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BACKGROUND ART
1. Field of the Invention
The present invention is generally directed toward an edge cleaning device for a coated web, and more particularly to a non-contact edge cleaning device for a moving web that has been coated and transported with the benefit of rollers.
2. Description of the Background Art
The following discussion of the background art is a result of the present inventors analysis of the systems and features of the related technology of the background art. The present inventors have determined that there are unique problems associated with coated webs and the available technology related to the cleaning of coated webs, particularly along the edges of coated webs moving through a coating or other similar process.
U.S. Pat. No. 3,351,039 to Heisterkamp, the entirety of which is hereby incorporated by reference, describes an exemplary roll cleaning device of the background art particularly designed to clean the edges of a sheet coating roll. Heisterkamp describes problems associated with the coating of certain sheet materials, such as sheets coated with latex materials. Often the coated sheet is applied with a coating in a quantity greater than the desired coating thickness to ensure full or adequate coverage over the sheet. The coated sheet is then carried over a backing roll where a proper coating weight is achieved by a knifing action of an air jet. The excess coating is subsequently sheared off to a collection pan below the air jet. The excess coating often carries over the edges of the sheet with the result that the backing roll is eventually coated with the excess coating material.
As seen in FIG. 1 of the present application, a coating is applied between a coating roll 22 pressed against a rubberized backing roll 20 in an exemplary coating process. However, another problem encountered in coating the web 10 is that some of the excess coating will try to wrap around the moving web from a first coated side 12 (underside of the web 10 ) to an opposite, typically uncoated side 14 both upstream of and at the backing roller 20 . The present inventors have determined that there are variety of edge cleaning approaches that can be advantageously applied to overcome these problems associated with coated, moving webs moving through similar processes.
SUMMARY OF THE PRESENT INVENTION
The present invention overcomes the shortcomings associated with the background art and achieves other advantages not realized by the background art.
An aspect of the present invention, in part, is directed toward an edge cleaner device for a moving web that is capable of cleaning the edge of a moving web both at and before (upstream) of a backing or coating roller.
An aspect of the present invention, in part, is directed toward an edge cleaner device for a moving web that is capable of cleaning the edge of a moving web while minimizing undesirable carryover of excess coating to uncoated portions of the moving web.
An aspect of the present invention, in part, is directed toward an edge cleaner device for a moving web that is capable of cleaning the edge of a wide range of sizes of moving web(s) and automatically aligning and positioning the edge cleaner device with respect to the outside edge or width of the moving web.
One or more of the foregoing aspects of the present invention is accomplished, in part, by an edge cleaning device for an outside edge of a moving, coated web, the device comprising a nozzle assembly imparting a fluid jet toward the outside edge of the moving, coated web; and a scraper device operatively secured with the nozzle assembly to a common carriage, wherein the nozzle assembly and the scraper device are capable of being simultaneously positioned by the carriage along the outside edge of the moving, coated web.
One or more of the foregoing aspects of the present invention is also accomplished, in part, by an edge cleaning device for an outside edge of a moving, coated web, the device comprising a nozzle assembly imparting a fluid jet toward the outside edge of the moving, coated web; and a collection container operatively secured with the nozzle assembly to a common carriage, wherein the collection container and the nozzle assembly are capable of being simultaneously positioned by the carriage along the outside edge of the moving, coated web, and the fluid jet of the nozzle assembly is directed in a direction toward an opening of the collection container.
One or more of the foregoing aspects of the present invention is also accomplished, in part, by a system for cleaning an outside edge of a moving, coated web, the system comprising a moving, coated web; a roller for operatively engaging the moving, coated web; a movable carriage supporting an edge cleaning device; a nozzle assembly imparting a fluid jet toward the outside edge of the moving, coated web; and a scraper device operatively secured with the nozzle assembly to the movable carriage, wherein the nozzle assembly and the scraper device are capable of being simultaneously positioned by the carriage along the outside edge of the moving, coated web.
One or more of the foregoing aspects of the present invention is also accomplished, in part, by a system for cleaning an outside edge of a moving, coated web, the system comprising a moving, coated web; a roller for operatively engaging the moving, coated web; a movable carriage supporting an edge cleaning device; a nozzle assembly imparting a fluid jet toward an outside edge of the moving, coated web; and a collection container operatively secured with the nozzle assembly to the movable carriage, wherein the collection container and the nozzle assembly are capable of being simultaneously positioned by the carriage along the outside edge of the moving, coated web, and the fluid jet of the nozzle assembly is directed in a direction toward an opening of the collection container.
One or more of the foregoing aspects of the present invention is also accomplished, in part, by a method of cleaning an outside edge of a movable, coated web, the method comprising positioning an edge cleaner device with respect to an outside edge of a movable, coated web, wherein the edge cleaner device is positioned upstream from a roller for operatively engaging the moving, coated web; imparting a fluid jet from a nozzle assembly of the edge cleaner device toward an underside and an outside edge of the moving, coated web; and simultaneously positioning a scraper device along the outside edge of the moving, coated web, wherein the scraper device is operatively engaged with an upper surface of the moving web without contacting a surface of the roller.
One or more of the foregoing aspects of the present invention is also accomplished, in part, by a method of cleaning an outside edge of a movable, coated web, the method comprising positioning an edge cleaner device with respect to an outside edge of a movable, coated web, wherein the edge cleaner device is positioned upstream from a roller for operatively engaging the moving, coated web; imparting a fluid jet from a nozzle assembly of the edge cleaner device toward an underside and the outside edge of the moving, coated web; and simultaneously positioning a collection container operatively secured with the nozzle assembly, wherein the collection container and the nozzle assembly are simultaneously positioned along the outside edge of the moving, coated web, and the fluid jet of the nozzle assembly is directed in a direction toward an opening of the collection container.
Further scope of the applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinafter and the accompanying drawings that are given by way of illustration only, and thus do not limit the present invention.
FIG. 1 is a side view of a coated web moving past a backing roller and an edge cleaner device of the present invention;
FIG. 2 is a perspective view of an edge cleaner device according to an embodiment of the present invention;
FIG. 3 is a schematic view of an edge cleaner device according to an embodiment of the present invention;
FIG. 4 is perspective view of an edge cleaner device according to an embodiment of the present invention;
FIG. 5 is a perspective view of a scraper blade device according to an embodiment of the present invention;
FIG. 6 is a schematic view of a scraper device being applied to an underside of a moving web;
FIG. 7 is a schematic view of a scraper device being applied to an underside of a moving web; and
FIG. 8 is a schematic view of a scraper device being applied to an underside of a moving web.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with reference to the accompanying drawings. The present inventors have analyzed the needs of the background art and identified several shortcomings associated with the systems of the background art. FIG. 1 is a side view of a coated web moving past a backing roller and an edge cleaner device of the present invention. FIG. 2 is a perspective view of an edge cleaner device according to an embodiment of the present invention. FIG. 3 is a schematic view of an edge cleaner device according to another embodiment of the present invention. FIG. 4 is perspective view of an edge cleaner device according to another embodiment of the present invention.
As seen in FIG. 1 , a coating is applied to a moving web 10 having a first coated side 12 and a second, uncoated side 14 moving through a process along a first process direction W. The web 10 is moved between a coating roll 22 (as seen in FIG. 3 in a retracted position) pressed against a rubberized backing roll 20 in order to ensure an even distribution of the coating applied to the web 10 . However, the present inventors have determined that some of the coating will appear to wrap around the moving web 10 from a first coated side 12 to an opposite, typically uncoated side 14 both before (upstream with respect to direction W) and at the backing roller 20 .
A first edge cleaning device of the present invention can incorporate a thin scraper device 30 , e.g., a blade is shown in FIG. 1 , constructed of foil or other thin metal, or thin non-metallic substances exhibiting non-stick properties such as Teflon (tetrafluoroethylene). The scraper device 30 is arranged to be positioned generally in parallel to the moving direction W of the web 10 . As seen in FIG. 1 , a portion of the scraper device 30 is positioned in contact with the moving web 10 and with a portion of the rubberized backing roll 20 . Accordingly, the scraper device 30 is designed to scrape away any excess coating attempting to carryover from the coated side 12 of the web to the surfaces of the backing roll 20 and/or the underside of the web, e.g., the uncoated side 14 of the web.
However, the present inventors have determined that abrasion marks form over time in the surface of the rubberized backing roll. In order to compensate for the effects of the scraper device 30 , coating runs are often scheduled so that the widest webs are ran through the rollers 20 , 22 first and the narrower webs are then gradually processed as the rubberized backing roll 20 is abraded or otherwise worn. After repeated coating runs, the rubberized backing 20 typically requires replacement resulting in costly machine down times and/or maintenance and repair.
Alternatively, the present inventors have determined that the scraper device 30 can be optimally positioned so that it only contacts the moving web, e.g., and does not significantly contact the surface of the backing roll 20 . The inventors have determined that this approach is successful in minimizing carryover of excess coating to the surfaces of the backing roller 20 and/or the underside 14 of the moving web 10 . The scraper device 30 rides only on the paper web 10 to the edge but does not overlap to touch the adjacent backing roller 20 surface (as shown in FIG. 1 ).
Accordingly, by not touching the backing roller 20 surface, the problem of marring of the roll is effectively eliminated. However, the present inventors have determined that additional features in combination with the optimized scraper device 30 and/or standing alone, when incorporated into a non-contact edge cleaning device will further optimize and/or offer alternative approaches to minimizing carryover of excess coating along the edge of the moving web. For example, the scraper device 30 preferably rides only on the paper web, e.g., riding on the underside or uncoated side 14 of the paper web 10 to the edge of web but not overlapping to touch an adjacent roller, e.g., such as backing roller 20 .
Alternatively, the scraper device 30 is preferably applied to a slightly or moderately tensioned web without need for a backing roll, e.g., the use of a backing roller 20 may be optional. In a more preferred embodiment, the scraper blade is positioned at about a 90° angle θ to the underside or uncoated side 14 of the paper web as part of the moveable carriage 70 assembly, although a wide range of angles may be employed as discussed in greater detail hereinafter. The scraper blade or scraper device 30 can be integral to the carriage assembly or a separately supported and movable component. By riding on the uncoated underside of the web, any coating that wraps around the web is easily and conveniently removed by scraper device 30 and the water jet of nozzle assembly 50 . The scraper device 30 is positioned in proximity to collecting container 40 and nozzle assembly 50 . The fluid jet from nozzle assembly 50 is directed toward the underside edge of the moving web (and in the direction of container 40 ) so as to direct excess coating toward container 40 . Therefore, any remaining coating or water wrapping around to uncoated side 14 is conveniently removed by scraper device 30 .
FIG. 6 is a schematic view of a scraper blade device being applied to an underside of a moving web. FIG. 7 is a schematic view of a scraper device (blunt object) being applied to an underside of a moving web. FIG. 8 is a schematic view of a scraper device (roller) being applied to an underside of a moving web. The role of the scraper device 30 is to remove any excess fluid or coating remaining or wrapping around to the uncoated underside 14 of the web. It will be readily evident to the skilled artisan that scraper device 30 can take the form of a blade ( FIG. 6 ), blunt object ( FIG. 7 ) or even a similar width (to this blade) small roller ( FIG. 8 ), such as a small metal or nylon wheel or roller, to which drag is applied to hinder rolling such that a dragging or scraping effect is achieved, or even a stationary roller separate from the movable carriage 70 . Drag can also be effectively created by offsetting such a small roller at a slight angle θ to the direction of travel of the web creating a slight scraping effect. The scraper device 30 can also take the form of a forceful air jet or air knife, though a blade as shown in a preferred embodiment in the enclosed figures. Therefore, all such variations are viewed as a scraper device 30 for purposes of simplicity in description for the present invention.
