48-inch cyclones having 10-inch apex openings are used in tests to determine feed solids concentrations and feed pressures required to achieve satisfactory desliming and dewatering of phosphate matrix slurry from the mine by the cyclones. In these tests, the cyclones are operated at 50 and 70 psi. feed pressures. At 50 psi. the slurry feed rate to the cyclones is maintained at about 10,000 gallons per minute, and at 70 psi. the feed rate is about 13,000 gallons per minute.
The solids concentration in the cyclone feed is varied between about 15% and 35% solids, and determinations of solids content are determined for both overflow and underflow at all pressures and solids concentrations. Data obtained are tabulated in Table 1. The tests indicate that solids concentration in the slurry feed to the cyclone should be maintained between about 20% and 30% in order to obtain a dewatered-deslimed matrix having a solids concentration between about 65% to 77%. Matrix from these tests was deposited on the continuous belt, shown as 21 in FIG. 1, and transported to the reslurry tank 22. Matrix having less than 65% solids when transported on the belt caused splash and deposition problems in loading the belt and washouts during belt transport up a 3% grade; whereas, matrix having 65% or more solids was satisfactorily deposited on the belt and transported to the reslurry tank.
TABLE I______________________________________Matrix Cyclone Test(Two 48-Inch Cyclones at 50 psi.)(10-Inch Apex Opening) (Feed Rate 10,000 gpm) Overflow Under- % % Losses TPH FlowΔP at Solids Sol- +150-mesh %Test Entry (Feed) ids per 1000 gpm Solids Remarks______________________________________A 50 psi. 15 4.4 0.1 57 Underflow Solids to lowB 50 psi. 20 6.0 0.3 65 ↑C 50 psi. 25 8.1 0.5 75 OperatingD 50 psi. 25 8.1 0.5 75 RangeE 50 psi. 30 10.0 1.2 76 ↓F 50 psi. 35 20.0 24.0 77 Cyclone ChokingG 70 psi. 15 4.8 0.1 59 Underflow Solids to lowH 70 psi. 20 6.9 0.2 66I 70 psi. 25 8.5 0.7 76 OperatingJ 70 psi. 25 8.5 0.7 76 RangeK 70 psi. 30 10.6 2.5 77L 70 psi. 35 20.0 30.0 77 Cyclone Over- loaded______________________________________
EXAMPLE 2
Sonic Mudball Disintegration Tests
The purpose of the test was to demonstrate the use of vibration or sound vibration to break up clay mudballs in phosphate pebble.
Sonic Unit
Standard Bodine sound drive unit driven by a 25 HP motor, coupled to a 51/4 inches inside diameter pipe approximately 4 feet long. Amplitude and cycles were variable but run at 96 cycles per second at the amplitude chosen by the operator. Fractional horsepower (1 HP) was required for the tests, but the unit is equipped with a large motor for other laboratory test purposes.
Procedure
Mixtures of plus 3-inch mudballs and muddy pebble from actual phosphate ore slurries [supplied by Brewster] were prepared as shown below. This mixture was placed in the 51/4 inches ID tube and sonically vibrated for the time shown. After treatment the sample was removed and examined for clay mudballs. In test 8, a 41/4 inches OD steel insert (carrot) was added with the feed sample. In test 9, a 31/2inches OD steel insert was added with the feed sample. In tests 6, 7, 10, 11 and 12, a 41/2 inches diameter steel insert was added inside the the tube with the feed. The sound drive was turned on and run for the time shown.
Conclusions
1. Clay mudballs can be dispersed in water by exposure to sonic vibrations.
2. Ten seconds exposure is required for 70-80% dispersion of mudballs with a 41/2 inches diameter insert.
3. Twenty seconds exposure is required for complete dispersion of mudballs with a 41/4 inches diameter insert.
4. Ten seconds exposure is required for complete dispersion of mudballs with a 41/4 inches insert when an equal amount of fine feed is added.
5. Sufficient water is required -- not over 66% -- to disperse the clay.
Data obtained are reported in Table II below.
TABLE II__________________________________________________________________________ CyclesTest % Sample Time perNumberFeed Mixture Solids Size Exposed Second Observations__________________________________________________________________________1 5 lbs Muddy Pebble 35 2 25% of mudballs dispersed1 lb Mudballs2 1 lb Mudballs 35 5 50% of mudballs dispersed3 1 lb Mudballs 35 10 75% of mudballs dispersed4 1 lb Mudballs 35 20 90% of mudballs dispersed5 5 lbs Mudballs 80 5 lbs 20 96 One-half mudballs crushed; water needed for dispersion6 22 lbs Muddy Pebble 50 25 lbs 10 96 Overloaded tube; water not3 lbs Mudballs dispersed7 3 lbs Mudballs 50 25 lbs 20 96 Overloaded tube; water not dispersed8 41/2 lbs Muddy Pebble 35 5 lbs 10 96 Crushed pebble and mud1/2 lb Mudballs9 41/2 lbs Muddy Pebble 35 5 lbs 10 96 One-half mudballs dipsersed1/2 Mudballs10 41/2 lbs Muddy Pebble 35 5 lbs 10 96 Three-quarters mudballs1/2 lb Mudballs dispersed11 41/2 lbs Muddy Pebble 35 5 lbs 20 96 All mudballs dispersed1/2 lb Mudballs12 11/2 lbs Muddy Pebble 35 31/2 lbs 10 96 All mudballs dispersed11/2 lbs Crushed Pebble1/2 lb Mudballs__________________________________________________________________________ | A method of processing hydraulically mined ore slurries containing, in addition to the valuable ore, substantial quantities of contaminating argillaceous material and silica, involving initially separating the argillaceous material from the ore slurry while concomitantly concentrating said slurry to at least 65% solids content, depositing the wet concentrate thus formed on a continuous belt and conveying said wet concentrate via said belt to a beneficiation plant for further treatment. | 2 |
This is a division of application Ser. No. 085,147, filed Oct. 15, 1979 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the preparation of polyisocyanurate polymers such as polymer foams, and is more particularly concerned with use of a class of catalyst which promote the trimerization of polyisocyanates to polyisocyanurate polymers.
2. Description of the Prior Art
Polyisocyanurate polymers such as rigid polyisocyanurate foams are known in the art. The prior art discloses methods for preparing such polymers by reacting an organic polyisocyanate with a polyether or polyester polyol utilizing a polyisocyanurate group formation catalyst. Foams are prepared by effecting such reaction in the presence of a blowing agent. In the optimum situation the isocyanurate catalyst utilized promotes formation of both isocyanurate linkages and urethane linkages to produce urethane-modified polyisocyanurate polymers. See, for example, U.S. Pat. Nos. 3,516,950; 3,580,868; 3,620,986; 3,625,872; 3,635,848; 3,725,319; and 3,745,133.
Compounds which are known as catalysts for polyisocyanurates are the N-alkal metal and N-alkaline earth metal compounds of primary and secondary aliphatic, arylaliphatic, aromatic amines and heterocyclic amines. Amines which may be employed are, for example, methylamine, N-butylamine, tert.-butylamine, methoxy-n-propylamine, oleylamine, diethylamine, di-n-butylamine, diisobutylamine, dicyclohexylamine, N-methylstearylamine, benzylamine, ethylbenzylamine, dibenzylamine, phenylbenzylamine, aniline, naphthylamine, 3-N-ethylaminotoluene, toluidine, methylaniline, N-isobutylaniline, diphenylamine, N-methylanisidine, and also pyrrolidine, piperidine, 1,2,3,4-tetrahydroquinoline, pyrrole, indole, 2-methylindole, 2,3-dimethylindole, 5-methoxy-2,3-dimethylindole, carbazole, 3,6-dinitrocarbazole, N,N'-dimethylethylenediamine and N,N'-dimethyl-p-phenylenediamine.
N-alkali metal and N-alkaline earth metal compounds of carboxylic acid amides are also known catalysts. These include aliphatic and aromatic carboxylic acid amides and also such cyclic acid amides as imides and lactams. The following compounds are examples of compounds suitable for the production of such N-metal compounds: acetamide, trimethylacetamide, myristinic acid amide, stearoyl amid, N-methylacetamide, phenylacetamide, benzamide, N-alkyl benzamides, succinimide, tetrapropenyl succinimide, phthalimide, pyrrolidone, butyrolactam, caprolactam, phthalimidine and saccharine.
Also, as catalysts alkali or alkaline earth metal may be combined with the amines or carboxylic acid amides such as, for example, lithium, sodium, potassium, magnesium, barium, and calcium, with the preferred metals being lithium, sodium, potassium and calcium.
Also, alkali or alkaline earth metal salts of carboxylic acids are useful as catalysts for isocyanurate polymers.
The catalyst of this invention do not contain alkali or metals and provide an unexpected beneficial delay in the isocyanurate reaction which aids in processing. This delay is especially helpful where molding is undertaken. The catalyst herein also gives a complete product cure.
SUMMARY OF THE INVENTION
This invention comprises a novel process for preparing a polymer containing recurring isocyanurate and urethane linkages, which polymer comprises a reaction product of a polyol and an aromatic polyisocyanate utilizing as an isocyanurate formation catalyst a particularly useful and novel specific class of compounds known as falling within the formula: ##STR2## where R 1 and R 2 are independently selected from alkyl groups of less than about 3 carbon atoms or where R 1 and R 2 together comprise cycloalkyl or morpholino groups and where R 3 is hydrogen or alkyl groups containing less than about 3 carbon atoms. The invention is also the novel compositions described above.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The catalysts of the invention are useful as catalysts for the production of isocyanurate either used alone or in combination with other known catalysts. Compounds having the general formula depicted in the summary of the invention are included within the scope of our invention.
In a preferred embodiment R 1 and R 2 are alkyl groups having less than about 3 carbon atoms and R 3 is hydrogen.
In a particularly preferred embodiment R 1 and R 2 are methyl and R 3 is hydrogen and the catalyst has the formula:
(CH.sub.3).sub.2 N--N═CH--CH.sub.2 OH (II)
and is called 1-(2,2-dimethylhydrazono)-2-hydroxyethane, also known as hydroxyacetaldehyde, 2,2-dimethylhydrazone.
Preparation of these materials can proceed as follows for example:
In order to obtain compound II, unsymmetrical methylhydrazine, (CH 3 ) 2 N--NH 2 , is added to formaldehyde at a temperature from about -50° C. to 150° C. but preferably from about 0° C. and 80° C. at pressures ranging from about 0.01 atm to 200 atm but preferably at about one (1) atm. A solvent may be used but is not necessary. Suitable solvents water, alcohols and others.