FIG. 5 is a perspective view of a scraper blade device according to an embodiment of the present invention. As mentioned hereinabove, the term scraper device 30 and scraper device 30 have been used interchangeably. One of skill in the art will appreciate that in a preferred embodiment, the scraper device (blade) 30 may include a blade 32 having a working edge that is operatively secured into a clamping mechanism and holder 31 . The holder 31 and the blade 32 can be positioned at a variety of angles θ with respect to each other to optimize the desired angle of attack with respect to the underside 14 of the moving web 10 . Although a variety of acute and obtuse angles θ may be employed, a desired range of angle θ is between 75 and 95 degrees, and more particularly between 90 and 95 degrees. In addition, the blade 32 may be secured to the holder 31 via fasteners, e.g., such as the pair of thumb screws 33 shown in FIG. 5 .
For example, as seen in FIG. 2 and FIG. 3 , the present inventors have determined that an edge cleaner device can incorporate a fluid jet from a nozzle assembly 50 that is directed at the underside 14 of the coated web 10 in a direction toward the outside edge of the moving web 10 . The fluid jet from the nozzle assembly 50 can be a jet of air, water or air/water mist that is directed in a position that will separate and/or carry away any excess coating migrating from the upper edge 12 of the coated web 10 toward the underside or uncoated side 14 of the coated web 10 away from the coated web 10 . As seen in FIGS. 2 and 3 , an optional receiving drain or collection container 40 is positioned with respect to an edge of the moving web 10 in a position that permits the container 40 to collect any excess coating separated and/or carried away with the fluid jet of the nozzle assembly 50 .
The nozzle assembly 50 may incorporate a needle nose jet of water, air, or combination thereof directed toward the opening 42 of the container 40 . U.S. Pat. No. 2,653,566 to Worden; U.S. Pat. No. 3,351,039 to Heisterkamp; U.S. Pat. No. 4,359,964 to Johnson; and U.S. Pat. No. 6,176,939 to Oechsle et al. describe the construction, materials and operation of several nozzle assemblies of the background art employing water, air and/or water/air mist fluid flows that may be incorporated into the unique edge cleaning device of the present application. Accordingly, the entirety of each of the above-identified applications is hereby incorporated by reference.
The collection drain or container 40 can be formed in a variety of shapes and positions that allow the container 40 to collect and/or carry away excess coating. For example, the container 40 can be a conical or cylindrically shaped receiving cup 40 or cone that includes a vacuum supplied by a vacuum hose 62 , e.g., such as a reinforced, flexible hose. The receiving cone or container 40 can be supplied with vacuum, but this arrangement is optional depending upon the desired application. As seen in FIGS. 2 and 3 , the container 40 is provided with an opening 42 at a front side of the container 40 for collecting excess coating and one or more optional guides 48 extending from the sides of the container 40 to engage the upper surface 12 of the moving web 10 and prevent the web from excessively deviating from the moving path W, e.g., curling in response to the fluid jet of the nozzle assembly 50 directed at the underside 14 of the web.
The nozzle assembly 50 is supplied via a supply hose 52 , 60 or rigid tubing providing some structural support and positioning of the nozzle assembly 50 with respect to the web 10 . The fluid of the nozzle assembly 50 is preferably a water jet positioned to disperse the coating material without need of applying a vacuum. The fluid jet can be a stream of water, preferably a needle stream or sharp stream of water under pressure. However, one of skill in the art will appreciate that various pressures and/or combinations of water/air and spray patterns may be useful for some coatings, e.g., depending upon the characteristics of the coating such as viscosity or rheology. However, a needle stream of water directed at the edge of the web 10 in the direction of the container 40 is utilized in a preferred embodiment.
As aforementioned, the scraper device 30 may be used in combination with the nozzle assembly 50 and/or the vacuum container 40 . The scraper device 30 in combination with water jet 50 moves or disperses the bead of any excess coating into the receiving container 40 . In addition, the edge cleaner device is preferably provided with a moveable carriage 70 or support structure that permits movement of the edge cleaning device sideways, e.g., movable toward and away from the edge of the web, and even vertically if desired. In a preferred embodiment, the carriage 70 includes a position controller 84 and a motor 75 or other device permitting movement and positioning of the carriage 70 of the edge cleaner device. Since the edge cleaning device is sideways movable toward and away the edge of the web 10 , it can be quickly and accurately positioned relative to a wide range of sizes of coated webs 10 . In addition to the guides 48 for controlling the positioning of the moving web 10 with respect to the edge cleaner device, the present invention may incorporate other self-positioning or position control features.
For example, as seen in FIGS. 3 and 4 , a positioning device 80 for detecting the position of the coated web 10 with respect to the edge cleaning device is provided in a position that allows the web 10 to pass through opposite sides 80 of the positioning device 80 . The positioning device 80 may include two or more electric eyes or sensors that are operatively coupled to the edge cleaning device. The sensors may be set so that a first beam is broken or interrupted by the web passing therebetween. A second set of sensors may be employed in an offset position that allows the beam passing therebetween to be uninterrupted when the edge cleaning device is engaged with the moving web 10 .
One of skill in the art will appreciate that the edge cleaning device is shown positioned in a retracted position, e.g., away from the moving edge of the coated web 10 in FIG. 4 . A logic circuit within the controller 84 of the positioning device 80 will maintain a proper positioning of the edge cleaning device, e.g., by moving the edge cleaning device along rails of the carriage 70 , with respect to the web. The signals from the sensors of the positioning device 80 may be transferred via communication lines or cables 82 operatively connecting the controller 84 with the sensors of the positioning device 80 . In a preferred embodiment, the nozzle assembly 50 , receiving container 40 , scraper device 30 (not shown in FIG. 4 ) and positioning device 80 are all mounted directly or indirectly to the movable carriage. Accordingly, the electronic eyes or sensors can be used to facilitate rapid and accurate positioning of the edge cleaning device and all its components with the outside edge of the moving web 14 . Since the resulting combination of components, e.g., scraper device 30 , nozzle assembly 50 , etc., is quickly and accurately positioned along the edge of the moving web 10 , the undesirable contact with the surfaces of the abradable, rubberized backing roll 20 of previous systems is effectively eliminated. Accordingly, coating processes of various webs may be scheduled in a variety of manners while effectively eliminating costly downtime to repair components, e.g., such as the replacement of the worn backing rollers 20 .
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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An edge cleaning device, a system for cleaning an outside edge of a movable, coated web, and a method of cleaning the outside edge of the movable, coated web include a unique combination of desirable features. An edge cleaner device is automatically positioned with respect to an outside edge of a movable, coated web, wherein the edge cleaner device is positioned upstream from a backing roller for operatively engaging an underside of the moving, coated web. A fluid jet from a nozzle assembly of the edge cleaner device is applied toward the underside and the outside edge of the moving, coated web. A scraper device can be operatively engaged with an upper surface of the moving web without contacting an upper surface of the backing roller and the collection device may be imparted with a vacuum to assist in the removal of excess coating collected by the edge cleaning device.
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BACKGROUND OF THE INVENTION
This invention relates to new formulations for finishing flat textiles based on esterquats and quatemized fatty acid imidazolines and to their use for conditioning fabrics and stabilizing them against yellowing.
The finishing of yarns and fabrics to the final textiles involves a complex requirement profile. The most important property which finishes are expected to show consists in providing textiles with a pleasant soft feel. Cationic surfactants are generally used for this purpose. Among these, esterquats are particularly important by virtue of their favorable ecological compatibility. Conditioning can be carried out both as a textile pretreatment and as an aftertreatment. Another requirement is to protect textiles against soiling, for which purpose polymers of the so-called “soil repellant” type are added to standard laundry aftertreatment products. A third important aspect is the stabilizing of fabrics against the effect of ozone which, in the case of blue denim in particular, leads very easily to yellowing. However, conventional conditioners do not satisfactorily meet this requirement.
Accordingly, the problem addressed by the present invention was to provide new conditioners which would enable flat textiles, i.e. yarns, woven fabrics and finished textiles, but especially blue denim cloth and jeans produced therefrom, to be given a pleasant soft feel and, at the same time, to be finished against yellowing.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to textile finishes containing
(a) esterquats and
(b) quaternized fatty acid imidazolines.
DETAILED DESCRIPTION OF THE INVENTION
It has surprisingly been found that mixtures of esterquats and quaternized fatty acid imidazolines not only provide flat textiles and, preferably, blue denim cloth with a pleasant soft feel, they also reliably stabilize them against yellowing, particularly when the fatty acid part of component (b) is derived from oleic acid.
Esterquats
“Esterquats” are generally understood to be quaternized fatty acid triethanolamine ester salts. They are known compounds which may be obtained by the relevant methods of preparative organic chemistry, cf. International patent application WO 91/01295 (Henkel), in which triethanolamine is partly esterified with fatty acids in the presence of hypophosphorous acid, air is passed through the reaction mixture and the whole is then quaternized with dimethyl sulfate or ethylene oxide. U.S. Pat. Nos. 3,915,867, 4,370.272, EP-A2 0 239 910, EP-A2 0 293 955 A2, EP-A2 0 295 739 and EP-A2 0 309 052 A2 are cited here as representative of the extensive prior-art literature. Overviews of this subject have been published, for example, by O. Ponsati in C.R. CED Congress, Barcelona, 1992, p. 167, by R. Puchta et al. in Tens. Surf. Det., 30, 186 (1993), by M. Brock in Tens. Surf. Det., 30, 394 (1993) and by R. Lagerman et al. in J. Am. Oil Chem. Soc., 71, 97 (1994).
The quaternized fatty acid triethanolamine ester salts correspond to formula (I):
in which R 1 CO is an acyl group containing 6 to 22 carbon atoms, R 2 and R 3 independently of one another represent hydrogen or have the same meaning as R 1 CO, R 4 is an alkyl group containing 1 to 4 carbon atoms or a (CH 2 CH 2 O) q H group, m, n and p together stand for 0 or numbers of 1to 12, q is a number of 1 to 12 and X is halide, alkyl sulfate or alkyl phosphate. Typical examples of esterquats which may be used in accordance with the present invention are products based on caproic acid, caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, isostearic acid, stearic acid, oleic acid, elaidic acid, arachic acid, behenic acid and erucic acid and the technical mixtures thereof obtained, for example, in the pressure hydrolysis of natural fats and oils. Saturated or predominantly saturated fatty acids, for example tallow or palm oil fatty acid, are preferably used. To produce the quaternized esters, the fatty acids and the triethanolamine may be used in a molar ratio of 1.1:1 to 3:1. With the performance properties of the esterquats in mind, a ratio of 1.2:1 to 2.2:1 and preferably 1.5:1 to 1.9:1 has proved to be particularly advantageous. The preferred esterquats are technical mixtures of mono-, di- and triesters with an average degree of esterification of 1.5 to 1.9 and are derived from tallow fatty acid. In performance terms, quatemized fatty acid triethanolamine ester salts corresponding to formula (I), in which R 1 CO is the acyl group of tallow fatty acid, R 2 has the same meaning as R 1 CO, R 3 is hydrogen, R 4 is a methyl group, m, n and p stand for O and X stands for methyl sulfate, have proved to be particularly advantageous.
Besides the quaternized fatty acid triethanolamine ester salts, other suitable esterquats are quaternized ester salts of fatty acids with diethanol-alkyamines corresponding to formula (II):
in which R 1 CO is an acyl group containing 6 to 22 carbon atoms, preferably an acyl group derived from tallow fatty acid, R 2 is hydrogen or has the same meaning as R 1 CO, R 4 and R 5 independently of one another are alkyl groups containing 1 to 4 carbon atoms, m and n together stand for O or numbers of 1 to 12 and X stands for halide, alkyl sulfate or alkyl phosphate.
Finally, another group of suitable esterquats are the quaternized ester salts of fatty acids with 1,2-dihydroxypropyl dialkylamines corresponding to formula (III):
in which R 1 CO is an acyl group containing 6 to 22 carbon atoms, preferably an acyl group derived from the fatty acid mixture containing tallow fatty acid, R 2 is hydrogen or has the same meaning as R 1 CO, R 4 , R 6 and R 7 independently of one another are alkyl groups containing 1 to 4 carbon atoms, m and n together stand for O or numbers of 1 to 12 and X stands for halide, alkyl sulfate or alkyl phosphate.