If formaldehyde is added to unsymmetrical dimethylhydrazine instead of the reverse as above, 1-(2,2-dimethylhydrazino)-2-(2,2-dimethylhydrazono)ethane,
(CH.sub.3).sub.2 N--NH--CH.sub.2 --CH═N--N(CH.sub.3).sub.2 (I)
is produced along with the 1-(2,2-dimethylhydrazono)-2-hydroxyethane.
The catalysts of this invention are surprisingly effective in catalyzing the isocyanurate reaction and provide a delayed reaction which is valuable for processing the foams. Furthermore, the catalysts of this invention are particularly advantageous in that they give a complete cure to the foam without other catalysts being present.
The Examples which follow depict the preparation of compounds I and II and the use of these materials as isocyanurate catalysts.
EXAMPLE I
To a 500 ml reactor equipped with a stirrer, thermometer, addition funnel and nitrogen atmosphere was charged 150 g unsym-dimethylhydrazine. With cooling to 5° C., 212 g formalin (37% formaldehyde) was added dropwise over 2 hours. After the addition, the reaction mixture was warmed to room temperature over 1.5 hours and water distilled under aspirator vacuum of 35 to 50 mm Hg. When about 150 ml remained a 12 inch distillation column was added and the distillation was continued. When ca. 30 ml remained, the column was removed and the remainder flash distilled; 21.6 g was collected bp 5-6 65°-67° C. This final distillate was used as a catalyst to prepare an isocyanurate foam in Example II below.
EXAMPLE II
A foam was prepared by premixing the B-component ingredients listed below, and mixing the B-component on a high speed stirrer with 57.6 parts THANATE®P-270 polyisocyanate, and pouring the blend into a standard box mold and allowing the formulation to rise.
B-component ingredients:
25.9 parts Novolak polyol (OH No.=187, F=2.5)
0.5 parts DC-193 silicone surfactant
12 parts R-11B FREON® fluorocarbon
4 parts catalyst from Example 1
The foam rise characteristics are recorded below:
______________________________________Cream time 22 secondsTack free time 60 secondsRise time 53 seconds______________________________________
This formulation exhibits desirable rise characteristics for many isocyanurate foam applications in that it has a relatively long cream time and yet still has a reasonably short track free and rise time. This permits mold filling of the fluid blend and yet provides rapid cycle times for repetitive molding operations.
EXAMPLE III
This example is similar to Example I but the products are identified.
To a 1-l flask equipped with an additional funnel and stirrer and nitrogen atmosphere was charged 300 grams unsym.-dimethylhydrazine. After cooling to 7° C., 424 grams formalin was added dropwise over 2 hours with cooling and stirring. After standing at ambient temperature for 64 hours following addition, vacuum distillation was conducted and fraction A boiling at 74° C. (4-6 mm) and fraction B boiling at 73° C. (3 mm) were collected. Analysis of these fractions showed them to contain the following compounds:
Fraction A--contained a 1:1 molar ratio of compounds I and II.
Fraction B contained compound II.
Combined isolated yields of I and II were 1.72% and 4.7% respectively.
EXAMPLES IV AND V
Rigid urethane/isocyanurate foams were prepared from the compounds of Example III by a technique similar to that described in Example II.
______________________________________ #4 #5______________________________________A ComponentTHANATE®P-270 isocyanate 58.3 parts 58.3 partsB ComponentNovolak polyol (OH No. 194, F 2.4) 25.2 parts 25.2 partsDC-193 silicone surfactant 0.5 parts 0.5 partsFREON®R-11B fluorocarbon 12 parts 12 partsCatalyst - Example III, Fraction 4 parts 0 partsCatalyst - Example III, Fraction B 0 parts 4 partsFoam Cure DataCream time, sec. 4-5 18-20Tack free time, sec. 28-30 60Rise time, Sec. 45 105______________________________________
Thus, compound I seems to be more active a catalyst providing a more rapid cure whereas compound II provides more of a delay.
EXAMPLE VI
To a nitrogen padded flask containing 81 g of formalin, 37% formaldehyde solution (1 mole), a stirrer, and thermometer was added 30 g unsym.-dimethylhydrazine dropwise over 110 minutes. The reaction solution was then warmed in a water bath 3 hours at temperatures not exceeding 44° C.
Gas liquid chromatographic analysis of the reaction mixture at this point revealed the presence of compound II. Although 33 g additional dimethylhydrazine was added and the temperature increased to 87° C. (reflux), none of compound I was detected and little additional II was formed.
Dimethylhydrazine and water were removed by heating the mixture at 60° C. while applying aspirator vaccum. The residue weighed 40 g and analysis showed it to be hydroxyacetaldehyde dimethylhydrazone (II). Both nmr and glpc analysis showed the product to be greater than 90% pure.
The next example illustrates the effectiveness of compound II as an isocyanurate catalyst in the absence of polyols.
EXAMPLE VII
To a nitrogen padded bottle containing 5.0 ml phenylisocyanate and 25 ml petroleum ether was added 2 drops of the catalyst of Example VI and 2 ml of allyl cyanide as a cosolvent. The bottle was sealed and allowed to stand at ambient temperature one hour. The solids which crystallized were filtered and washed pentane and reprecipitated from acetone/heptane. The crystals, 2.6 g, which were collected were identified as triphenylisocyanurate.
The following examples illustrate the comparison between the catalysts of this invention and commercially available amine based isocyanurate catalysts.
EXAMPLES VIII-XII
Foams were prepared by blending the A component and premixed B-components on a high speed stirrer.
______________________________________Experiment Number A B C D______________________________________A-Component (parts by wt.)MONDUR®MR 59 -- -- --polyisocyanateTHANATE®P-270 -- 60 56.6 58polyisocyanateB-Component (parts by wt.)Novolak based polyol(OH#194, F 2.4) 25.5 26 -- --Novolak based polyol(OH#192, F 2.4) -- -- 24.9 25.5DC-193 silicone surfactant 0.5 0.5 0.5 0.5FRENON®R-11B fluorocarbonblowing agent 12 12 12 12Catalyst from Example VI 5 -- -- --50% potassium octoate in700 molecular wt. triol -- 1.5 -- --DMP-30 (2,4,6-tris-(dimethyl-aminomethyl)phenol fromRohm and Haas -- -- 6 --1,3,5-tris-(dimethylamino-propyl)hexahydrotriazine -- -- -- 4Foam Cure CharacteristicsCream time, sec. 13 4 4 5Tack free time, sec. 59 45 55 35Rise time, sec. 100 50 120 90Comments about cured foam Good Good Poor Skin exter- cracks nal under friabi- slight lity pres- sure______________________________________
In comparison of the catalysts above, only the catalyst from Example VI gave a cream time delay. Other amine catalysts such as DMP-30 and 1,3,5-tris(dimethylaminopropyl)-hexahydro-1,3,5-triazine do not give good isocyanurate foams when used as the only catalyst. Alkali metal carboxylates give good foams but do not give the desired delay useful in many applications. Lower levels of alkali metals in formulations give incompletely cured foams. | Polyisocyanurate catalysts are disclosed which have the formula: ##STR1## where R 1 and R 2 are independently selected from alkyl groups of less than about 3 carbon atoms or where R 1 and R 2 together comprise cycloalkyl or morpholino groups and where R 3 is hydrogen or alkyl groups containing less than about 3 carbon atoms. Said catalysts are useful in promoting the reaction between a polyol and an aromatic polyisocyanate to prepare a polymer containing recurring isocyanurate and urethane linkages. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of U.S. Provisional Patent Application No. 60/346,683 filed Jan. 7, 2002, entitled “A SYSTEM AND A METHOD FOR ACCELERATING COMMUNICATION BETWEEN CLIENT AND MS EXCHANGE SERVER” and International Application Number PCT/IL03/00014 fled on Jan. 5, 2003 and entitled “A SYSTEM AND A METHOD FOR ACCELERATING COMMUNICATION BETWEEN CLIENT AND AN EMAIL SERVER” the subject matter of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates to the field of data communications and, more specifically, to the enhancement of transferring data throughput in communication system between an Email Server and a client utilizing Email software.
BACKGROUND OF THE INVENTION
[0003] Historically, in server based networks serving one or more clients, the servers have utilized powerful computers while the client computers have utilized computers possessing limited computing power and limited storage capacity. Generally, communication between the clients and the servers has been enabled through the use of a LAN (Local Area Network) using a high capacity communication link and generating a domain.
[0004] A domain is a group of computers and devices on a network that are administered as a unit with common rules and procedures. Within the Internet, domains are defined by the IP address that is assigned. All devices sharing a common part of the IP address are said to be in the same domain.
[0005] Therefore, in client/server architectures, the storage and the processing is primarily performed on the server side while the client computer operates as a terminal and an interface unit between the user and the server. Obviously, this type of an architecture results in heavy transportation of information between the client and the server. It should be noted that the terms “client” and “user” are used interchangeably herein.
[0006] In recent years, the portable computer has experienced explosive growth in utilization, as well as in the performance capabilities, features, processing power, memory availability and capabilities. There has also been a great deal of expansion in use and availability of the global data communication network known as the Internet, and the use of portable communication systems like, but not limited to, cellular or satellite systems.
[0007] It is desirable for an enterprise that is using a client/server architecture, for example MICROSOFT OUTLOOK and the MS exchange server, to provide users with the ability to access their MS Office documents and E-mail messages while being out of the office and connected through the Internet via telephone lines or a wireless network, like but not limited to Cellular or Satellite networks. Outlook is Microsoft's mail client and personal information manager. The full version includes a PIM (Personal Information Manager) calendaring, to-do list and groupware functions. OUTLOOK also provides a journaling capability for keeping track of hourly billing. OUTLOOK can be used as the client end to MICROSOFT'S Exchange Server or as the e-mail client with any ISP (Internet Service Provider) account. The paragraphs that follow refer to an MS exchange server as an example of an Email Server of the present invention, and to OUTLOOK as an example of an Email application.
[0008] One technical hurdle, in meeting this desire, is that the wireless communication systems or networks have a limited bandwidth. Using such limited bandwidth networks to replace a LAN results in increasing the communication time between the remote users and reduces the quality of the connection.
[0009] Therefore there is a need in the art for a system and a method that can reduce the transportation between a remote user and a server in an on-line operation. Such a system can increase the speed of the communication. Further, there is a need in the art for a system and method to reduce the transportation between a remote user and a server over a wireless communication channel.
[0010] A specific example of this need can be seen in the setting of a user mailbox within an exchange server. In this setting, the user mailbox is part of the exchange server information store. The information store consists of three implementations of MAPI message stores: the public information store, the private information store, and the personal folder store (PST). MAPI is an abbreviation of Messaging Application Programming Interface, a system built into Microsoft Windows that enables different e-mail applications to work together to distribute mail. As long as both applications are MAPI-enabled, they can share mail messages with each other. The paragraphs that follow refer to MAPI as an example of an application programming interface of the present invention.
[0011] The information store organization of public folders, private folders, and messages is referred to as the organization hierarchy. Another implementation of a MAPI message store is configured when a user works offline or not connected to the exchange server. This message store is called the offline folder store (OST) and the content and structure of the OST mirrors the mailbox while offline.
[0012] A mailbox is the delivery location for all incoming mail messages addressed to a designated owner. Information in a user's mailbox is stored in the private information store on a Microsoft Exchange Server computer. A mailbox can contain received messages, message attachments, folders, folder hierarchy, and more.
[0013] OUTLOOK uses MAPI over Remote Procedure Calls (RPC) as it's transport provider to connect the user to its mailbox that resides physically at the exchange server as part of the information store. RPC is a call that is based on a client server model. Procedures that are called within the client application are actually performed within the server side over a communication channels. The MAPI transport provider and the MAPI message store, called the exchange server service, are tightly coupled in such a way, that it is impossible to use only the MAPI message store and a different transport provider and still maintain the provision of all the services the Exchange server service offers.
[0014] Using RPC as the communication between a remote user and its mailbox at the exchange server over low bandwidth is very slow and has a lot of communication overhead. When the user uses OUTLOOK in the offline mode, outgoing messages are kept in the user outbox in its offline folders, and incoming messages are kept for him at the exchange server. When the user is going back online, the exchange server and outlook synchronize those messages. This process results in a significant amount of data transfer to occur, depending on the amount of traffic received and the time that the user has been off line. In a wireless configuration, this process can absorb a significant percentage of the available bandwidth. Thus, there is a need in the art for a method to reduce the transportation between a remote user and a server in an on-line operation when large amounts of data, such as during a synchronization function, is necessary.
SUMMARY OF THE INVENTION
[0015] The present invention provides a system and a method that improves the on-line operation between a remote email or application program and the exchange server to which it interfaces, such as a mailbox exchange server. The present invention operates by tricking or controlling the email application program in such away that the email application program operates as it is on-line although it is off-line. In an embodiment of the present invention, this is accomplished by spoofing the OUTLOOK application program and as a result, the OUTLOOK system operates off-line but the user has on-line type experience.
[0016] More specifically, the present invention replaces the MAPI/RPC as the transport provider while the user is operating the email application program in an off-line mode. The data transfer between the email application program and the email server is handled by the present invention in the background. On the server end of the connection, the present invention operates to spoof the server and thus causes the server to operate as though the remote customer is an interactive user presently connected to the domain.
[0017] Another aspect of the present invention is using the multi-tasking feature of an NT machine to overcome the MAPI session limitation of an Exchange Server. The Exchange Server operates to enable only a limited number of MAPI sessions per interactive user's computer. The present invention overcomes this limitation by generating a separate task for each active remote user (a User Agent (UA)). This method of spoofing the Exchange Server enables the Exchange server to support a plurality of remote users via a single NT/Win2000 machine or equivalents.
[0018] An exemplary embodiment of present invention may include, but is not limited to, two logical modules that work within the client/server architecture:
[0019] (1) A Domain Logical Module (DM), which is installed on an NT machine or similar machine and has a computer account in the domain; and
[0020] (2) A Client Logical Module (CM), which is installed in the client's computer as an extension of the mail program.
[0021] The present invention may be a DLL OUTLOOK extension/add-in, and replaces the MAPI/CDO as the transport provider. CDO, or Collaboration Data Objects is a technology for building messaging or collaboration applications. DLL is short for Dynamic Link Library, a library of executable functions or data that can be used by a Windows application. Typically, a DLL provides one or more particular functions and a program accesses the functions by creating either a static or dynamic link to the DLL. A static link remains constant during program execution while a dynamic link is created by the program as needed. DLLs can also contain just data. DLL files usually end with the extension “.dll”.
[0022] A DLL can be used by several applications at the same time. Some DLLs are provided with the Windows operating system and available for any Windows application. Other DLLs are written for a particular application and are loaded with the application as in the exemplary embodiment of the present invention.
[0023] CDO is the bridge from Visual Basic and scripting languages to MAPI. CDO exposes COM objects, but these COM objects are of the right nature to be accessible through both languages.
[0024] The present invention may be used in conjunction with an additional system, which operates to accelerate the communication over a problematic network channel such as, but not limited to cellular, satellite or other wireless channels. This additional system may operate to compress or otherwise modify the communication protocol to create a more efficient protocol or make other changes and adjustments. Examples of such additional systems include NettGain 1100 of Flash Networks. If the accelerating system is used, two additional modules may be needed—one in each end of the problematic line. However, it should be noted that these additional modules are not required elements of the present invention but rather, can be incorporated into the present invention. These additional modules include:
[0025] Client Booster (C. BST).
[0026] Gateway Booster (G. BST).
[0027] The present invention supports substantially all OUTLOOK built-in forms, such as the E-mail messages, appointments, contacts, calendar, tasks etc.
[0028] Other objects, features, and advantages of the present invention will become apparent upon reading the following detailed description of the embodiments with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a block diagram illustrating a common environment in which an exemplary embodiment of the present invention may be used.
[0030] FIG. 2 a illustrates a block diagram of an exemplary embodiment of a Client Module (CM).
[0031] FIG. 2 b illustrates a block diagram of an exemplary embodiment of a Client Module (CM), which is connected to a booster module.
[0032] FIG. 3 illustrates a block diagram of an exemplary embodiment of a Domain Module (DM) in a corporate domain.
[0033] FIG. 4 a and FIG. 4 b are a flow chart illustration of a method implemented by an exemplary embodiment of the present invention during the login stage. FIG. 4 a illustrates a method implemented by an exemplary embodiment of a Client Module and FIG. 4 b illustrates a method implemented by an exemplary embodiment of a Domain Module.
[0034] FIG. 5 illustrates a method implemented by an exemplary embodiment of a Client Module during on going operation after the Login stage.
[0035] FIG. 6 illustrates a method implemented by an exemplary embodiment of a User Agent (UA) 360 during the on going operation, after the Login stage.
[0036] FIG. 7 illustrates a method implemented by an exemplary embodiment of a UA 360 during A Logoff stage.
DETAILED DESCRIPTION
[0037] Referring now to the drawings, in which like numerals refer to like parts throughout the several views, exemplary embodiments of the present invention are described.
[0038] FIG. 1 is a block diagram illustrating a common environment in which the present invention may be used. A cellular system 100 has been selected as an exemplary environment that is suitable for implementing the present invention. However, it should be noted, and readily observable to those skilled in the art, that the present invention is not limited to operation within a cellular environment, and for that matter, any other specific communications system. But rather, the present invention can be implemented using various communication systems such as, but not limited to, satellites, the PSTN (Public Switched Telephone Network), ISDN (integrated services digital network) lines etc.
[0039] A plurality of laptop computers 110 a to 110 n are connected via cellular connections 120 to a gateway (GW) 130 , which can be located in a particular cell or in an operator station. The laptop computers 110 may represent any portable devices that use MAPI messages services for communicate with an exchange server, like but not limited to palm computers, cellular phones etc., and will collectively be referred to as client 110 .
[0040] The communication over connection channels 120 can be based on TCP/IP or, it can be based on a proprietary accelerating protocol. In case of using a proprietary accelerating protocol, two additional modules are needed (one for each end of the line 120 ).
[0041] GW 130 may be connected via a VWB (Very Wide Bandwidth) connection 140 to the Internet 150 and from there, via the appropriate Domain Modules (DM), 160 a to 160 m, to the domain of each of the cooperates, 170 a to 170 m, which comprises the appropriate Exchange Server, 175 a to 175 m.
[0042] More than one client 110 may be connected to the same domain 170 via the same DM 160 and be engaged in an interactive connection with the same Exchange Server 175 simultaneously.
[0043] FIG. 2 a illustrates a block diagram of an exemplary embodiment of a Client Module (CM). The CM 205 is a OUTLOOK extension DLL. The CM 205 operates to receive indications from OUTLOOK, or some other email application program, when a new message has been submitted to the outbox; change the message from the messaging application format into a proprietary messaging format (Msg. FT) and export the translated message over TCP/IP.
[0044] The CM 205 comprises several modules including: Event Manager 207 ; format converter 210 ; Messaging System (Mes. Sys.) 220 ; priority queue (Q) 230 and TCP/IP module 240 .
[0045] The User, operating an email application program in an off-line mode and desiring to send an outgoing message, presses the send button, or its equivalent, and the message is submitted to the outbox. The email application program then indicates to its extensions that a new message is waiting in the outbox. Upon receiving this indication, the Event Manager 207 calls the Format Converter 210 , which reads the new message in MAPI format and translates it into the Mes. FT. The Mes. FT is a chain of properties, which, among other things, includes the message. The format converter 210 which translates the MAPI message into the Mes. FT and vice versa, may select part of the properties that are sufficient to reconstruct the right message in the other side of the communication channel. Mes. Sys. 220 receives the chain of objects of the new converted message, organizes it into a complete message and sends the complete message to the queue 230 . By using a proprietary messaging format, the present invention has the flexibility to be connected to a mail client and personal information manager system, other than OUTLOOK, by simply modifying the Event Manager 207 and the Format Converter 210 , to fit the API of the other mail system.
[0046] Queue 230 organizes the messages according to the priority that has been chosen or selected by the user. Queue 230 is the buffer between OUTLOOK and the network. Transmitting and receiving of the messages are transparent to the user, thus giving the user off-line operation with an on-line experience.
[0047] The output of the queue 230 is transferred to the TCP/IP module 240 that handles the communication over TCP/IP from or to OUTLOOK. The TCP/IP module 240 picks a complete message from the queue 230 and transfers it over TCP/IP via the configured socket. The TCP/IP module 240 also maintains the connection and tries to reconnect to its defined socket in case the connection has been broken.
[0048] In the exemplary embodiment of FIG. 2 a, the message is then sent out over TCP/IP.
[0049] Alternatively, in the exemplary embodiment of FIG. 2 b, the message from OUTLOOK is sent via TCP/IP to a booster unit 260 that translates the TCP/IP buffers into a more efficient protocol, manipulates the message to accelerate the communication and sends the transformed message via a proprietary tunnel (BST connection) 265 to the GW 130 .
[0050] In the other direction, when a message is received from the Exchange Server 175 ( FIG. 1 ), the TCP/IP module 240 handles the data on a packet basis and transfers it to the input section of queue 230 . The data from queue 230 is transferred to Mess. Sys. 220 . The Mess. Sys. 220 gathers the information from the relevant packets into the whole message and transfers it to the format converter 210 . The format converter 210 translates the proprietary format back to the MAPI format, and the message is then transferred to its destination (e.g. the inbox, the calendar etc.). In parallel, the Event Manger 207 sends an indication to the user that the message has arrived at client 110 .