So far as the optimal degree of esterification is concerned, the examples mentioned for (I) also apply to the esterquats corresponding to formulae (II) and (III). The esterquats are normally marketed in the form of 50 to 90% by weight solutions in alcohol which may readily be diluted as required with water.
Quaternized fatty acid imidazolines are also known cationic surfactants which are normally obtained by condensation of fatty acids with diamines, preferably ethylenediamines, and subsequent quaternization with alkyl halides or dialkyl sulfates. Processes for producing the imidazolines and their quaternization products are known, for example, from German references DE-A1 40 20 271, DE-A1 40 38 983 and DE-A1 41 16 648 (Henkel). The imidazolines may also contain open-chain hydrolysis products. However, they normally correspond to the following formula:
in which R 8 is an alkyl and/or alkenyl group containing 7 to 21 carbon atoms and preferably 11 to 17 carbon atoms, R 9 represents optionally hydroxysubstituted alkyl groups containing 1 to 4 carbon atoms or a benzyl group, R 10 represents hydroxysubstituted alkyl groups containing 2 to 4 carbon atoms or a CH 2 CH 2 NHCOR 8 group and X stands for halide or alkyl sulfate. In one particular embodiment of the invention, products derived from oleic acid or from a fatty aced cut predominantly containing oleic acid are used. Quaternized fatty acid imidazolines obtained by condensation of oleic acid with diethylenetriamine or aminoethyl ethanolamine and subsequent quaternization with dimethyl sulfate or methyl chloride are particularly preferred. The ratio by weight of component (a) to component (b) in the textile finishes according to the invention may be from 90:10 to 10:90 and is preferably from 15:85 to 50:50 and more preferably, from 20:80 to 25:75.
Commercial Applications
The finishes according to the invention not only provide flat textiles, preferably blue denim cloth, with a pleasant soft feel, they also protect them reliably against yellowing. Accordingly, the present invention also relates to the use of the mixtures as finishes for simultaneously conditioning flat textiles and stabilizing them against yellowing. The finishes themselves are normally present in the form of aqueous solutions or pastes with an active substance content of 5 to 30% by weight. They may additionally contain electrolyte salts, for example, for adjusting viscosity.
EXAMPLES
Ozone stabilization was evaluated using blue denim cloth. The test substances were applied by the padding method: quantity used 30 g/l, 20° C., liquor uptake 70%, pH=5.5 to 6.5. They were absorbed in a horizontal washing machine: quantity used 4% by weight, based on the weight of the cloth (50° C., 20 mins., pH=5.5 to 6.5, liquor ratio 1:20). The evaluation is based on the ozone test according to AATCC 109-1992 using an ozone chamber of the TriC-03 type available from Textile Innovators Corp., USA. Ozone protection was evaluated against a grey standard; feel was determined in a panel test: 6=very good, 1=poor. The results are set out in Table 1 below. The following surfactants were used:
A1) methyl-quaternized fatty acid imidazoline obtained from oleic acid (iodine value 90 to 100) and aminoethyl ethanolamine in the form of the methyl sulfate salt;
A2) methyl-quaternized fatty acid imidazoline obtained from oleic acid (iodine value 85 to 90) and aminoethyl ethanolamine in the form of the methyl sulfate salt;
A3) methyl-quaternized fatty acid imidazoline obtained from tall oil fatty acid and aminoethyl ethanolamine in the form of the methyl sulfate salt;
B1) methyl-quaternized ditallow fatty acid triethanolamine ester in the form of the methyl sulfate salt.
TABLE 1
Discoloration and softness (quantities as % by weight)
R1
R2
R3
R4
Quat. fatty acid imidazoline A1
12.3
—
—
—
Quat. fatty acid imidazoline A2
—
12.3
—
—
Quat. fatty acid imidazoline A3
—
—
7.1
—
Esterquat B1
3.2
3.2
8.4
—
Water
to 100
Grey standard
4.0
4.5
3.5
2.5
Softness
4.5
5.0
5.5
1.0
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A textile finish composition containing: (a) an esterquat; and (b) a quatemized fatty acid imidazoline.
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FIELD OF THE INVENTION
[0001] The present invention relates to unmanned aerial vehicles (UAVs). In particular to a modular design aircraft for the efficient high speed transportation of cargo and freight, and the completion of missions where unacceptably high risks make the use of human piloted vehicles unfeasible.
BACKGROUND OF THE INVENTION
[0002] There has been a recent increased emphasis on the use of unmanned aerial vehicles for performing, various activities in both civilian and military situations where the use of manned flight vehicles is not appropriate or efficient. One particular potential application is air cargo and freight transportation.
[0003] The process of shipping goods throughout the world is complicated by various factors such as geographic remoteness, lack of ground transportation infrastructure, political instability and environmental factors such as temperature. In some cases while it is possible to ship goods to remote or hard to reach locations, the risk to human life is too great to utilize conventional air cargo.
[0004] Transportation of cargo within remote undeveloped areas, for example, sections of Africa, Asia and South America is presently difficult because of the geographic remoteness and lack of ground transportation infrastructure. Therefore, goods shipped by land face a long and arduous journey, while conventional air cargo can be prohibitively expensive.
[0005] Another problem with the shipment of cargo arises from the lack of infrastructure to handle the volume of freight to be moved in a time efficient manner. For example, most trade in Europe in accomplished by utilizing ground freight containers. There are currently a large number of container ports being utilized, however due to the ever-increasing volume; the movement in and out of these container ports is severely restricted. In addition, because of the formalities required at border crossings, traffic flow is constrained, thus increasing transportation time and cost.
[0006] A further problem encountered using convention air freight methods has been reaching locations that have severe weather conditions such as in the Artic and Antarctic. These locations are typically accessed using air transport during temperate seasons due to the risks to pilots and other aircraft personnel presented during seasons severe weather. Such seasonal supply limitations presented by weather conditions can present difficulties for personnel stationed in these regions, especially in emergency situations such as medical emergencies.
[0007] A further problem associated with conventional air vehicles is the risk encountered by pilots engaging activities such as fire fighting. Conditions such as pilot fatigue, darkness, and environmental factors caused by the fire all present increased risk factors to pilot performing this type of activity.
[0008] In addition to the factors concerning the difficulties in moving freight and cargo due to geographic and environmental factors, the use of conventional air freight also presents several logistical problems. Such logistical problem prevalent in conventional air freight operations are the time needed to load and unload a plane, and the expense of the aircraft. Loading and unloading aircraft in the conventional manner generally requires the movement of the cargo in small discreet loads, such as palletized loads. The use of palletized loads is an inefficient use of an air transport vehicle because time spent on the ground increases turn-around time, (the time required to unload an aircraft, perform service, and load the next freight shipment), which slows the process for moving freight.
[0009] Additionally, the high cost of an air cargo vehicle, especially with respect to the size of the load that can be transported, is a problem. For example, the cost of ground transportation per unit of mass transported is far less than the cost of air transportation per unit of mass transported. A portion of the excess cost is due to the greater cost of the air transport vehicle in relation to the ground transport vehicle and the cost of operation, another factor is the high cost of air crews (pilots, copilots which materially add to the operational cost of the vehicle. A factor in increasing both of these costs is increased cost of aircraft avionics in relation to ground based vehicle control systems and aircraft cabin environmental controls.
[0010] Prior air cargo systems did not satisfactorily address these problems. The prior air cargo vehicles were not designed to satisfy these particular uses. The present air cargo vehicles tended to be inefficient to load and unload due to the difficulty access to the cargo hold and the manner in which cargo had to be loaded into the vehicle. Environmental factors also limited the usefulness of prior art systems. The prior air cargo vehicles were relatively expensive as well.
[0011] None of the prior air cargo vehicles satisfactorily provided the efficiency of transporting cargo and freight that is desired. It is therefore desirable to provide such a vehicle that will allow cargo and freight, to be easily and securely transported to remote areas, lacking in infrastructure to adequately provide for ground transportation needs using a low cost and efficient vehicle. In addition, there is a need for an air cargo and transport system to provide airborne service in applications of high risk in order to accomplish essential tasks.
SUMMARY OF THE INVENTION
[0012] The present invention accomplishes those needs by providing a unmanned aerial vehicle (UAV) of modular design for efficiently and inexpensively transporting cargo and freight to remote or hard to reach area and to perform tasks that would otherwise be too risky for a manned aircraft to undertake. The UAV of the present invention provides a modular design aircraft that can be remotely piloted or autonomously controlled by way of an on-board computer system. The design of the present invention provides a modular gondola and an air vehicle. The modular gondola includes an interchangeable electronics bay, avionics, telemetry, Forward Looking Infrared Radiometer (FLIR), Side-looking Aperture Radar (SAR) and other systems required to remotely locate and pilot the aircraft. The air vehicle includes the structural and aerodynamic and aircraft elements as well as engines. The structural elements of the aircraft include the fuselage cargo bay and support structures for aerodynamic elements and engines. The aerodynamic elements include the wings and all control surface required to generate sufficient lift and control flight. The modular gondola and air vehicle utilizes quick release connectors to attach all control systems to the air vehicle. The gondola and aircraft structure can be attached and separated in the same manner as a typically road going tractor truck and trailer unit. The present invention further provides the capability to remotely control the aircraft without the need for an onboard pilot. Therefore the gondola portion of the aircraft need not include any facilities for accommodating a human pilot such as seating, environmental controls, or safety features to protect the pilots. Additionally, the aircraft of the present invention can be flown in conditions what would in prior systems pose an unacceptable risk to the human pilots onboard. Furthermore, the present invention incorporates an air vehicle for receiving a freight container, such as, for example a container typically used in the ground transportation industry. The air vehicle will be adapted to be of sufficient size for such a container to be easily loaded and unloaded. The loading and unloading can thus be accomplished quickly and with a minimum of manual labor.
[0013] The present invention therefore provides a modular automated air transport system comprising an unmanned autonomous aircraft having a selectively detachable control systems portion and a structural air frame portion, wherein the structural air frame portion contains an interior cargo hold, aerodynamic members having control surfaces and at least one propulsion device attached to the structural air frame portion; and wherein the control system portion includes a control computer for autonomously controlling the flight of said air transport system from one known location to a second known location.
[0014] These and other features of the present invention are evident from the drawings along with the detailed description of preferred embodiments.
BRIEF DESCRIPTION OF DRAWINGS
[0015] [0015]FIG. 1 is a diagram of the UAV system of the present invention.
[0016] [0016]FIG. 2 is a side view of the UAV of the present invention.
[0017] [0017]FIG. 3 is a side view of the air vehicle and gondola of the present invention.
DETAILED DESCRIPTION
[0018] Referring in more detail to the drawings, as shown in FIGS. 1 - 3 , a preferred embodiment of the present invention is described. It is to be expressly understood that this exemplary embodiment is provided for descriptive purposes only and is not meant to unduly limit the scope of the present inventive concept. Other embodiments and variations of the carriers of the present invention are considered within the present inventive concept as set forth of the claims herein. For explanatory purposes only, the unmanned aerial vehicle of the preferred embodiments is discussed primarily for use as a cargo and freight transportation system. It is to be expressly understood that other types of equipment are contemplated for use with the present invention as well.
[0019] The unmanned aerial vehicle (UAV) system, as shown in FIG. 1, is a preferred embodiment of the present invention. UAV system 100 includes a ground station 102 and an UAV 104 , wherein the UAV includes a modular gondola 106 and air vehicle 108 . The ground station systems include flying 110 and maintenance 112 systems. The flying systems include data for navigation, flight control, communications, autopilot, engine control, flight planning, and vehicle monitoring. The maintenance systems include operations and facilities for aircraft loading and unloading as well as repair of the air vehicle and gondola of the present invention.
[0020] Turning now to FIG. 2, there is shown a depiction of the UAV of the present invention. The UAV includes a gondola 202 and air vehicle 204 . The gondola 202 portion houses a central control computer embodying the avionic componentry, for performing the functions of navigation, flight control, communications, autopilot, engine control, flight planning, TCAS and ATC communications radio and vehicle monitoring. All avionic would include redundancy in order to eliminate catastrophic single and dual point failures. The gondola 202 would be attached to the air vehicle 204 by way of quick disconnect “umbilical” wiring which will connect all avionics to the air vehicle. In this way, the gondola portion can be used interchangeably between various air vehicles. It should be apparent to one skilled in the art that the central computer of the present invention would be open architecture and programmable.
[0021] In the preferred embodiment, navigation will be implemented using Global Positioning System (GPS). GPS is available worldwide on a full time basis, in addition it provides sufficient accuracy to handle take-offs, in flight navigation, approach and landings. In addition, enhancement such as radar and altimeter can be added to the GPS system to control dynamic in-flight conditions such as air space separation and landing.
[0022] Actual flight control can be handled by an autopilot system as is known in the art. For example, the autopilot system may include be the S-TEC® system sold by Meggitt Avionics/S-TEC, Mineral Wells, Tex. Such autopilot systems are easily integrated into GPS and vehicle controls.
[0023] Engine control is accomplished through the use of Full Authority Digital Engine Control (FADEC) Interface that is well known in the art. This interface provides complete integration of engine controls with the flight control central computer and other related avionics systems. The modular design of the UAV of the present invention facilitates the reduction of turn around time by providing the capability of attaching a gondola 202 to a waiting and loaded air vehicle 204 . Therefore, the UAV of the present invention can be utilized in much the same way as ground based tractor-trailer or railroad transportation, wherein trailers or cargo cars are loaded independently of the power source, thereby increasing the efficient use of the cargo carrying and power component. Additionally, costs for operating the UAV of the present invention can be minimized by the modular design since a single gondola can be attached to a plurality of air vehicles. Alternately, the present invention can be implemented using a single structure air vehicle. In such an embodiment, the central computer can be an open architecture and programmable design, quick turn-around of the air vehicle can be accomplished by reprogramming the central computer after a flight leg, while the cargo is being unloaded and loaded. The single structure UAV is utilized in the same way as the modular design embodiment without the need for removing or attaching the gondola component. In this embodiment cargo can be maintained in a plurality of containers which are “staged” awaiting loading onto a predetermined UAV.
[0024] Turning again to FIG. 2, there is depicted a preferred embodiment of the air vehicle of the present invention. The air vehicle 204 includes the fuselage 206 , the aerodynamic surfaces (not shown), control systems (not shown), the engines 208 and landing gear 210 . The fuselage can be formed of a variety of structural designs to satisfy the parameters of the present invention, such as a monocoque design or other designs known in the art. In a particular embodiment, the fuselage structure can be partially provided by the cargo container. As will be hereinafter described, the air vehicle is adapted to receive a standard cargo container, which once loaded onboard is rigidly affixed to the air vehicle fuselage. In that way it becomes a stressed member of the fuselage structure, contributing to the torsional stiffness of the structure. Therefore, the fuselage is less expensive to construct since some of the structure is provided by the cargo vessel. In a preferred embodiment the air vehicle of the present invention should have the capability to carry a loaded standard shipping container weighing up to 30000 lbs. It is also desirable to have the ability to load and unload the such a container in a short period of time, directly from the cargo hold of the aircraft as a single load to a wheeled vehicle without separating the load into a plurality of packages. The loading and unloading of a single cargo vessel will facilitate the quick turnaround of the UAV. The turnaround time would include loading, unloading, fueling, flight planning. The UAV is designed to operate autonomously as a remotely piloted vehicle having no flight crew.
[0025] To meet the operational requirement of the UAV of the present invention, having a payload mass fraction of about 33%, the vehicle will have a gross weight on the order of approximately 90,000 pounds, having sufficient power to fly at modest speeds of 150 to 180 knots. Projected cruising altitude is expected to be approximately 10,000 to 15,000 feet. The UAV design approach is to make a mechanically simple vehicle to reduce the manufacturing costs. For example, the wing would be a constant cord design to minimize tooling and wing complexity. Additionally, advanced assembly techniques would be used such as friction stir welding in order to decrease costs of fabrication and assembly.
[0026] The wings of the air vehicle of the present invention would be of high lift design, which, while resulting in slower flight speeds would eliminate the need for complex high lift devices such as flap and slats. These devices materially complicate the design, cost, and maintenance of the aircraft. A similar approach to design will be applied to all aspects of the air vehicle, in order to minimize costs and complexity.
[0027] The air vehicle flight control system will include a conventional six degree of freedom (three axis) control mechanism. The aircraft will use ailerons for roll, elevator for pitch, and rudder for yaw with the control surfaces actuated either hydraulically or electronically. Additionally systems such as landing gear will be designed to accommodate use on airfields in undeveloped areas where uneven or unpaved landing sites are likely to be encountered. For example, the tires used will be a wide, low-pressure design to permit the air vehicle to land on unpaved landing areas, such as a grass field.
[0028] In the preferred embodiment, the aircraft of the present invention will be powered by propeller driven turbine engines, in order to meet the flight profile for altitude and range. For example, the engines may include turbine propeller engines sold under the trade designation AE2100® by Rolls Royce/Allison Corporation, Indianapolis, Ind.
[0029] Turning now to FIG. 3 there is shown the UAV 302 of the present invention. In the embodiment depicted, the air vehicle is adapted to carry cargo by receiving standard cargo containers 304 which are known in the art, into the cargo hold, 306 . Typically, such containers are carried on wheeled trailers 308 as shown. The preferred embodiment of the UAV of the present invention will receive the container through a hinged ramped door 310 in the rear of the aircraft. In that way the cargo can be loaded or unloaded in a single action without long delays or extensive use of manual labor. The air vehicle of the present invention will also incorporate weight sensing devices throughout the cargo bay. Thus, when a cargo container is loaded into the air vehicle, the total weight, as well as the weight distribution of the load can be immediately measured. The central computer of the UAV according to the present invention can be programmed to calculate any changes to total weight and weight distribution as needed.
[0030] The use of a rear hinged door to access the cargo hold will also facilitate the removal of cargo by use of a parachute drop, wherein the container is slid out the rear of the plane during a low speed, low altitude pass over an appropriate drop site, where actual landing of the plane is not feasible. The ramped door can have several operating positions. For example, the ramp would be lowered to the ground so that containers on the ground could be slid up the ramp for loading. The door can also have an intermediate position to load containers directly into the body of the air vehicle from a truck. The air vehicle can also be equipped with a winch to assist in loading and unloading of containers. It should be understood that the ramp can be raised or lowered to accommodate the loading of a container from a variety of positions.
[0031] In an alternate embodiment, the UAV of the present invention can be adapted to utilize a hinged front opening, however the front loading method would obviously preclude the delivery of cargo by parachute drop it would have the advantage of requiring less structural reinforcement of the air vehicle.
[0032] In addition to the UAV, the system of the present invention includes a ground station for flight and maintenance control. The flight control portion includes data for navigation, flight control, communications, autopilot, engine control, flight planning, and vehicle monitoring that is downloaded to the central control computer of the gondola 202 .
[0033] In a preferred embodiment, the UAV system of the present invention will include a central hub ground station and a plurality of remote locations. The central hub location will encompass the functions of control the fleet of UAV's including fleet scheduling, service and scheduled maintenance and flight planning. Flight planning will include the generation of flight plans as well as their transmission to remote locations for installation into UAV's awaiting flight plans for ensuing routes.
[0034] In a remote location, a ground crew will provide the functions of loading/unloading, fueling for the ensuing leg of the flight, flight plan downloading and installation into the gondola central computer and resolution of any exigent maintenance issues.
[0035] In operation, the UAV of the present invention in a preferred embodiment will receive a cargo load from a wheeled vehicle. The cargo load will be contained in a standard 40 foot shipping container as used in the freight industry. The container will be loaded onto the air vehicle preferably through a rear door ramp system and secured therein. Prior to, or during loading the air vehicle would be services as needed. Service may typically include fueling, structural inspection, inspection of aerodynamic and control devices and engine servicing.
[0036] A trained ground crew would conduct all of the loading and servicing procedures in order to prepare the air vehicle for connection to the gondola and subsequent flight. If the air vehicle is not already connected with a gondola, it can be held in a staging area until a gondola is available. Once available, the gondola will be attached to the air vehicle. The gondola electronic flight systems will be programmed with all flight plan information. Flight planning would be accomplished from a central headquarters, transmitted to the remote location, preferably by way of a wide area network, such as the internet or by satellite link. The flight plan data would then be transferred to the central computer of the gondola. Once the flight plan has been transferred to the central computer the program would be instantiated and the UAV launched to autonomously complete the flight plan. While in flight the central computer would provide continuously monitoring of all vehicle functions. Furthermore, the flight computer can provide telemetry to transmit data concerning all monitored systems to a ground based central station.
[0037] The complete flight plan would also include approach and landing data, although in an alternate embodiment, approach and landing could be controlled by a ground based system at the arrival location. This system could be under the control of a “operator” utilizing a two way telemetry system or a computer based expert system for controlling approach and landing at a particular location. Once completing the flight plan, the UAV of the present invention is met by ground crew that unloads the air vehicle, transfers the container to wheeled ground transport, performs maintenance and prepares the UAV for subsequent flights. The ground crew can also transfer the gondola to a waiting air vehicle, download a new flight plan and program the gondola central computer for the next flight. Alternately, the central computer of the present invention can be remotely programmed without the intervention of the remote location ground crew. Such programming could occur by utilizing a direct RF link from the central headquarters utilizing satellite technology for example.
[0038] Various changes to the foregoing described and shown structures will now be evident to those skilled in the art. Accordingly, the particularly disclosed scope of the invention is set forth in the following claims.
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A modular automated air transport system comprising an unmanned autonomous aircraft having a selectively detachable control systems portion and a structural air frame portion, wherein the structural air frame portion contains an interior cargo hold, aerodynamic members having control surfaces and at least one propulsion device attached to the structural air frame portion; and wherein the control system portion includes a control computer for autonomously controlling the flight of said air transport system from one known location to a second known location.
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The present invention relates to thermoplastic resins and methods for producing said resins utilizing a single component heterocyclic amine catalyst system. More particularly, the invention relates to resins such as high molecular weight polycarbonate resins that are produced by a solventless melt condensation reaction between diphenol carbonate (DPC) and bisphenol A (BPA) in the presence of a heterocyclic amine catalyst.
BACKGROUND OF THE INVENTION
A large number of catalytic systems have been examined for application to melt polycarbonates. Most of these methods require either a variety of co-catalysts or the subsequent addition of a catalyst quencher to ensure polymer stability. The need for high purity, high quality thermoplastic resins requires the reduction of residual contaminants in the final resin. This need for minimal residual impurities is particularly acute in optical quality (OQ) grade polycarbonate resins. One approach towards elimination of residual solvent contamination--particularly methylene chloride--is through the implementation of a solventless (melt) process.
Most current melt technology programs employ a two component catalyst system. The first component is tetramethylammonium hydroxide (TMAH or β-catalyst) which is used to initiate oligomer formation in the melt. The TMAH decomposes in the first two reactors to produce a variety of products, some of which contaminate the final polymer. The second catalyst is sodium hydroxide ("sodium" or Na: the α-catalyst) which is the finishing catalyst. Due to its intrinsic stability, the α-catalyst must be quenched. This quenching process requires the addition of yet another component to the polymer formulation. All the materials from the quenching process remain in the final resin, further contaminating the final polymer.
The use of a thermally stable, volatile heterocyclic amine catalyst circumvents the degradation problem of the β-catalyst and the need for additional reagents due to the use of an α-catalyst. The advantage of volatile amines are that they are "self-quenching", i.e., these catalysts slowly distill from the resin over the course of the reaction. As a result, no additional quencher is needed and no detrimental catalyst residue is left in the final resin.