[0051] Incoming messages can occur in one of two methods. In one method, a new message notification has been sent to the user's mailbox within the Exchange Server 175 and wakes up the user agent to start downloading the message. In another method, the user presses the Send/Receive button on the OUTLOOK menu when the OUTLOOK application is not connected. The Event Manager 207 that waits for this event, sends a refresh message to the user agent to instruct the user agent to start download new messages.
[0052] FIG. 3 illustrates a block diagram of an exemplary embodiment of a Domain Module (DM) 160 in a Corporate Domain 170 . Corporate Domain 170 comprises an Exchange Server 175 and an exemplary DM 160 .
[0053] The DM 160 may be an NT machine, a Window 2000 machine etc., and comprises several logical modules including: a TCP/IP module 340 , a DM priority queue (Q) 330 , Dispatcher 350 with its Messaging System 352 , and a plurality of User Agents (UA) 360 .
[0054] On the upper side, the DM 160 is connected to an Exchange Server 175 and on the other side is connected to a plurality of clients 110 via TCP/IP connection 345 over the Internet (not shown in FIG. 3 ). Because OUTLOOK in the client computer 110 is operating in off-line mode, the transportation between the CM 200 and the DM 160 is carried by a proprietary Transport Provider over the TCP/IP connection 345 .
[0055] The TCP/IP logical module 340 handles the incoming data from the remote user, via the configured socket, on a packet basis, processes them according to the protocol and transfers the data to the input section of queue 330 . The TCP/IP module 340 also maintains the connection and tries to reconnect to its defined socket in case the connection has been broken.
[0056] The data from the input section of queue 330 is grabbed by the Dispatcher Mess. Sys. 352 . The Dis. Mess. Sys. 352 pulls the information, organizes it into a message and transfers the message to the Dispatcher 350 .
[0057] Dispatcher 350 reads the envelop of the message and, based on its current dispatching list, determines whether the source of the message is a new remote user 110 . If the source of the message is a new user, the Dispatcher 350 assigns a free User Agent 360 to the new user, adds this assignment to its dispatching list and submits the message to the selected UA 360 . If the source of the message is not a new user, the Dispatcher 350 , based on the dispatching list, transfers the message to the appropriate UA 360 .
[0058] UA 360 represents its assigned user in front of the Exchange Server 175 . The UA 360 performs login and logout in the name of current user of the remote client 110 , spoofing the Exchange Server 175 into operating as though the remote user is connected locally to the domain and operating as an interactive user, who receives and transmits OUTLOOK messages and mail.
[0059] A UA 360 comprises of priority queue logical module 363 , Mes. Sys. logical module 320 , format converter logical module 310 and Event Manager logical module 307 .
[0060] Uploaded messages from the remote user are submitted by the Dispatcher 350 to the input section of priority Queue 363 of the UA 360 . Messaging System 320 pulls the information from the input section based on its priority, organizes the information into a message in the proprietary messaging format and transfers it to the Format Converter 310 . Format Converter 310 translates the proprietary messaging format into MAPI/CDO format and transfers the message in MAPI format to the Event Manager 307 .
[0061] Upon receiving a new message from the remote user, the Event Manager 307 determines whether the message is a Login-request or an Inter Personal Messaging (IPM) message. If the message is a Login-request, the Event Manager 307 impersonates as the remote user and performs a logon sequence to the Exchange Server 175 on behalf of this user. The Event Manager 307 uses the credentials of the remote user that have been collected by the Event Manager 207 of the CM 200 and initiates a MAPI session in the Exchange Server 175 . The operation of the UA Event Manager 307 is described in more detail below.
[0062] Moreover, in some embodiments the: UA Event Manager 307 , the Format Converter 310 and the Mes. Sys. 320 may be combined into a single logical module or into two logical modules instead of the three modules of the current exemplary embodiment.
[0063] Messages from the Exchange Server 175 to the remote users, which are currently connected to the DM 160 , are processed by the appropriate UA 360 and submitted to the output section of Priority Queue 330 . The output section of the Priority Queue 330 of the DM 160 , collects the outgoing messages from each UA 360 . The outgoing messages, from Priority Queue 330 , preferably based at least in part on their priority, are pulled and processed by TCP/IP logical module 340 and are sent as packets over TCP/IP to the appropriate user of remote client 110 .
[0064] Alternatively, in another exemplary embodiment (not shown in the drawings) a booster unit may be used between the TCP/IP logical module 340 and the network. This booster unit manipulates the transportation into a more efficient protocol, manipulates the message to accelerate the communication and sends the transformed message via a proprietary tunnel (BST connection) to the GW 130 . This unit may perform the complementary operations of the booster unit 260 in FIG. 2 b.
[0065] As part of the installation process of the CM in its computer, the user is required to select one of its on-line OUTLOOK profiles. The user may generate this profile by using the Windows Mail Configuration within the control panel.
[0066] FIG. 4 a is a flow chart illustrating one method for implementing an exemplary embodiment of a CM 205 ( FIGS. 2 a & 2 b ) during the login stage. The OUTLOOK application, upon initiation by the user, prompts the user at step 410 to select one of the OUTLOOK Profiles. At step 420 , if the selected profile is a profile that does not invoke the present invention, the CM 205 is not initiated and processing continues at step 422 where the user may use OUTLOOK in its common way of operation.
[0067] If at step 420 the selected profile is a profile that invokes the present invention, the CM 205 , at step 424 , starts the Login process with the user. This step includes prompting the user with a login dialog box, in which the user is required to enter his credentials (user name, password domain name and the Exchange Server name). In one embodiment, the CM 205 may be configured to take these credentials from the user profile without prompting the user for the dialog box.
[0068] The user credentials with additional configuration parameters (for example: compression attributes, the last synchronization time etc.) are sent over the network to the DM 160 ( FIG. 1 ) at step 427 , using the TCP connection 250 ( FIGS. 2 a & 2 b ) or via a booster system 260 in case that such a system exists. Then the CM 205 is waiting 429 for receiving a response from DM 160 .
[0069] FIG. 4 b is a flow chart illustrating one method for implementing an exemplary embodiment of a DM 160 during the login stage. Upon receiving a Login request from a remote user, the Dispatcher 350 ( FIG. 3 ) verifies (not shown in the drawing) whether the remote user has been assigned a UA 360 ( FIG. 3 ). If the remote user has been assigned a UA 360 , the Dispatcher 350 forwards the request to the appropriate UA 360 . If there is no assignment yet, at step 430 the Dispatcher 350 determines whether there is a free UA. If there are no free UAs, at step 432 the Dispatcher 350 waits until a time-out expires and then rechecks for a free UA at step 430 again. If there is a free UA 360 , at step 434 the Dispatcher 350 assigns the client to the UA 360 , updates its assignment table and forwards the call to the selected UA 360 .
[0070] Upon receiving the Login-request, at step 440 the Event Manager 307 of the selected UA 360 determines whether it is the first Login-request of this user 110 . If this is not the first Login-request, at step 448 the Event Manager 307 ( FIG. 3 ) updates the connection parameters and processing continues at step 456 and retrieves new mail.
[0071] However, if it is the first Login-request of a new user 110 ( FIG. 1 ), processing continues at step 442 where the selected UA 360 gets the current client's parameters and starts the impersonation process at step 444 . During the impersonation process, the UA 360 performs an NT login to the domain 170 , and impersonates the remote user 110 by using the client credentials. The UA 360 then creates an OUTLOOK profile for this new client, on the machine on which the DM 160 runs, pretending that it is the remote client and at step 446 , starts a MAPI session to the Exchange Server.
[0072] At step 450 , if the credentials of the user are valid and the login succeeds, at step 454 the UA 360 sends a Login-success message to the CM 205 and the CM 205 processing continues at point B in FIG. 4 a. In parallel, the UA 360 processing continues at step 456 to synchronizes the mailbox.
[0073] At step 450 , if the credentials of the user are not valid and the login fails, the UA 360 enters the login fail process at step 452 which sends a Login-fail message to the CM 205 and causes the CM 205 to continue processing at point B in FIG. 4 a. Then, the UA 360 provides notice to the Dispatcher 350 about the disconnection and enters into a free position. The Dispatcher 350 updates its assignment table by removing this assignment.
[0074] At step 456 the UA 360 retrieves all new messages, which have arrived to the user's mailbox (within the exchange server) between the last login and the current login, and sends these messages to the remote client 110 via the CM 205 . Then at step 458 , the UA 360 registers itself for new message notification within the user's mailbox.
[0075] From this point forward, as long as there is a valid connection between the client 110 and the DM 160 , the new messages will be automatically downloaded to the user's off-line mailbox through the DM 160 and CM 205 ( FIGS. 2 a & 2 b ).
[0076] Returning now to the operation of the CM 205 , FIG. 4 a point B, upon receiving the response for the Login-request, at step 470 the CM 205 determines whether the login has been successful. If the login has been successful, at step 474 the CM 205 waits for the next event, which may be incoming mails from the Exchange Server or outgoing messages from the user 110 . If the login fails, the CM 205 sends 478 a Login-fail indication to the user 110 and processing continues at step 424 where the CM 205 prompt the user to login again.
[0077] FIG. 5 illustrates a method implemented by an exemplary embodiment of a CM 205 during the on going operation after the login stage. Initially, the CM 205 is waiting for a notification that an event has occurred. Upon receiving an event notification, at step 510 the CM 205 determines whether the event arrived 520 from the OUTLOOK outbox or from 540 the TCP/IP connection.
[0078] If the event arrives from the OUTLOOK outbox, which means that the user has sent a new message, processing continues at step 522 . The new message may be mail, calendar, task etc. At step 522 , the CM 205 grabs the message from the outbox and pushes it via the chain comprising the Format Converter 210 , the Mes. Sys. 220 , the output section of priority queue 230 and the TCP/IP module 240 and at step 530 sends the message over the network as described above in conjunction with FIG. 2 a. The CM 205 then returns to step 510 to wait for the next event.
[0079] If the event arrives from the TCP/IP connection indicating that new message arrives from DM 160 ( FIG. 1 ), processing continues at step 542 . The message may be a mail, calendar, task etc. message. At step 542 , the CM 205 grabs the message via the chain as described above, and at step 544 determines the type of the message. If the type of the message 560 is mail or calendar, at step 562 the CM 205 pushes the message into the inbox of the remote client 110 and at step 564 , sends an indication to the user. Then the CM 205 returns to step 510 and waits for the next event.