SUMMARY OF THE INVENTION
A variety of basic nitrogen heterocyclic catalysts and complex nitrogen-containing organic bases were examined for their efficiency to form thermoplastic resins in general, and bisphenol A ("BPA") polycarbonates in particular. The following amines exhibit excellent polymer build and molecular weight distribution: 1,10-Phenanthroline (Phen), 2,2'-Dipyridyl (Bipy), 2-Phenylimidazole, 1,8-Diazobicyclo[5.4.0]undec-7-ene (DBU), 1,1,3,3-Tetramethylguanidine, Imidazo[1,2-a]pyridine, and 2,2':6',2"-Terpyridine.
Early attempts to use amines to catalyze the formation of polycarbonate oligomers gave little or no reaction, leading to the abandonment of this type of approach. Inadequate polymer formation is not a problem with the present process. High molecular weight polycarbonate resins are readily produced with these heterocyclic amines. A variety of polycarbonate grades may be made with applicants' method by merely controlling the catalyst loading and reaction conditions (i.e., temperatures, pressures, and residence times). At a given catalyst loading, the higher the boiling point of the heterocyclic amine, the higher the intrinsic viscosity ("IV") build in the finishing stage of the reaction. This change in finishing reactivity versus catalyst boiling point is one indication that this species is distilling from the resin. Hard evidence for the "self-quenching" ability of the volatile catalysts comes from examination of the overhead distillate from the melt reactor. Gas chromatography ("GC/GCMS") analysis of the overheads indicates the catalyst distills unchanged during the course of the reaction. Thus, no undesirable catalyst residue results from the use of these systems. The rate of loss of catalyst from the system is a function of its boiling point and the reaction conditions. Furthermore, the catalysts can be recovered from the overheads and reused if desired.
A number of variations will be immediately apparent to those of skill in the art. In one such variation, the disclosed catalysts can be used in combination in order to optimize the process. Thus, for example, a large amount of a very low boiling heterocyclic amine can be used to rapidly generate oligomers (with/without high end-capping). A small amount of a high boiling heterocyclic amine could then be used as a finishing catalyst in conjunction with the low(er) boiling species. This combination could be used in order to produce high molecular weight polymers with an appropriately tailored end-capping percentage.
of course, the present invention should not be limited to the heterocyclic amines listed above. Any mono- or poly-nitrogen containing heterocyclic compound such as 1,6-diazacyclo[4.3.0]non-5-ene DBN, imidazopyridines, triazoles, pyridines, dipyridines, terpyridines, phenanthrolines, quinolines, isoquinolines, as well as simple amidines and guanidines should effectively catalyze this process. Optimization of the catalyst loading, organic base boiling point, reaction temperatures, pressure, and residence times improve the process further.
The invention is also not limited to the BPA homopolymer. Any base-catalyzed reaction for the formation of polycarbonates, polyesters, polyamides, polyestercarbonates, polyesteramides, and polyamidecarbonates, whether branched, unbranched, homo- or copolymers, will work. Other dihydric phenols that can be employed in the practice of this invention include bis(4hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2bis(4-hydroxyphenyl)propane, also called bisphenol-A or BPA, 2,2-bis(4-hydroxy-3-methylphenyl)propane, 3,3-bis(4hydroxyphenyl)pentane, 2,2-bis(4-hydroxyl-3chlorophenyl)propane, 2,2-bis(4-hydroxy-3,5-dibromophenyl)propane,1,1-bis(4-hydroxyphenyl)cyclohexane, p,p'-dihydroxydiphenyl, 3,3-dichloro-4,4'dihydroxydiphenyl, bis(4-hydroxyphenyl)ether, bis(4hydroxyphenyl)sulfone, bis(3,5-dimethyl-4-hydroxyphenyl)sulfone, resorcinol, hydroquinone, 1,4-dihydroxy-2,5-dichlorobenzene, 1,4-dihydroxy-3methylbenzene, bis(4-hydroxyphenyl)sulfoxide, bis(3,5-dimethyl-4-hydroxyphenyl)sulfoxide, etc. Additional dihydric phenols can also be employed such as are disclosed in U.S. Pat. Nos. 2,999,835; 3,028,365; 3,153,008; and 4,001,184. It is, of course, possible to employ two or more different dihydric phenols or a copolymer of a dihydric phenol with glycol or with hydroxy or acid terminated polyester, or with a dibasic acid in the event a polycarbonate copolymer or interpolymer (co-polyester-carbonate), rather than a homopolymer, is desired. The preferred dihydric phenol is bisphenol-A (BPA).
Typical of the carbonate esters which may be employed herein are diphenyl carbonate, di(halophenyl) carbonates such as di-(chlorophenyl) carbonate, di-(bromophenyl) carbonate, di-(trichlorophenyl) carbonate, di(tribromophenyl) carbonate, etc., di-(alkylphenyl) carbonate such as di(tolyl) carbonate, etc., di-(naphthyl) carbonate, di-(chloronaphthyl carbonate, phenyl tolyl carbonate, chlorophenyl chloronaphthyl carbonate, etc., or mixtures thereof. Diphenyl carbonate is preferred.
Finally, the process can be applied to produce oligomeric materials, as well. Thus, either simple or crystalline oligomeric compositions can be generated by the disclosed process. The oligomeric materials can then be polymerized to produce a desired grade of material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Two experimental reaction sequences were used for the polymer preparation. The first is a short run procedure that quickly screens catalyst activity, polymer color, rate of IV build, etc. Its short run times allow efficient, qualitative catalyst screening. A second, longer procedure is used as a secondary check for catalyst activity; the IV builds are always better (higher) under these conditions, but the run times are hours longer. The reactions were all run for prescribed lengths of time, not polymer build to allow comparison of the catalytic efficiency. The listed IVs do not indicate a limit to the polymer molecular weight these systems could produce if run for extended periods of time. Occasionally, the dispersivities are listed twice for each sample. The first value reflects the use of 1000 molecular weight as a cut-off point for sampling while the (M w /M n ) all represents an alternative practice of reporting the total GPC data. The reaction materials were from the following sources: BPA and DPC--General Electric; heterocyclic amine catalysts--Aldrich Chemical Company. The reactor vessels were made out of pyrex glass unless specified otherwise. It should be noted that under the disclosed reaction conditions these DPC/BPA compositions do not produce polycarbonate without the addition of catalyst.
The present invention is more fully defined in the following illustrative, non-limiting Examples:
EXAMPLE 1
2-Phenylimidazole Catalyst
BPA (136.98 g; 0.600mol) and DPC (133.67g; 0.624mol) were added into a liter melt polymerizer apparatus as powders. The reactor vessel was deoxygenated by evacuating it to about 1 torr and then refilling the apparatus with nitrogen. This deoxygenation procedure was repeated three times. The reactor vessel was immersed in a fluidized heat bath preheated to 180° C. The DPC/BPA mixture was allowed to melt, producing a colorless, homogeneous liquid; once a small amount of the mixture melts, the remaining material can be stirred slowly to promote better heat exchange. The system was allowed to thermally equilibrate (5-10 min). Into this solution was added the 2-phenylimidazole catalyst (110.3 mg; 7.5×10 -4 mol). The reaction solution was stirred for 250 rpm unless otherwise stated. At this time the reaction temperature was raised to 210° C. and the pressure lowered to 175 torr. No phenol distilled from the reactor vessel during this period. After 25 min, the reactor pressure was lowered to 100 torr and held there for another 25 min. Phenol continued to distill into the receiver flask (1 drops/sec). The reactor pressure was lowered to 15 torr while the temperature was raised to 250° C. These conditions were held for 30 min (fast flow out of reactor; 1-3 drop/sec-DPC). The pressure was dropped to 2 torr while the temperature was increased to 285° C. These conditions were maintained for 10 min (flow to receiver approx. 1 drop/2 sec; solids in receiver-BPA). The final stage of the reaction was initiated by placing the melt material under full vacuum (0.7 torr; 1.5 tort at the reactor head) at 305° C. for 1 h. No foaming occurred in this reaction. The melt polycarbonate appeared colorless with an IV methylene chloride =0.231 dl/g. The receiver mass (distillate; phenol +DPC+BPA trace )=153.1 g; theoretical distillate mass (phenol+DPC excess )=118.1 g. Polymer yield was quantitative. M w =3,760, M n =2,570, M w /M n =1.50, (M w /M n ) all =2.28.
EXAMPLE 2
Imidazo[1,2-a]pyridine Catalyst
BPA (136.98 g; 0.600 mol) and DPC (133.67 g; 0.624 mol) were added into a liter melt polymerizer apparatus as powders. The reactor vessel was deoxygenated by evacuating it to about 1 tort and then refilling the apparatus with nitrogen. This deoxygenation procedure was repeated three times. The reactor vessel was immersed in a fluidized heat bath preheated to 180° C. The DPC/BPA mixture was allowed to melt, producing a colorless, homogeneous liquid; once a small amount of the mixture melts, the remaining material can be stirred slowly to promote better heat exchange. The system was allowed to thermally equilibrate (5-10 min). Into this solution was syringed the imidazo[1,2-a]pyridine catalyst (76.8 ml; 7.5×10 -4 mol). The resulting solution was stirred for 5min at 180° C. The stirring rate was held at 250 rpm unless otherwise stated. At this time the reaction temperature was raised to 210° C. and the pressure lowered to 175 torr. After a couple of minutes, phenol began to distill out of the reactor vessel into an evacuated receiver flask (very slow flow to receiver). After 25 min, the reactor pressure was lowered to 100 tort and held there for another 25 min. Phenol continued to distill into the receiver flask (1 drop/sec). The reactor pressure was lowered to 15 tort while the temperature was raised to 250° C. These conditions were held for 30 min (approx. 1 drop/3-5 sec flow). The pressure was dropped to 2 torr while the temperature was increased to 285° C. These conditions were maintained for 10 min (flow to receiver approx. 1 drop/10 sec). The final stage of the reaction was initiated by placing the melt material under full vacuum (0.4 torr at the pump head) at 305° C. for 0.5 h. The pressure at the reactor head never got below 0.85 torr. No foaming occurred during this reaction. The melt polycarbonate appeared colorless with an IV methylene chloride =0.245dl/g. The receiver mass (distillate; phenol+DPC+BPA trace )=122.0 g; theoretical distillate mass (phenol+DPC excess )=118.1 g. Polymer yield was quantitative. M w =4,580, M n =2,874, M w /M n =1.59, (M w /M n ) all =2.36.
EXAMPLE 3
1,10-Phenanthroline Catalyst
BPA (136.98 g; 0.600 mol) and DPC (133.67 g; 0.624 mol) were added into a liter melt polymerizer apparatus as powders. The reactor vessel was deoxygenated by evacuating it to about 1 torr and then refilling the apparatus with nitrogen. This deoxygenation procedure was repeated three times. The reactor vessel was immersed in a fluidized heat bath preheated to 180° C. The DPC/BPA mixture was allowed to melt, producing a colorless, homogeneous liquid; once a small amount of the mixture melts, the remaining material can be stirred slowly to promote better heat exchange. The system was allowed to thermally equilibrate (5-10 min). Into this solution was added the phenanthroline catalyst (136.5 ml; 7.5×10 -4 mol). The resulting solution was stirred for 5 min at 180° C. The reaction solution was stirred at 250 rpm unless otherwise stated. At this time the reaction temperature was raised to 210° C. and the pressure lowered to 175 torr. No phenol distilled from the reactor vessel initially- After 25 min, the reactor pressure was lowered to 100 torr and held there for another 25 min. Phenol started to distill into the receiver flask (1-3 drop/sec)The reactor pressure was lowered to 15 torr while the temperature was raised to 250° C. These conditions were held for 30 min (approx. 1 drop/2 sec flow). The pressure was dropped to 2 torr while the temperature was increased to 285° C. These conditions were maintained for 10 min (flow to receiver approx. 1 drop/5 sec). The final stage of the reaction was initiated by placing the melt material under full vacuum (0.40 torr; 0.8 reactor head pressure) at 305° C. for 0.5 h. Foaming began immediately when the temperature reached 305° C. and continued for about 10 min. The melt polycarbonate had an IV methylene chloride =0.384 dl/g. The receiver mass (distillate; phenol+DPC+BPA trace )=118.3 g; theoretical distillate mass (phenol+DPC excess )=118.1 g. Polymer yield was quantitative. M w =15,790, M n =7,705, M w /M n =2.05, (M w /M n ) all =2.81.