[0080] If the type of the message is an error message 570 , at step 576 the CM tries to reconnect again by returning to step 424 in FIG. 4 a and continues from there. If the type of the message is login feedback 550 from the DM 160 , at step 552 the CM 205 performs the part of the process, which is described above in conjunction to FIG. 4 a, from point B.
[0081] FIG. 6 illustrates one method for implementing an exemplary embodiment of a UA 360 ( FIG. 3 ) during the on going operation, after the login stage. Initially, UA 360 is waiting for an event to occur. Upon receiving notification that an event has occurred, at step 610 the UA 360 determines whether the event arrived from the Exchange Server 175 ( FIG. 1 ) (step 620 ) or from the Dispatcher 350 ( FIG. 3 ) (step 640 ).
[0082] If the event 620 arrives from the Exchange Server 175 , it means that the client 110 has received a new message. The new message may be mail, calendar etc. At step 622 , the UA 360 grabs the message from the inbox of the relevant client 110 in the Exchange Server 175 , and pushes it via the chain comprising the Format Converter 310 ( FIG. 3 ), the Mes. Sys. 320 ( FIG. 3 ), the output section of priority queue 330 and the TCP/IP module 340 ( FIG. 3 ), and at step 630 sends the message over the network as described above in conjunction with FIG. 3 . Then, the UA 360 returns to step 610 and waits for the next event.
[0083] If the event 640 arrives from the Dispatcher 350 , it means that the client has sent this new message. The message may be a mail, calendar, login request etc. At step 542 , the UA 360 grabs the message via the chain as described above and at step 644 determines the type of the message. If the type of the message is mail or calendar or etc. 660 , then at step 662 the UA 360 submits it into the outbox in the Exchange Server 175 associated with the user 110 . The Exchange Server 175 ( FIG. 1 ) takes responsibility to deliver the message to its destination.
[0084] If the type of the message is a disconnection message 650 , then the UA 360 closes the MAPI session with the Exchange Server 175 and clears up the allocated resources. Then the UA 360 provides notice to the Dispatcher 350 that the connection is broken and waits for new assignment.
[0085] If the type of the message is Login-request 680 from the CM 205 , then at step 682 the UA 360 performs 682 the part of the login process, which is described above, in conjunction to FIG. 4 b. At the end of the login process, the UA 360 returns to step 610 and waits for the next event.
[0086] FIG. 7 illustrates one method for implementing an exemplary embodiment of a UA 360 during the Logoff stage. This routine is initiated upon receiving a disconnection indication 720 from the TCP/IP module 340 . Otherwise the UA 360 continues in its on going operation as described above in conjunction to FIG. 6 . Upon receiving a disconnection indication 720 , the UA 360 starts several operations for terminating the on-line operation within the Exchange Server. First of all, at step 725 the UA 360 unregisters itself from event notifications that occur in the mailbox at the Exchange Server 175 . Then at step 730 , the UA 360 closes the MAPI session within the Exchange Server 175 . Upon terminating the logoff process within the Exchange Server 175 , at step 750 the UA 360 notifies the Dispatcher 350 that it is free again and at step 760 waits for the next assignment.
[0087] In the description and claims of the present application, each of the verbs, “comprise” “include” and “have”, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements or parts of the subject or subjects of the verb.
[0088] The present invention has been described using detailed descriptions of embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the present invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the present invention that are described and embodiments of the present invention comprising different combinations of features noted in the described embodiments will occur to persons of the art. The scope of the invention is limited only by the following claims. | The communication between a remote email or application program and the server to which it interfaces, such as a mailbox exchange server, is improved. The present invention operates by tricking or controlling the application program in such away that the application program operates as thought it is on-line although in actuality it is off-line. This is accomplished by spoofing the application program and as a result, the application program operates off-line but the user has on-line type experience. More specifically, the present invention replaces the MAPI/RPC as the transport provider while the user is operating the application program in an off-line mode. The data transfer between the email application program and the email server is handled by the present invention in the background. On the server end of the connection, the present invention operates to spoof the server and thus causes the server to operate as though the remote customer is an interactive user presently connected to the domain. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to valves and in particular to solenoid-operated cartridge valves.
2. Description of the Prior Art
In one form of fluid flow control valve, a poppet is seated against a valve seat to close the valve. The poppet is provided with a through bore which is selectively closed by a pilot valve. The poppet is spring-biased to the closed position with fluid pressure acting on opposite sides of the poppet so as to permit the spring biasing to maintain the poppet closed. When the pilot valve is raised from the valve seat, the fluid pressure behind the poppet is relieved to the through bore, thus permitting the fluid pressure acting upwardly on the poppet to move the poppet from the valve seat and thereby permit flow through the valve.
In one form, the pilot valve is operated by a suitable solenoid having a plunger connected to the pilot valve for selective positioning thereof in effecting the desired fluid flow control.
Such valves are provided in a wide range of sizes depending on the flow capacity desired.
It is further conventional to provide such valves in the form of cartridges, including both the valve and the solenoid operator in a single assembly which, illustratively, may be connected to suitable ports by a threaded adapter portion thereof.
SUMMARY OF THE INVENTION
The present invention comprehends an improved solenoid poppet valve structure providing improved performance and economy of manufacture.
The invention comprehends the provision of such a valve having an improved pilot valve guide arranged to utilize the single size pilot valve with any one set of a plurality of different size cooperating sets of valve seat members and poppets, each having the same pilot valve seat configuration.
In the illustrated embodiment, the pilot guide comprises any one of a plurality of pilot guides each having a different lateral extent outturned flange for permitting a single size valve pilot to be utilized with any one of the different size sets of seat members and poppets.
The invention comprehends the provision of such a valve structure wherein the slide portion of the pilot defines a flatted cross section to define flow passages extending longitudinally at the periphery of the slide portion.
In the illustrated embodiment, a pair of flats on diametrically opposite sides of the pilot slide portion is provided.
The invention further comprehends providing a T-slot in the solenoid plunger, with the valve pilot having a connecting head received in the T-slot.
In the illustrated embodiment, the T-slot extends fully diametrically across the plunger.
More specifically, the invention comprehends the provision in a solenoid valve structure having a plunger and a valve pilot for controlling the movement of a main valve poppet, of means in an end portion of the plunger defining a radially extending T-slot, the longitudinal portion of which opens through the end of the plunger, and means on the valve pilot defining a connecting head received in the slot, the T-slot extending fully transversely through the plunger, the longitudinal extent of the longitudinal portion of the T-slot being less than approximately one-half the longitudinal extent of the T-slot.
The connecting head has a transverse extent throughout less than that of the T-slot permitting ready fluid flow past the connecting head into the T-slot.
The pilot guide defines a surface adjacent the end portion of the plunger forming a fluid chamber opening to the longitudinal portion of the T-slot.
The invention further comprehends the provision of a solenoid valve structure having solenoid means defining a plunger chamber, a solenoid plunger reciprocally slidable in the chamber, and valve means connected to the plunger at one end of the plunger chamber defining a tapered surface narrowing to a transverse end surface, means on an adjacent end of the solenoid plunger defining a complementary tapered surface and transverse end surface, passage means in the solenoid plunger for conducting fluid from the portion of the chamber between the surfaces, and means for limiting the movement of the solenoid plunger toward the surface means at one end of the plunger chamber to prevent engagement of the transverse end surfaces and maintain a fluid transfer portion in the plunger chamber between the end surfaces at all times communicating with the passage means.
In the illustrated embodiment, the tapered surfaces are substantially frustoconical.
In the illustrated embodiment, the transverse end surfaces are substantially planar.
The movement limiting means in the illustrated embodiment comprises cooperating stop surfaces on the solenoid plunger and solenoid means at the wide end of the plunger chamber tapered surface.
The cartridge solenoid poppet valve structure of the present invention is extremely simple and economical of construction while yet providing the highly desirable features discussed above.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawing wherein:
FIG. 1 is a perspective view of a cartridge valve embodying the invention;
FIG. 2 is an enlarged diametric section thereof;
FIG. 3 is a transverse section taken substantially along the line 3--3 of FIG. 2;
FIG. 4 is a transverse section taken substantially along the line 4--4 of FIG. 2;
FIG. 5 is a diametric section of a modified form of cartridge form embodying the invention having a pilot guide adapted for use with different size poppet and seat members; and
FIG. 6 is a diametric section of a cartridge valve generally similar to the cartridge valve of FIGS. 1-5, but arranged for normally open operation
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the illustrative embodiment of the invention as disclosed in the drawing, a cartridge solenoid poppet valve generally designated 10 includes an adapter 11 having a threaded portion 12 adapted to be threaded into a fluid port. The adapter includes a threaded end 13. A seat member 14 is provided with a threaded end 15 threaded to the adapter end 13 so as to be received within the fluid port.
A first sealing ring 16 is provided on the adapter and a second sealing ring 17 is provided on the seat member for sealing the valve assembly within the fluid port.
As shown in FIG. 2, a backup ring 18 may be associated with the sealing ring 17 in a suitable outwardly opening, annular recess 19 of the seat member.
The seat member is provided with a pair of diametrically opposite inlet openings 20 and 21, which open radially inwardly into a valve chamber 22 within the seat member. An outlet opening 23 opens axially from the valve chamber 22 and is normally closed by a valve member 24 seating on an annular seat 25 of the seat member at the inner end of the outlet port 23.
Thus, when installed in a suitable port member, fluid pressure between seals 16 and 17 is applied through the inlet ports 20 and 21 against the valve member 24. In the illustrated embodiment, valve member 24 comprises a poppet valve having a lower seating portion 26 engaging the valve seat 25 and provided with an axial bore 27 having an outer counterbore 28 receiving a check valve 29. The check valve prevents fluid pressure in the outlet port 23 from causing a reverse flow through the bore 27 into a pilot valve chamber 30 within the valve member 24.
Bore 27 is normally closed by a pilot valve 31 having a slide portion 32 slidably received in an upper cylindrical recess 33 of the valve member 24. The slide portion 32 is provided with a pair of diametrically opposite flats 34 for providing fluid communication between a transfer chamber 35 and the pilot valve chamber 30.
Slide portion 32 acts as a pilot guide and defines an upper end 36 abutting a lower end 37 of a solenoid plunger 38 in the normally closed arrangement of the valve. A helical coil spring 39 extends between the guide portion 32 and the seating portion 26 of valve member 24 to bias the poppet valve downwardly relative to the guide portion 32. As shown in FIG. 2, however, when plunger 38 is in the outermost position with portion 37 thereof abutting the inner end 36 of the pilot guide portion 34, the plunger urges both the pilot valve and the poppet valve 24 outwardly into the seated arrangements of FIG. 2.
In the normally closed arrangements of the solenoid valve 10, the plunger is biased outwardly by a helical coil spring 43 acting between an inner end portion 40 of the plunger and a plug 41. Spring 43 has a strength greater than spring 39 and, thus, overcomes the spring 39 to arrange the valve components in the normally closed position of FIG. 2.
As further illustrated in FIG. 2, valve member 24 is provided with a bleed passage 42 providing communication between the inlet 20 and the pilot valve chamber 30 at all times. Thus, in the normally closed position wherein the pilot valve 31 is closing the pilot opening 27, fluid pressure at the inlet openings 20 is transmitted through the bleed passage 42 into the pilot valve chamber 30 and acts to maintain the poppet valve member 24 in the closed position illustrated in FIG. 2, in cooperation with the springs 43 and 39.
Pilot valve 31 is moved from the seated position illustrated in FIG. 2 by suitable longitudinal movement of plunger 38 inwardly toward plug 41 under the control of a solenoid coil 44. In the illustrated embodiment, the coil 44 is carried in an annular bobbin 45 mounted within an open-sided, generally parallelepiped shaped, enclosing frame 46 having an inner end 47 and an opposite outer end 48. Frame end 47 is provided with an opening 47a inwardly through which plug 41 extends and frame end 48 is provided with an opening 48a outwardly through which plunger 38 extends. The frame is encapsulated in an outer housing 49 which may be formed of a suitable synthetic resin. The space within the frame surrounding the coil may be filled with a suitable synthetic resin, such as an epoxy resin.
A washer 50 is provided in the housing surrounding the upper end of plug 41, and is provided with an axially turned inner end portion 51 extending outwardly to the outer surface of the housing to be engaged by a nut 52 threaded to the distal threaded end 53 of the plug 41.
End 48 of the frame abuts the adapter 11 radially inwardly of the housing 49 and, thus, nut 52 acting through washer 50 and frame 46 effectively clamps the solenoid structure generally designated 53 to the adapter.
As further illustrated in FIG. 2, a slide tube 54 is secured to the plug 41 as by brazing 55 to extend inwardly of the bobbin 45 and includes a lower end portion 56 received in a suitable recess 57 in the adapter 11. Plunger 38 is reciprocably slidable in the tube 54 between the normally closed position of the valve illustrated in FIG. 2, and an open position of the valve wherein the plunger is raised into abutment with plug 41.
Upper end 36 of pilot valve 32 defines a cylindrical head received in a T section transverse slot 58 provided in the lower end of the plunger 38. The stem portion 59 of the slot is relatively short so as to provide high strength in the end portion 60 of plunger 38 confronting the transfer chamber 35.
A fluid flow passage 61 extends from the T-slot upwardly to a recess 62 receiving coil spring 43 and opening to the space 63 between the upper end 64 of plunger 40 and the lower end 65 of plug 41.
Illustrated in FIG. 2, surface 64 of the plunger is defined by a radially inner frustoconical portion 66 and a radially outer annular planar portion 67. Surface 65, in turn, is defined by a planar radially inner portion 68, a frustoconical midportion 69 and an annular planar outer portion 70.
The length of frustoconical surface portion 66 is made to be slightly less than the length of frustoconical surface portion 69 of plug 41 so that when the plunger is moved inwardly upon energization of the coil 44, surface 67 of the plunger abuts surface 70 of the plug, with the plunger remaining spaced from the planar surface 68 of the plug, thereby to avoid entrapment of fluid in the space 63 upon energization of the solenoid.
Fluid may flow freely from space 63 upon such energization of the solenoid downwardly through recess 62 and passage 61 into T-slot 58. End portion 36 of the pilot valve includes a cylindrical head portion 71 and a reduced diameter cylindrical stem portion 72 connected to the slidable guide portion 32 of the pilot valve. Stem portion 72 has clearance with the plunger portion 60 within the stem portion 59 of the T-slot so that fluid may flow freely downwardly past the stem portion 72 of the pilot valve end portion into the transfer chamber 35.
As indicated above, the slidable guide portion 32 of the pilot valve is provided with at least a pair of diametrically opposite flats 34 defining flow passages for permitting flow of the entrapped fluid outwardly therethrough into the pilot valve chamber 30 for delivery with the fluid flowing through the valve in the open condition of the valve.
As shown in FIG. 2, outer end surface 90 of the plunger is urged against an inner end surface 91 of guide portion 32 of the pilot valve. As shown, the axial length of head 71 and stem 72 of guide portion 36 is less than the spacing between surface 90 and the inner end 92 of T-slot 58 to provide clearance with the guide head 71 to permit fluid flow between flow passage 61 and T-slot 58 at all times.
By maintaining the plunger spaced from end surface 68 at all times, entrapment of fluid between the plunger and plug is effectively prevented. By providing the improved fluid flow passages, including the diametrically extending T-slot and the flats on the guide portion 32 of the pilot valve, improved free movement of the pilot valve is provided for improved functioning of the valve structure 10.
The solenoid valve 10 is adapted, as indicated above, to be mounted to a port, such as port 73 illustrated in FIG. 1, having a threaded opening 74 to which threaded portion 12 of the adapter 11 is threaded, with the seat member 14 disposed innermost within the port opening. As indicated above, sealing ring 16 seals the valve to the port about the opening 74 and the O-ring 17 seals the seat member to the port within the opening to provide a sealed fluid passage through the valve within the port.
As illustrated in FIG. 5, the invention further comprehends the provision of a modified form of poppet valve generally designated 110 similar to poppet valve 10 but wherein the pilot valve guide portion 132 is slidably received in a pilot guide 175 clamped between the seat member 114 and the adapter 111.
Thus, as more specifically illustrated in FIG. 5, pilot guide 175 includes a radially inner portion 176 slidably receiving the pilot valve guide portion 132, and an annular outturned portion 177 defining a radially and axially outwardly opening annular corner recess 178 seating against the inner end of the seat member 114 when the seat member is threaded fully into the adapter threaded end 113.
As shown in FIG. 5, the pilot valve spring 139 extends between the outturned portion 177 of the pilot guide and the outer end of the poppet valve member 124.
The pilot valve member is provided with a bleed passage 142 providing communication at all times between the inlet 120 and the pilot valve chamber 130.
The combination of the pilot guide 175, poppet valve member 124 and seat member 114 illustrated in FIG. 5 comprises one set of a plurality of different size cooperating sets of such adapters, poppet valve members and seat members each having the same pilot valve seat configuration so that the same pilot valve structure may be used with a line of valves differing only in the flow capacity provided by the different size poppet valves and seat members. Thus, the pilot guides may be adapted for such a wide range of valve capacities by varying the radial extent of the outturned portion 177 to mate with the selected seat member 114 and complementary valve member 124.
Other than for the use of the pilot guide 175 providing for adaption of the solenoid valve structure to a wide range of different size fluid control valves utilizing the same pilot valve configuration, poppet valve structure 110 is similar to poppet valve structure 10 and functions in a similar manner.
Referring now to the embodiments of FIG. 6, a poppet valve generally similar to poppet valve 10 but arranged to function in a normally open manner, is shown to comprise a poppet valve structure generally designated 210. The solenoid structure 253 is generally similar to solenoid structure 53 except that a threaded cap 252 is provided on the threaded end 279 of the plug 241 fitting to a projecting end 280 of the slide tube.
The plunger 240 is slidably received in the slide tube within the solenoid structure 253. The plunger defines an outer frustoconical end 281 having a planar distal end surface 282. A pilot housing 283 is retained coaxially within the outer end of the slide tube and defines a frustoconical recess 284 complementary to the frustoconical end 281 of the plunger.
The pilot housing further defines a through bore 285 opening outwardly into the pilot chamber 230.
Pilot valve 231 includes an inwardly projecting rod 286 which extends inwardly into abutment with the plunger surface 282, as shown in FIG. 5.
The pilot valve further defines an annular flange 287. A pilot valve biasing spring 239 is seated inwardly against flange 287 and outwardly against a spring retainer plate 288 clamped between the seat member 214 threaded to the adapter 211.
The pilot valve stem 272 extends outwardly through a suitable opening 289 in the spring retainer plate.
Spring 239 normally biases the pilot valve inwardly permitting fluid pressure from inlet openings 220 to urge the poppet valve 224 from the valve seat 225. However, when solenoid structure 253 is energized, the plunger 240 is urged outwardly moving the pilot valve rod 286 outwardly and thereby urging the pilot valve outwardly against the poppet valve 224 so as to move the poppet valve into seated relationship with valve seat 225, thereby closing the valve.
Thus, the normally open valve structure 210 is similar to the normally closed valve structure except for the rearrangement of the parts to provide the normally open functioning.
As discussed above, each of valve structures 110 and 210 is generally similar in structure and functioning to valve structure 10 and similar elements thereof are identified by similar reference numerals except for being 100 and 200 higher, respectively.
The foregoing disclosure of specific embodiments is illustrative of the broad inventive concepts comprehended by the invention. | A cartridge solenoid poppet valve (10) arranged to use a single size pilot valve (31) with any one of a set of a plurality of different size sets of valve seat members (14) and poppet valves (24). Pilot guides (175) are provided having different transverse extents to accommodate such different size valve members. The valve further includes a flatted pilot guide (32) defining flow passages communicated between a transfer chamber (35) and a pilot valve chamber (30) in which the pilot valve (31) is disposed. A T-slot (58) is provided in the solenoid plunger (38) extending fully diametrically thereacross and the pilot valve includes a T-shaped connecting head (71) received therein. The plunger (38) and plug (41) define cooperating stop surfaces (67,70) for maintaining a small spacing between the plunger and plug at all times. | 5 |
TECHNICAL FIELD
The present invention relates to Session Initiation Protocol message handling in a communications network.
BACKGROUND
IP Multimedia Subsystem (IMS) is the technology defined by the Third Generation Partnership Project (3GPP) to provide IP Multimedia services over mobile communication networks (3GPP TS 22.228). IMS provides key features to enrich the end-user person-to-person communication experience through the integration and interaction of services. IMS allows new rich person-to-person (client-to-client) as well as person-to-content (client-to-server) communications over an IP-based network.
The IMS makes use of the Session Initiation Protocol (SIP) to set up and control calls or sessions between user terminals (UEs) or between UEs and application servers (ASs). SIP is described in RFC3261. The Session Description Protocol (SDP), carried by SIP signalling, is used to describe and negotiate the media components of the session. Whilst SIP was created as a user-to-user protocol, IMS allows operators and service providers to control user access to services and to charge users accordingly.
Within an IMS network, Call/Session Control Functions (CSCFs) operate as SIP entities within the IMS. The 3GPP architecture defines three types of CSCFs: the Proxy CSCF (P-CSCF) which is the first point of contact within the IMS for a SIP terminal; the Serving CSCF (S-CSCF) which provides services to the user that the user is subscribed to; and the Interrogating CSCF (I-CSCF) whose role is to identify the correct S-CSCF and to forward to that S-CSCF a request received from a SIP terminal via a P-CSCF.