EXAMPLE 4
2,2'Dipyridyl (Bipy) Catalyst
BPA (136.98 g; 0.600 mol) and DPC (133.67 g; 0.624 mol) were added into a liter melt polymerizer apparatus as powders. The reactor vessel was deoxygenated by evacuating it to about 1 torr and then refilling the apparatus with nitrogen. This deoxygenation procedure was repeated three times. The reactor vessel was immersed in a fluidized heat bath preheated to 180° C. The DPC/BPA mixture was allowed to melt, producing a colorless, homogeneous liquid; once a small amount of the mixture melts, the remaining material can be stirred slowly to promote better heat exchange. The system was allowed to thermally equilibrate (5-10 min). The solution was stirred at 250 rpm unless otherwise stated. Into this solution was added the bipy catalyst (118.3 mg; 7.5×10 -4 mol). The resulting solution was stirred for 5 min at 180° C. At this time the reaction temperature was raised to 210° C. and the pressure lowered to 175 torr. No phenol distilled from the reactor vessel during this period. After 25 min, the reactor pressure was lowered to 100 torr and held there for another 25 min. Phenol started to distill into the receiver flask (1 drop/sec). The reactor pressure was lowered to 15 torr while the temperature was raised to 250° C. These conditions were held for 30 min (approx. 1 drop/sec flow). The pressure was dropped to 2 torr while the temperature was increased to 285° C. These conditions were maintained for 10 min (flow to receiver approx. 1 drop/3 see). The final stage of the reaction was initiated by placing the melt material under full vacuum (1.5 torr; 2.2 at the reactor head) at 305° C. for 0.5 h. Foaming began after 8 min at 305° C. and continued for about 5 min. The stirring rate was lower to 100 rpm and kept there for the remainder of the reaction. The melt polycarbonate had an IV methyl chloride =0.464 dl/g. The receiver mass (distillate; phenol+DPC+BPA trace )=117.1 g; theoretical distillate mass (phenol+DPC excess )=118.1 g. Polymer yield was quantitative. M w =22,525, M n =10,496, M w /M n =2.14, (M w /M n ) all =2.72.
EXAMPLE 5
2,2':6',2"-Terpyridine Catalyst
BPA (136.98 g; 0.600 mol) and DPC (133.67 g; 0.624 mol) were added into a liter melt polymerizer apparatus as powders. The reactor vessel was deoxygenated by evacuating it to about 1 torr and then refilling the apparatus with nitrogen. This deoxygenation procedure was repeated three times. The reactor vessel was immersed in a fluidized heat bath preheated to 180° C. The DPC/BPA mixture was allowed to melt, producing a colorless, homogeneous liquid; once a small amount of the mixture melts, the remaining material can be stirred slowly to promote better heat exchange. The system was allowed to thermally equilibrate (5-10 min). The solution was stirred at 250 rpm unless otherwise stated. Into this solution was added the terpyridine catalyst (178.5 mg; 7.5×10 -4 mol). The resulting solution was stirred for 5 min. At this time the reaction temperature was raised to 210° C. and the pressure lowered to 175 torr. After a few minutes, phenol began to distill out of the reactor vessel into an evacuated receiver flask (1 drop/sec). After 25 min, the reactor pressure was lowered to 100 tort and held there for another 25 min. Phenol continued to distill into the receiver flask (1 drop/sec). The reactor pressure was lowered to 15 tort while the temperature was raised to 250° C. These conditions were held for 30 min (approx. 1 drop/sec flow). The pressure was dropped to 2 tort while the temperature was increased to 285° C. These conditions were maintained for 10 min (flow to receiver approx. 1 drop/3 sec). The final stage of the reaction was initiated by placing the melt material under full vacuum (0.50 torr; 0.8 at the reactor head) at 305° C. for 0.75 h. Foaming began after 8 min at 305° C. and continued for about 7 min. After 25 min the stirring rate was lowered to 150 rpm due to the polymer viscosity build. The melt had an IV methylene chloride =0.432 dl/g. The receiver mass (distillate; phenol+DPC+BPA trace )=118.6 g; theoretical distillate mass (phenol+DPC excess )= 118.1 g. Polymer yield was quantitative. M w =18,942, M n =9,203, M w /M n =2.03, (M w /M n ) all =2.86.
EXAMPLE 6
1,8-Diazabicyclo [5.4.0]undec-7-ene (DBU) Catalyst
BPA (136.98 g; 0.600 mol) and DPC (133.67 g; 0.624 mol) were added into a liter melt polymerizer apparatus as powders. The reactor vessel was deoxygenated by evacuating it to about 1 tort and then refilling the apparatus with nitrogen. This deoxygenation procedure was repeated three times. The reactor vessel was immersed in a fluidized heat bath preheated to 180° C. The DPC/BPA mixture was allowed to melt, producing a colorless, homogeneous liquid; once a small amount of the mixture melts, the remaining material can be stirred slowly to promote better heat exchange. The system was allowed to thermally equilibrate (5-10 min). Into this solution was added the DBU catalyst (114.5 ml; 7.5×10 -4 mol). The resulting solution was stirred for 5 min at 180° C. The reaction solution was stirred at 250 rpm unless otherwise indicated. At this time the reaction temperature was raised to 210° C. and the pressure lowered to 175 torr. The phenol began to distill out of the reactor vessel into an evacuated receiver flask immediately (3-5 drop/sec). After 25 min, the reactor pressure was lowered to 100 torr and held there for another 25 min. Phenol continued to distill into the receiver flask (2 drop/sec). The reactor pressure was lowered to 15 torr while the temperature was raised to 250° C. These conditions were held for 30 min (approx. 1 drop/3 sec flow). The pressure was dropped to 2 tort while the temperature was increased to 285° C. These conditions were maintained for 10 min (flow to receiver approx. 1 drop/5 sec). The final stage of the reaction was initiated by placing the melt material under full vacuum (0.48 torr; 0.78 at the reactor head) at 305° C. for 0.5h. Foaming began after 12 min at 305° C. and continued for about 13 min. After 25 min the stirring rate was lowered to 150 rpm and kept there for the remainder of the reaction. The melt had an IV methylene chloride =0.423 dl/g. The receiver mass (distillate; phenol +DPC+BPA trace )=117.6 g; theoretical distillate mass (phenol+DPC excess )=118.1 g. Polymer yield was quantitative. M w =18,889, M n =9,135, M w /M n =2.07, (M w /M n ) all =2.63.
EXAMPLE 7
1,1,3,3-Tetramethylguanidine Catalyst
BPA (136.98 g; 0.600 mol) and DPC (133.67 g; 0.624 mol) were added into a liter melt polymerizer apparatus as powders. The reactor vessel was deoxygenated by evacuating it to about 1 torr and then refilling the apparatus with nitrogen. This deoxygenation procedure was repeated three times. The reactor vessel was immersed in a fluidized heat bath preheated to 180° C. The DPC/BPA mixture was allowed to melt, producing a colorless, homogeneous liquid; once a small amount of the mixture melts, the remaining material can be stirred slowly to promote better heat exchange. The system was allowed to thermally equilibrate (5-10 min). Into this solution was syringed the guanidine catalyst (95.7 ml; 7.5×10 -4 mol). The resulting solution was stirred for 5 min at 180° C. At this time the reaction temperature was raised to 210° C. and the pressure lowered to 175 torr. After a couple of minutes, phenol began to distill out of the reactor vessel into an evacuated receiver flask (2 drop/sec). After 25 min, the reactor pressure was lowered to 100 torr and held there for another 25 min. Phenol continued to distill into the receiver flask (1 drop/sec). The reactor pressure was lowered to 15 torr while the temperature was raised to 250° C. These conditions were held for 30 min (approx. 1 drop/sec flow). The pressure was dropped to 2 torr while the temperature was increased to 285° C. These conditions were maintained for 10 min (flow to receiver approx. 1 drop/5 sec). The final stage of the reaction was initiated by placing the melt material under full vacuum (0.50 torr) at 305° C. for 0.5 h. Foaming began after 17 min at 305° C. and continued for about 15 min. The melt polycarbonate appeared light yellow with an IV methylene chloride =0.354 dl/g. The receiver mass (distillate; phenol+DPC BPA trace )=123.1 g; theoretical distillate mass (phenol+DPC excess )=118.1 g. Polymer yield was quantitative. M w =11,948, M n =6,187, M w /M n =1.93, (M w /M n ) all =2.62.
The foregoing examples were given by way of illustration of the invention and are not to be construed as a limitation thereof. Obviously, other modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments of the invention described which are within the full intended scope of the invention defined by the appended claims.
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The present invention discloses thermoplastic resins and methods for producing said resins utilizing a single component heterocyclic amine catalyst system. More particularly, the invention discloses resins such as high molecular weight polycarbonate resins that are produced by a solventless melt condensation reaction between diphenol carbonate (DPC) and bisphenol A (BPA) in the presence of a heterocyclic amine catalyst.
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BACKGROUND OF THE INVENTION
Supplemental storage is a continuing paramount problem with home owners, retailers, business and commercial establishments, and many others. The ever-attendant suppliers of storage systems have presented to the marketplace shelving systems to meet the ongoing storage problems of the consumer.
The shelving systems available in the present marketplace typically are of the type which are sold in a knockdown configuration leaving the plight of the erection of the system to the purchaser. The typical steel shelf package includes a myriad of threaded fasteners, shelving components, and a scanty, at best, list of instructions. Considerable time is required for the process of the erection of the system and, often times, a fastener or two is missing from the kit or is lost in the excitement of the assemblage.
Once fully constructed, the problem of disassemblage and removing requires the same activities in reverse all to the consternation of the persons involved.
SUMMARY OF THE INVENTION
The present invention relates to a shelving or storage system which substantially eliminates the problems of the prior system. The resultant system of the invention is inherently extremely strong, easy and economical to install, and is rugged and rigid in use. The assemblage of the system incorporating the features of the invention requires no tools or particular expertise, and later may be removed and installed at a different site with the same ease. The system may readily be adopted to accommodate any anticipated load requirement.
The virtues of the invention are achieved by a shelving system for supporting horizontally disposed shelving adjacent a vertical wall surface having a horizontally extending sill wherein the system includes at least a pair of spaced-apart vertically extending rail members having aperture means formed therein for receiving shelving support brackets, the improvement comprises means for releasably securing the rail members to the horizontally extending sill which means include prong means integral with and spaced from the rail member and having an axis generally parallel to the vertical axis of the rail member and adapted to position and support the rail member adjacent the vertical wall beneath the sill.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other objects of the invention, will become readily apparent to one skilled in the art from reading the following detailed description of a preferred embodiment of the invention when considered in the light of the accompanying drawings, in which:
FIG. 1 is a fragmentary perspective view of shelving system incorporating the features of the invention;
FIG. 2 is a fragmentary, sectional view of the system illustrated in FIG. 1 taken along line 2--2 thereof;
FIG. 3 is a fragmentary, elevational view of the upper portion of one of the vertically extending rail members illustrated in FIGS. 1 and 2; and
FIG. 4 is a slightly enlarged top plan view of the rail member illustrated in FIG. 3 showing an associated shelf supporting bracket affixed thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings wherein like reference numerals designate similar parts throughout, there is shown a shelving system for use adjacent a typical wall formed of cement block members 10 and having a horizontally extending plate 12 of wood disposed to extend along the uppermost course of the block members 10.
A pair of spaced-apart vertically extending rail members 14 are positioned adjacent the inner surface of the wall formed by the block members 10. The rail members include opposed side walls 16 and 18 which have their inner edges interconnected by a generally U-shaped, in cross-section, web 20. The web 20 is provided with a plurality of spaced-apart slots or apertures 22 adapted to receive the hook-like portions of cooperating brackets as will be hereinafter explained in detail.
The uppermost end of the rail member 14 is provided with a pair of outwardly extending generally vertical plate portions or tabs 24 and 26 which are typically designed to be formed from sheet metal stock and welded or otherwise suitably secured to the rail members 14 and to extend from the side walls 16 and 18, respectively of the rail member 14. In the preferred embodiment, the tabs 24 and 26 are disposed at a slightly greater angle to one another than the angle between the side walls 16 and 18 of the rail members 14. The distal edges of the tabs 24 and 26 are formed to include prongs 28 and 30, respectively. The prongs 28 and 30 extend generally parallel to the longitudinal axis of the associated rail member 14. As shown in FIG. 2, the prong 28 includes a first edge portion 28a in generally parallel, facing relationship with the rail member 14. The prong 28 also includes a second edge portion 28b which forms an acute angle with the first edge portion 28a and intersects the edge portion 28a at point 28c. As shown in FIG. 3, the prong 30 is formed in a manner similar to the prong 28.
The rail members 14 are typically formed from sheet metal stock and may be of any desired lengths. It has been found that excellent results have been achieved by utilizing galvinized steel stock of fourteen gauge thickness. The resultant structure is thereby strong and rugged and will have an extremely long life cycle.
In use, at least two rail members 14 are deemed necessary to provide the primary supporting structure for the shelving system clearly illustrated in FIG. 1. It will be understood, that the system employed may be varied to accommodate increased loads by increasing the number of rail members and spacing the rail members closer together. Initially, the first of the rail members 14 is positioned in such a manner that the free edges of the rail members 14 are juxtaposed to the exposed wall surface and the prongs 28 and 30 are disposed to merely begin to slightly pierce or puncture the top surface of the wooden plate 12. As soon as the position of the rail member is thus determined, the rail member is raised or lifted one or two inches above the upper surface of the wooden plate 12 and is then thrust downwardly causing the prongs 28 and 30 to pierce and be firmly embedded in the wooden plate 12.
The position of the next adjacent rail member is selected in a similar manner to that explained above and the rail member 14 is then secured in place. In certain instances where longer shelves are required or desired, or additional load requirements are anticipated, additional rail members 14 are positioned and similarly secured.
After the desired number of rail members 14 are suitably positioned and secured in place, shelf brackets 32 are manually affixed to the rail members 14 at the desired vertical spacing for the eventual support function of associated shelving members 34, preferably formed of wood stock. The shelf brackets 32 are typically formed of sheet metal stock and include a plurality of outwardly and downwardly extending spaced fingers 36,38, and 40. The spacing of the fingers 36, 38, and 40 is typically the same as the spacing between the slots or apertures 22 of the rail members 14 so that the fingers may be readily received by the associated slots. It will be appreciated that the installation procedure of the brackets 32 to the supporting rail members 14 is accomplished by initially positioning the brackets 32 so that the fingers 36, 38, and 40 are aligned with an equivalent number of slots or apertures 22 of the rail member 14. As soon as the alignment occurs, the bracket 32 is moved toward the rail member 14 causing the fingers 36, 38, and 40 to be received by and within associated slots 22. When the outer ends of the fingers 36, 38, and 40 have completely traversed the slots 22, the bracket 32 is then lowered slightly to allow the outwardly and downwardly extending ends of the fingers 36, 38, and 40 to hook around the opposite inner surface of the rail member 14 and thus effectively secure the bracket 32 to the rail member 14. It will be noted that in the secured position, the bracket 32 is maintained against any downward rocking movement. However, in the illustrated embodiment, the bracket 32 may be slightly pivoted or moved about a vertical axis. Such movement is limited by the outer sidewalls of the U-shaped web 20 of the rail member 14.
The remaining shelf brackets are then similarly affixed to the rail members 14 preparatory to receiving the shelving members 34.
The upper edges of the brackets 32 are provided with a plurality of spaced-apart upwardly projecting teeth or prongs 42 to assist in militating against any relative movement of the brackets and the associated shelving members when in operative position.
Finally, the shelving members 34 are positioned in supported relationship on the brackets 32. In certain instances, the weight of the shelving members 34 may be sufficient to cause the teeth 42 of the brackets 32 to penetrate or bite into the lower surface thereof. This effect will be, indeed, supplemented when materials to be stored are placed on the shelves.
It will be appreciated from the foregoing description that the invention has resulted in a shelving system comprised of a minimum number of components which can be installed quickly, economically, and without the requirements of any particular expertise or tools or fasteners. Also, the system is one which can be easily removed and installed in another location with the same ease as initial installation.
In accordance with the provisions of the patent statutes, the principle and mode of operation of the invention has been explained and what is considered to represent its best embodiment has been illustrated and described. It should, however, be understood that the invention may be practiced otherwise than as specifically as illustrated and described without departing from its spirit and scope.
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A shelving system for supporting horizontally disposed shelving adjacent a vertical wall surface having associated horizontally extending sill or the like at the upper extremity of the wall. The system includes vertically extending rail members having supporting and positioning means which are capable of puncturing or piercing the sill to achieve the supporting and positioning of the rail members.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mobile telephone, and more particularly to a method for switching a mobile telephone for selectively transmitting or receiving a voice signal.
2. Description of the Related Art
Recently, a more compact sized mobile telephone, such as the folder-type mobile telephone, has been developed. These newer mobile telephones incorporate an additional function of a speakerphone mode that enables the user to conduct a voice communication without holding the mobile telephone by his ear. However, the conventional mobile telephone with such an additional function inherently suffers particular drawbacks. One of these drawbacks is that the received voice signal emanating from a speaker may unintentionally feedback through the microphone to the sender, thus causing unwanted interference. This interference, or garble, is known as a howling phenomenon. Moreover, the mobile telephone only operates in either a receive mode or transmit mode at any point in time based on the voice signal (i.e. the transmitted voice signal or the received voice signal) with the greater intensity. This limitation creates a problem in that the user cannot be assured that his voice signal input through the microphone is being transmitted to the other user. The present invention solves this longstanding problem in the present technology.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for switching a mobile telephone for selectively receiving or transmitting a voice signal in the speakerphone mode so as to prevent the howling phenomenon.
According to one embodiment of the present invention, a method for switching the mobile telephone for selectively receiving or transmitting a voice signal in the speakerphone mode, comprises the steps of counting the number of the full-rate voice data received from the sender, and blocking the transmission path from the receiver to prevent the received voice data from being retransmitted back through the microphone of the receiver to the sender if the number of the full-rate voice data exceeds a predetermined value.
The present invention will now be described more specifically with reference to the drawings attached only by way of example.
BRIEF DESCRIPTION OF THE ATTACHED DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram for illustrating the structure of a mobile telephone according to an embodiment of the present invention; and
FIG. 2 is a flow chart for illustrating the steps of switching a mobile telephone for selectively receiving or transmitting a voice signal in the speakerphone mode according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a microprocessor 112 controls the functions of the mobile telephone 200 . A duplexer 100 delivers a signal received by an antenna ANT to a radio receiver 102 or transmits the signal of a radio transmitter 108 through the antenna ANT. The radio receiver 102 delivers the non-voice data to the microprocessor 112 . The radio receiver 102 also delivers the voice signal to a signal level detector 122 . The voice signal is then delivered to a voice signal processor 104 . A frequency synthesizer 106 generates a carrier eliminator signal delivered to the microprocessor 112 to eliminate the received carrier signal corresponding to the receiving channel. The frequency synthesizer 106 also generates a transmitter carrier signal that is applied to the output signal of the radio transmitter 108 . The radio transmitter 108 combines the carrier signal from the frequency synthesizer 106 and the voice signal from the voice signal processor 104 , and outputs it to a duplexer 100 for transmission through the antenna ANT.
The voice signal processor 104 decodes the coded voice signal from the radio receiver 102 , delivers it through a speakerphone part 107 , and outputs it to a speaker SPK. The voice signal processor 104 also encodes the voice signal delivered from the microphone MIC through the speakerphone part 107 , and ultimately to the radio transmitter 108 . A signal level detector 122 detects the levels of the received and transmitted voice signals delivered to the microprocessor 112 . A ringer 114 generates a ringing sound when a ring signal is received. A memory device 110 includes a ROM for storing a control program of the microprocessor 112 , a non-volatile memory for storing a plurality of names and associated telephone numbers, and a RAM for temporarily storing data generated when operating the mobile telephone. A key input part 118 includes various functional keys for establishing and terminating communication and dialing a telephone number. A display 116 displays the characters and images representing the various operational states of the mobile telephone.
Referring to FIG. 2, the switching operation of the mobile telephone for selectively receiving or transmitting a voice signal in the speakerphone mode according to an embodiment of the present invention will be described. The microprocessor 112 determines in step 201 whether the mobile telephone has received a call. If a call is received, the microprocessor 112 generates a ring signal and sends it to the ringer 114 in step 202 . Accordingly, the user, in step 203 , presses a key of the key input part 118 to establish a communication channel and the microprocessor 112 establishes a single communication path between the sender and receiver.
In step 204 , the microprocessor 112 determines whether the mobile telephone is set in the speakerphone mode. If so, it enables the speakerphone part 107 to make the sender and receiver communicate in the speakerphone mode. Otherwise, the microprocessor 112 proceeds to step 205 to operate the mobile telephone in the ordinary communication mode. If speakerphone mode is selected the signal level detector 122 compares the level of the voice signal from the radio receiver 102 with that from the voice signal processor 104 . The signal with the greater level is delivered to the microprocessor 112 .
If the voice signal from the radio receiver 102 is delivered to the microprocessor 112 , the microprocessor 112 proceeds to step 206 to determine whether the received voice data is of a full-rate. This is accomplished by reading the configuration byte contained in the voice data information. Generally, a single voice data has a length of 20 ms. If the received voice data is determined to have a full-rate in step 206 , the microprocessor 112 proceeds to step 207 to count the full-rate value of the received voice data. The voice data is continuously received until the counted value reaches a predetermined value, at which point the microprocessor 112 determines it to be the valid voice data. Then, if the counted full-rate value exceeds the predetermined value in step 208 , the microprocessor 112 proceeds to step 210 to control the rate of the transmitted voice data from the microphone.
Each block of received voice data is checked to determine if it is at full-rate. If is it at full-rate, an accumulator, stored in the memory device 110 , is increased by 1. Each time a full-rate voice data block is received the accumulator is increased by 1. The value stored in the accumulator is referred to as the counted value. If the received voice data is not of a full-rate the accumulator is decreased by a value of 1. When a full-rate signal is received, the microprocessor 112 checks if the counted value exceeds a predetermined value, signifying that the received voice signal is at a level to begin controlling the transmission rate of the mobile telephone. If the counted value does not exceed the predetermined value, the counted value, stored in the accumulator, is increased by 1, transmission is not controlled, and the process returns to check the level of the next received voice data block. This process of receiving the voice data, checking for full-rate, and increasing or decreasing the counted value continues until the predetermined value is exceeded, at which time transmission control begins. The process then returns to check the next received voice data block for full-rate.
The transmitted voice data is divided into four different rates according to the amount of the sound, e.g., full-rate, ½ rate, ¼ rate, and ⅛ rate. In addition, the voice data with no voice information is called the blank rate. In order to control the packet rate of the transmitted voice data, the value ‘1’ is assigned to the bit of the configuration byte, representing that the voice data is presently the blank rate, while the other bits representing the other rates are all assigned with the value ‘0’. Thus, no changes are made to the configuration byte with the information of the voice data. When the counted value exceeds the predetermined value one of two events occur. Either the voice data is deleted from the transmitted data or the voice data is changed into ⅛ rate data to minimize the echoing effect.