IMS service functionality is implemented using application servers (ASs). For any given UE, one or more ASs may be associated with that terminal. ASs communicate with an S-CSCF via the IMS Service Control (ISC) interface and are linked into a SIP messaging route as required (e.g. as a result of the triggering of IFCs downloaded into the S-CSCF for a given UE).
A user registers in the IMS using the specified SIP REGISTER method. This is a mechanism for attaching to the IMS and announcing to the IMS the address at which a SIP user identity can be reached. In 3GPP, when a SIP terminal performs a registration, the IMS authenticates the user using subscription information stored in a Home Subscriber Server (HSS), and allocates a S-CSCF to that user from the set of available S-CSCFs. Whilst the criteria for allocating S-CSCFs is not specified by 3GPP, these may include load sharing and service requirements. It is noted that the allocation of an S-CSCF is key to controlling, and charging for, user access to IMS-based services. Operators may provide a mechanism for preventing direct user-to-user SIP sessions that would otherwise bypass the S-CSCF.
Further signalling sent to and from the user is also controlled using SIP signalling. Each SIP client between the two end-points of the signalling uses the Domain Name System (DNS) to route the signalling and find the next hop to route the request. SIP uses several mechanisms for routing requests between hops. One of the key mechanisms used is rewriting the Request-URI in he header of the SIP message to the next hop to which the request will be routed. This will cause the original target identity in the header to be replaced with an address of an intermediate hop. The original target address is lost, and this can cause problems in scenarios where the receiver requires knowledge about the target address that was used to address that receiver.
For example, in the case where a single User Agent (UA) has multiple addresses associated with it, a single address is registered and the UA would accept incoming signalling sent to any of the associated addresses. It is desirable for the UE to know which of the addresses is being used when it receives, for example, a call, as it may play different ring tones depending on which address was used by the originator of the call. However, if the Request-URI is re-written then UA will not know which address was used to make the call.
Another example where the problem arises is in making a call for emergency services using Voice over IP (VoIP). A SIP INVITE request for an emergency must be marked to indicate that it is an emergency call in order that it can receive priority treatment. The marking is made to the target address of the request itself, to identify the target as being a recipient of emergency service calls. The Request-URI contains an SOS URN, which must remain in the Request-URO as the request is routed towards the emergency services target. However, this is lost if any of the intermediate nodes re-write the Request-URI.
More examples of scenarios where re-writing the request causes a problem can be found in internet draft IETF draft-rosenberg-sip-ua-loose-route-01. The cases where Request-URI rewrites occur are as follows:
Retarget: In this case, the Request URI contains a new target address, and so the end target is no longer the original end target; Reroute: In this case, the target address remains the same but a different or intermediary route is chosen to reach the same user, and so the Request-URI is rewritten to contain the routing address Translation: In this case a name (URN) is translated to an address.
The problem described above has been partly addressed by using the Route header, together with loose routing (http://tools.ietf.org/html/rfc3261). According to loose routing, the Request-URI is not overwritten, and so it will always contains the URI of the target UA. The SIP request is sent to the URI in the topmost Route header field, and so the Request-URI does not always contain the URI of the next hop to which the request will be sent. Effectively, the request target and the next route destination are kept separate in the SIP request header.
Another part of the problem has been solved on the last hop from a home proxy to the UA, in which a P-Called-Party-ID header retains the Request-URI value which had been replaced by the contact address of the registered user (see http://tools.ietf.org/html/rfc3455).
The internet draft (http://tools.ietf.org/html/draft-rosenberg-sip-ua-loose-route-01) proposes to extend the routing mechanism by extending the loose routing concept to the UE. However, there are several problems with this that need to be addressed. A simple extension of loose routing to UEs would not work unless the target node for the next physical hop supports loose routing. Each entity in the path must therefore know that the next-hop entity supports loose routing. If previous entities in the signalling path have used the loose routing mechanism, and an entity realizes that the next hop does not support it, it must “fix” the message by restoring the correct value back into the R-URI in order for that next hop to be able to process and route the message correctly.
Furthermore there are services that rely on receiving entities having knowledge of the “previous” R-URI that will only work if entities (which have nothing to do with the service as such) in the message path support the mechanism, which makes the usage of such services very limited and unpredictable.
Examples of scenarios in which the application of the loose routing mechanism to UEs would make the SIP routing fail include the following:
1. An intermediate SIP proxy (such as a Call Session Control Function in an IMS network) that does not support the loose routing mechanism. Such a SIP proxy would receive a Route header with one entry representing the proxy, and remove the Route entry. The proxy would then attempt to route the message based on the Request URI, using RFC 3263 procedures, and find the first proxy that the target identity resolves to. This would result in a loop back to the first proxy that the target normally resolves to, and so consequently routing would fail.
2. A Home SIP proxy that does not support the mechanism. In this case the home SIP proxy would receive a Route header with one entry representing the Home SIP proxy and remove the Route entry. The Home proxy would then analyse the Request URI to see if it is a registered Address of Record (AoR). Of course, it will not be and so the Home SIP proxy will attempt to route the message based on the Request URI, using RFC 3263 procedures. It will find the first proxy that the target identity resolves to, resulting in a loop back to the first proxy that the target normally resolves to, and so consequently routing would fail.
3. A Media Gateway Control Function (MGCF) that receives a request that has been routed using the loose routing mechanism may find a Uniform Resource Name (URN) in the Request URI. The MGCF cannot interwork with the URN and so call setup fails.
SUMMARY
The inventors have realised the problems associated with extending the loose routing mechanism, and devised a method and apparatus to address this.
According to a first aspect of the invention, there is provided a method of handling Session Initiation Protocol message in a communications network. A network node receives a Session Initiation Protocol (SIP) message, which comprises Request-URI header. The node rewrites the Request-URI header in the SIP message, and adds information to the SIP message useable by a remote node to determine the current target address of the message. The SIP message is then sent to a further node. In this way, any remote node that receives the message can determine the current target in the SIP message, even if the target has been re-written in the Request-URI as the result of a translation or re-routing operation. The information may include, for example, information identifying the current target identity or information identifying where a Request-URI has been re-written as a result of a re-target operation. The current target address may optionally be the original target address of the message or, in the case where the Request-URI has been re-written owing to a retarget operation, the current target address is the address as re-written by the retarget operation.
Optionally the information useable by the remote node to determine the current target address of the message comprises a new message header, the header including the current target identity. This is referred to herein as a “Target” header. In an alternative embodiment, the information useable by the remote node to determine the current target address of the message comprises a tag associated with the entry in a History-Info header of the message. The tag indicates that the entry arose from a re-target operation. In this case, the node optionally removes existing tags associated with previous target address entered in the History-Info header, and associates a tag with the current target address entered in the History-Info header. This reduces the size of the SIP message.
According to a second aspect of the invention, there is provided an intermediate node for use in a communications network. The intermediate node, which may be a SIP proxy such as an IMS Call Session Control Function, comprises a receiver for receiving a Session Initiation Protocol message. A processor is provided for rewriting a Request-URI header in the SIP message and adding information to SIP message useable by a remote node to determine the current target address of the message. The intermediate node further comprises a transmitter for sending the SIP message to a further node. By providing the information, a remote node can determine the current target address even if the target has been re-written in the Request-URI as the result of a translation or re-routing operation.
The processor is optionally arranged to insert a new message header in the SIP message, the header including the current target identity. Alternatively, the processor is optionally arranged to add a tag to an address entry in a History-Info header of the message, the tag indicating that the entry arose from a re-target operation. In a further alternative, the processor is arranged to add a tag to an address entry in a History-Info header of the message, the tag indicating that the entry contains a target address of the message.
According to a third aspect of the invention, there is provided a node for use in a communications network, the node comprising a receiver for receiving a SIP message, and a processor for determining, on the basis of information added to the message by an intermediate node between an originating node and the node, the current target address of the message. The node can therefore determine the current target address of the SIP message even if the target has been re-written in the Request-URI as the result of a translation or re-routing operation by an intermediate node. The node may be a terminating node such as User Equipment, or may be an intermediate node such as an Application Server.
Optionally, the processor is arranged to determine the current target address of the message by determining the contents of a target header inserted in the message by the intermediate node prior to sending the message to the node. In an alternative option, the processor is arranged to determine the current target address of the message by analysing tagged entries in a History-Info header of the message.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram illustrating the basic steps of an embodiment of the invention;
FIG. 2 is a signalling diagram showing example signalling according to embodiments of the invention;
FIG. 3 illustrates schematically in a block diagram an intermediate node in a SIP signalling path according to an embodiment of the invention; and
FIG. 4 illustrates schematically in a block diagram a terminating node according to an embodiment of the invention.
DETAILED DESCRIPTION
In order to overcome the problems described above, it is proposed that a SIP message retains the original target information in a separate information element from the Request-URI. Ways in which this can be achieved include introducing a new SIP header, and extending the usage of the existing History-Info header.
New Target SIP Header
A new header, referred to herein as a “Target” header, is inserted into a SIP message by a SIP entity whenever the Request-URI is rewritten by the SIP entity (assuming that a Target header is not already present in the SIP message), and the rewriting is due to a rerouting of the request. If the Target header is already present in the SIP message, and the Request-URI is rewritten due to a retarget operation, then the Target header is rewritten with the new target. The Target header includes the initial target identity that was used to generate the message. In a further alternative, the Target header is removed in the case of retargeting.
If the Target header is available on the request and the Request-URI is rewritten due to a re-route or translation operation, the Target header will be left unchanged.
For all alternatives in this embodiment, a receiving entity that receives a SIP message containing a Target header can determine the current target from the Target header field.
Furthermore, for all alternatives in this embodiment a receiving entity that receives a SIP message not containing a Target header can determine the current target from the Request-URI.
If a SIP entity, which acts as registrar/home proxy for the terminating user, re-writes the Request-URI with the contact address of the registered UA it may additionally insert a P-Called-Party-ID header field with the previous value of the Request-URI, as described in RFC3455.
Note that the Target header field and P-Called-Party-ID header fields have different semantics. Where the Target header field represents the initial target identity that was used to initiate a session to the target, the P-Called-Party-ID represents the last AoR used to reach the user before Request-URI value for cases where the last route taken presents significant information.
Extending History-Info Usage
The History-Info header (RFC4244) is a blind record of values that a Request URI has had in the course of the message being routed. Consequently this header also contains the target for the current request.
An alternative to the new Target header solution described above is to extend the use of the History-Info header by marking the entry in the History-Info header recording the current target of the request. When a SIP message traverses a SIP entity supporting this extension and the SIP entity re-writes the Request-URI value due to a retarget operation, the SIP entity adds the previous Request-URI value into an entry of the History-Info header field and additionally it tags that entry as a retarget entry. In order for a receiving entity to determine which History-Info header entry is pointing towards the intended target, it can lookup the last History-Info entry that is tagged as being due to a retarget operation, or when no entry is tagged, to use the first entry. The sequence of tagged entries provides a target trail as a meta level in the history.
In a further alternative, only the current target of the request is marked. When a SIP message traverses a SIP entity supporting this extension and the SIP entity re-writes the Request-URI value due to a retarget operation, the SIP entity adds the previous Request-URI value into an entry of the History-Info header field and additionally it tags that entry as a retarget entry. The SIP entity additionally removes such tags from previous History-Info elements. In order for a receiving entity to determine which History-Info header entry is pointing towards the intended target, it can lookup the last History-Info entry that is tagged as being due to a retarget operation, or when no entry is tagged to take the first entry.
In a further alternative mechanism, only re-targets are recorded in the History-Info header, although that may be incompatible with SIP elements that implement the current RFC4244. In order for a receiving entity to determine the current target, it looks up the last History-Info entry.
For all alternatives in this embodiment, a receiving entity that receives a SIP message not containing a History-Info header can determine the current target from the Request-URI.
If the SIP entity acts as registrar/home proxy for the terminating user, it re-writes the Request-URI with the contact address of the registered UA and it may additionally insert a P-Called-Party-ID header field with the previous value of the Request-URI, as described in RFC3455.
The alternative embodiments described above can be summarized in the flow diagram of FIG. 1 , with the following numbering corresponding to the numbering in the Figure:
1. A SIP message is received at a SIP proxy node, for example a CSCF in an IMS network; 2. The node re-writes the Request-URI header of the SIP message; 3. The node checks to see if the Request-URI rewrite is due to a retarget operation. If so, then move to step 4 , if the retarget is due to a reroute or translation operation, then move to step 6 ; 4. Where the target header embodiment is used, check to see if a target header is already present in the SIP message. If so, then move to step 5 , if not then move to step 8 . Where the History-Info header embodiment is used, the node checks to see if the current recorded target is tagged in the History-Info header. If so, then move to step 5 , if not then move to step 8 ; 5. Where the target header embodiment is used, the target header is either removed or rewritten with the new target, then move to step 8 . Where the History-Info header embodiment is used, the history entry that represents the new current target is tagged. Additionally a tag may be removed from a previously tagged entry. Then move to step 8 ; 6. Where the target header embodiment is used, check to see if a target header is already present in the SIP message. If so, then move to step 8 , if not then move to step 7 . Where the History-Info header embodiment is used, the node checks to see if the current recorded target is tagged in the History-Info header. If so, then move to step 8 , if not then move to step 7 ; 7. Where the target header embodiment is used, a target header is inserted into the SIP message with the Request URI value before the retarget operation. Where the History-Info header embodiment is used, no further action is required. 8. The SIP message is sent to a further node in the communications network.
Referring to FIG. 2 , an example signalling diagram is shown. Where the target header embodiment is used, message 1 from UEA to rerouting intermediary 1 is a SIP INVITE message including target1 in the Request URI. The following correspond to the route and target for each message in the signalling sequence:
m1
INVITE
target1
m2
INVITE route1
Target: target1
m3
INVITE route2
Target: target 1
m4
INVITE target2
m5
INVITE route3
Target: target2
In another target header embodiment, the signalling sequence shown in FIG. 2 is as follows:
m1
INVITE
target1
m2
INVITE route1
Target: target1
m3
INVITE route2
Target: target 1
m4
INVITE target2
Target: target 2
m5
INVITE route3
Target: target2
Where the History-Info header is used, an example the signalling sequence according to FIG. 2 is as follows:
m1
INVITE
target1
m2
INVITE route1
History-Info:
<target1>;index=1; targetentry,
<route1>;index=1.1
m3
INVITE route2
History-Info:
<target1>;index=1; targetentry,
<route1>;index=1.1
<route2>;index=1.1.1
m4
INVITE target2
History-Info:
<target1>;index=1; targetentry,
<route1>;index=1.1
<route2>;index=1.1.1
<target2>;index=1.1.1.1;targetentry
m5
INVITE route3
History-Info:
<target1>;index=1; targetentry,
<route1>;index=1.1
<route2>;index=1.1.1
<target2>;index=1.1.1.1;targetentry
<route3>;index=1.1.1.1.1
In another History-Info header embodiment, an example the signalling sequence according to FIG. 2 is as follows:
m1
INVITE
target1
m2
INVITE route1
History-Info:
<target1>;index=1; targetentry,
<route1>;index=1.1
m3
INVITE route2
History-Info:
<target1>;index=1; targetentry,
<route1>;index=1.1
<route2>;index=1.1.1
m4
INVITE target2
History-Info:
<target1>;index=1; [Note the target entry tag has been removed]
<route1>;index=1.1
<route2>;index=1.1.1
<target2>;index=1.1.1.1;targetentry
m5
INVITE route3
History-Info:
<target1>;index=1;
<route1>;index=1.1
<route2>;index=1.1.1
<target2>;index=1.1.1.1;targetentry
<route3>;index=1.1.1.1.1
Referring to FIG. 3 , there is illustrated schematically a node for use in a communications network. The node 6 could be, for example, a SIP proxy node in an IMS network, such as a CSCF. The node 6 has a receiver 7 for receiving a SIP message, and a processor 9 for rewriting the Request-URI header in the SIP message and adding information (either a new target header or tagging entries in the History-Info header as described above). The node further comprises a transmitter 8 for transmitting the SIP message to a further node.
Referring to FIG. 4 , there is illustrated schematically a terminating node, such as a UE. The terminating node 10 comprises a receiver 11 for receiving a SIP message, and a processor 12 for determining whether the contents of the Request-URI header included in the received SIP message are different from the contents of the Request-URI of the message as originally sent. In this way the terminating node can determine the original target address, and use this for executing policies on behalf of the user or services to the user.
EXAMPLES
The following are examples of how the new Target header described above can be used. However, the extended History-Info usage could be used in the following examples in a similar manner.
1. Unknown Aliases:
A single UA may have multiple AoRs associated with it, for example to use as aliases. It would be desirable for the recipient of a call to know which alias the call was addressed to. The P-Called-Party-ID header field (RFC3455) was introduced to address the scenario of unknown aliases, and the new Target header field would also address this issue.
2. Unknown Globally Routable User Agent URI (GRUU)
A GRUU is a URI assigned to a UA which has many of the same properties as the AoR, but causes requests to be routed only to that specific instance. In some circumstances it may be desirable for a recipient of a call to know whether the call was addressed using its GRUU or its AoR. This is a variant of the “Unknown Aliases” problem, and is addressed by RFC3455. The new Target header field also solves this issue for GRUU's used as initial target.
3. Limited Use Addresses
A limited use address is a SIP URI that is created and provided to a UA on demand. Incoming calls are only accepted whilst the UA desires communications addressed to that URI. Limited use addresses are used in particular to combat voice spam. This is another variant of the “Unknown Aliases” problem, and is addressed by RFC3455. The new Target header field also solves this issue.
4. Sub-Addressing
A sub-address is an address within a sub-domain that is multiplexed with other sub-addresses into a single address with a parent domain. This is used, for example, by employees of small companies, or family groups that wish to have separate sub-addresses by which they can be contacted. The sub-addressing feature is not currently available using SIP because a SIP URI parameter used to convey the sub-address would be lost at the home proxy, due to the fact that the Request-URI is rewritten there. This problem is overcome using the new Target header field.
5. Service Invocation
A URI can be used to address a service within the network rather than a subscriber. The URIs can include parameters that control the behaviour of the service. However, when a proxy has re-written the Request-URI to point to the service, there is no guarantee that the Request-URI will not be re-written by a further proxy in the signal path. The new Target header field would solve this scenario as it will retain the original complex URI, containing all the service invocation information.
6. Emergency Services
A key requirement of systems supporting emergency calling is that a SIP INVITE request for an emergency call is ‘marked’ in some way to ensure that the network knows that the SIP INVITE relates to an emergency call, and accord a priority to the SIP signalling. To avoid abuse by attackers, the marking is applied to the target address of the request itself. This mechanism will not work if any of the proxies along the way try to rewrite the Request-URI for the purposes of directing the call to a proxy or UA that will handle the call. However, the new Target header field solves this scenario as it will retain the emergency URN.
7. Freephone Numbers
Freephone numbers allow a user to call a number without being charged. If an intermediate node in the signalling path re-writes the Request-URI, a charging function may not recognize that the user should not be charged for the call. The new Target header field would solve this scenario as it retains the Freephone Number.
Whilst beyond the scope of this specification, it should be noted that the invention reveals to the UA the target address used to contact the UA, which was previously hidden. There may be circumstances in which it would be undesirable to reveal this information to the UA, in which case the home proxy should remove the header (or other indication) containing the target address.
The invention allows corporate networks and receiving UEs to know under which target identity a request was forwarded. Only the relevant target identity need be retained, and not a history of Request URI rewrites. This improves the efficiency of bandwidth usage and processing. Furthermore, the invention does not interfere with the existing routing mechanism and is compatible with home proxies that do not support loose routing. There is no need for entities using the mechanism to have knowledge whether the next hop supports it, and there is no need for the terminating UA to inform its home proxy whether it supports the mechanism or not. The invention does not require the terminal to support loose routing, and so is backwards compatible. In a scenario in which one of the traversed proxies does not understand the mechanism, routing will still succeed as the routing mechanism of SIP itself is not changed. The worst thing that can happen is that a terminating UA might receive incorrect information about the intended target identity by which it has been reached. The Target header might carry information identifying a forwarding party, where the forwarding party does not want to reveal its identity.
The invention is fully backward compatible with MGCFs that use the Request-URI value for mapping and routing towards a PSTN network, according to the interworking procedures described in RFC3398, 3GPP TS 29.163 and ITU-T Recommendation Q.1912.5.
It will be appreciated by the person of skill in the art that various modifications may be made to the embodiments described above without departing from the scope of the present invention. For example, many of the examples provided above use IMS as an example network, but it will be appreciated that the invention applies to any communications network that uses SIP signalling. | A method and apparatus for handling a Session Initiation Protocol message in a communications network. When a network node receives a Session Initiation Protocol message, which comprises Request-URI header, the node rewrites the Request-URI header in the SIP message, and adds information to the SIP message useable by a remote node to determine the current target address of the message. The SIP message is then sent to a further node. In this way, the remote node that receives the message can determine the current target in the SIP message, even if the target has been re-written in the Request-URI as the result of, for example, a translation or re-routing operation. | 7 |