Subsequently, if the communication is terminated in step 211 , the microprocessor 112 cuts off the communication path between the sender and receiver, or otherwise returns to step 206 . Meanwhile, if the received voice data is not of full-rate in step 206 , the microprocessor 112 proceeds to step 212 to determine whether the counted value is ‘0’. If so, it directly proceeds to step 211 . Or otherwise, it proceeds to step 213 to reduce the counted value by ‘1’, returning to step 206 . Alternatively, if the counted full-rate value does not exceed the predetermined value in step 208 , it proceeds to step 209 to increase the counted value by ‘1’, returning to step 206 .
Thus, the inventive switching method in the speakerphone mode employs the full-duplex operation to enable the mobile telephone to function in speakerphone mode with no additional device. It also reduces the number of cases where the communication is interrupted in the VOX (voice operated switch) function. In addition, the voice data of one user is prevented from being transmitted in the speakerphone mode when the voice data of the other user is transmitted with the full-rate, thus preventing voice communication garbling.
While the present invention has been described in connection with specific embodiments accompanied by the attached drawings, it will be readily apparent to those skilled in the art that various changes and modifications may be made thereto without departing the gist of the present invention.
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Switching a mobile telephone for selectively receiving or transmitting a voice signal in a speakerphone mode by counting the number of the full-rate voice data received from the sender, and blocking the transmission path from the receiver to prevent the received voice data from being retransmitted through the receiver's microphone to the sender if the number of the full-rate voice data exceeds a predetermined value.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates in general to data processing systems and in particular to managing memory access in data processing systems. Still more particularly, the present invention relates to a system, method and computer program product for preserving the ordering of read and write operations in a direct memory access system by delaying read access.
[0003] 2. Description of the Related Art
[0004] A conventional symmetric multiprocessor (SMP) computer system, such as a server computer system, includes multiple processing units coupled to a system interconnect, which typically comprises one or more address, data and control buses. Coupled to the system interconnect is a system memory, which represents the lowest level of volatile memory in the multiprocessor computer system and which generally is accessible for read and write access by all processing units. In order to reduce access latency to instructions and data residing in the system memory, each processing unit is typically further supported by a respective multi-level cache hierarchy, the lower level(s) of which may be shared by one or more processor cores.
[0005] One aspect of design that affects cache performance and design complexity is the handling of writes initiated by the processor or by an alternate bus master. Because two copies of a particular piece of data or instruction code can exist, one in system memory and a duplicate copy in the cache, writes to either the system memory or the cache memory can result in an inconsistency between the contents of the two storage units. For example, consider the case in which the same data in both the cache memory and the system memory in association with a particular address. If the processor subsequently initiates a write cycle to store a new data item at the predetermined address, a cache write “hit” occurs and the processor proceeds to write the new data into the cache memory. Since the data is modified in the cache memory but not in the system memory, the cache memory and system memory become inconsistent. Similarly, in systems with an alternate bus master, direct memory access (DMA) write cycles to system memory by the alternate bus master modify data in system memory but not in the cache memory. Again, the data in the cache memory and system memory become inconsistent.
[0006] Inconsistency between data in the cache memory and data in system memory during processor writes can be prevented or handled by implementing one of several commonly employed techniques. In the first technique, a “write-through” cache guarantees consistency between the cache memory and system memory by writing the same data to both the cache memory and system memory. The contents of the cache memory and system memory are always identical, and so the two storage systems are always coherent. In a second technique, a “write back” cache handles processor writes by writing only to the cache memory and setting a “dirty” bit to indicate cache entries which have been altered by the processor. When “dirty” or altered cache entries are later replaced during a “cache replacement” cycle, the modified data is written back into system memory.
[0007] Inconsistency between data in the cache memory and corresponding data in system memory during a DMA write operation is handled somewhat differently. Depending upon the particular caching architecture employed, one of the variety of bus monitoring or “snooping” techniques may be used. One such technique involves the invalidation of cache entries which become “stale” or inconsistent with system memory after a DMA write to system memory occurs. Another technique involves the “write-back” to system memory of all dirty memory blocks within the cache memory prior to the actual writing of data by the alternate bus master. After the dirty memory blocks that are targeted by the DMA write is written back to the system memory, the memory blocks are invalidated in the cache, and the write by the alternate bus master may be performed.
[0008] As systems become larger and the latency required to resolve cache coherence increases, this latency can limit the bandwidth that a DMA device is able to achieve in the system. To sustain full DMA write throughput, the system must balance the amount of time to resolve cache coherence with the amount of data transferred per request. The traditional method of balancing time required to resolve cache coherence and the amount of data transferred per request is to design the system with a larger cache line size. Thus, with a larger cache line size, more data can be invalidated per cache line invalidation request. However, the major drawbacks of increasing the cache line size include trailing edge effects and the increased likelihood of false sharing of data within the larger cache lines.
[0009] Therefore, there is a need for an improved system and method of increasing the throughput capacity of DMA devices without increasing the size of the cache line within the cache memory.
SUMMARY OF THE INVENTION
[0010] A method, system and computer program product for handling write requests in a data processing system is disclosed. The method comprises receiving on an interconnect bus a first write request targeted to a first address and receiving on the interconnect bus a subsequent second write request targeted to a subsequent second address. The subsequent second write request is completed prior to completing the first write request, and, responsive to receiving a read request targeting the second address before the first write request has completed, data associated with the second address of the second write request is supplied only after the first write request completes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed descriptions of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0012] FIG. 1 illustrates a high level block diagram of a processing unit in accordance with the present invention;
[0013] FIG. 2 depicts a high level block diagram of a memory controller in accordance with the present invention;
[0014] FIG. 3 is a high level logical flowchart of a process for assigning instructions to an appropriate queue in accordance with the present invention;
[0015] FIG. 4 is a high-level logical flowchart of a process for queuing read requests and performing read operations in accordance with a preferred embodiment of the present invention; and
[0016] FIG. 5 is a high-level logical flowchart of a process for queuing write requests and performing write operations in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] In the present invention, DMA write requests are sent to interconnect logic upon receipt from the I/O controller or interconnect logic. If an older DMA write request receives retry response while a newer DMA write is in flight, the newer DMA write is allowed to complete, but the I/O controller issues a retry response to any subsequent read of the newer DMA write data until all older DMA writes have completed.
[0018] With reference now to the figures and, in particular, with reference to FIG. 1 , there is illustrated a high level block diagram of an exemplary embodiment of a data processing system 10 containing a plurality of processing units 100 in accordance with the present invention. In the depicted embodiment, processing unit 100 is a single integrated circuit including two processor cores 102 a, 102 b for independently processing instructions and data. Each processor core 102 includes at least an instruction sequencing unit (ISU) 104 for fetching and ordering instructions for execution and one or more execution units 106 for executing instructions. The instructions executed by execution units 106 may include, for example, fixed and floating point arithmetic instructions, logical instructions, and instructions that request read and write access to a memory block.
[0019] The operation of each processor core 102 a, 102 b is supported by a multi-level volatile memory hierarchy having at its lowest level one or more shared system memories 132 (only one of which is shown in FIG. 1 ) and, at its upper levels, one or more levels of cache memory. As depicted, processing unit 100 includes an integrated memory controller (IMC) 124 that controls read and write access to a system memory 132 in response to requests received from processor cores 102 a, 102 b and operations snooped on an interconnect fabric.
[0020] In the illustrative embodiment, the cache memory hierarchy of processing unit 100 includes a store-through level one (L1) cache 108 within each processor core 102 a, 102 b and a level two (L2) cache 110 shared by all processor cores 102 a, 102 b of the processing unit 100 . L2 cache 110 includes an L2 array and directory 114 , masters 112 and snoopers 116 . Masters 112 initiate transactions on the interconnect fabric and access L2 array and directory 114 in response to memory access (and other) requests received from the associated processor cores 102 a, 102 b. Snoopers 116 detect operations on the interconnect fabric, provide appropriate responses, and perform any accesses to L2 array and directory 114 required by the operations. Although the illustrated cache hierarchy includes only two levels of cache, those skilled in the art will appreciate that alternative embodiments may include additional levels (L3, L4, etc.) of on-chip or off-chip in-line or lookaside cache, which may be fully inclusive, partially inclusive, or non-inclusive of the contents the upper levels of cache.
[0021] As further shown in FIG. 1 , processing unit 100 includes integrated interconnect logic 120 by which processing unit 100 may be coupled to the interconnect fabric as part of a larger data processing system. In the depicted embodiment, interconnect logic 120 supports an arbitrary number N of interconnect links 121 , which include in-bound and out-bound links. With these interconnect links 121 , each processing unit 100 may be coupled for bi-directional communication to up to N/2+1 other processing units 100 .
[0022] Each processing unit 100 further includes an instance of response logic 122 , which implements a portion of a distributed coherency signaling mechanism that maintains cache coherency between the cache hierarchy of processing unit 100 and those of other processing units 100 . Finally, each processing unit 100 includes an integrated I/O (input/output) controller 128 supporting the attachment of one or more I/O devices, such as I/O device 130 . I/O controller 128 may issue I/O read and I/O write operations and transmit data to and receive data from the local IMC 124 and interconnect links 121 in response to requests by I/O device 130 .
[0023] Turning now to FIG. 2 , a high-level block diagram of a memory controller in accordance with the present invention is depicted. Integrated memory controller 124 contains dispatch logic 200 for routing incoming read and writes requests to a read queue 202 and a write queue 204 , respectively. Read queue 202 holds read requests before servicing by reference to them to system memory 132 . Read queue 202 contains several entries 206 a- 206 n, each of which has a Ttype 208 and an address 210 , regulated by a read queue control 212 .
[0024] Similarly, write queue 204 holds write requests before servicing by reference to them to system memory 132 . Write queue 204 contains several entries 220 a - 220 n, each of which has a reorder bit 222 , a Ttype 224 and an address 226 , regulated by a write queue control 230 . As will be explained below with respect to FIGS. 3-5 , IMC 124 allows multiple DMA writes from a single I/O device 130 to remain ordered as observed by any potential consumer of data within data processing system 10 by reordering writes 220 a - 220 n through adjustment of reorder bit 222 and control of read queue 202 .
[0025] Referring now to FIG. 3 , a high-level logical flowchart of a process by which IMC 124 assigns read and write requests to an appropriate queue in accordance with the present invention is illustrated. The process starts at step 300 and then moves to step 302 , which depicts dispatch logic 200 of integrated memory controller 124 determining whether or not a read-type request has been received. If not, then the process iterates at step 302 . If a request is received at step 302 , then the process next proceeds to step 304 . At step 304 , dispatch logic 200 of integrated memory controller 124 determines the Ttype (transaction type) of the request received in step 302 . If the request is a read-type request, the process next moves to step 306 , which depicts dispatch logic 200 of integrated memory controller 124 allocating an entry in read queue 202 to the read-type request received in step 302 and placing the read-type request in the allocated entry in read queue 202 . The process then ends at step 308 .
[0026] Returning to step 304 , if dispatch logic 200 of integrated memory controller 124 determines that the Ttype of the request received in step 302 is a write-type request, then the process next moves to step 310 . At step 310 , dispatch logic 200 of integrated memory controller 124 allocates an entry in write queue 204 to the request received in step 302 and places the write-type request in the allocated entry in write queue 204 . The process then ends at step 308 .
[0027] Turning now to FIG. 4 , a high-level logical flowchart of a process by which read queue 202 services a read-type request in accordance with the preferred embodiment of the present invention is depicted. The process starts at step 400 and then moves to step 404 , which depicts read queue controller 212 determining whether a read-type request has been received from dispatch logic 200 . If no read-type request has been received, then the process iterates to step 404 .
[0028] If read queue controller 212 determines that a read-type request has been received in one of the entries 206 of read queue 202 , then the process next moves to step 406 , which depicts read queue controller 212 determining whether any pending re-ordered write request exists within write queue 204 having a matching request address. In one preferred embodiment, read controller 212 queue makes this determination by reference to comparing address field 210 of the read request with the address fields 226 of the pending write requests and by checking the reorder flag 222 of any matching entry. In a preferred embodiment, if no address match is found for a re-ordered write request, then the process proceeds to step 408 . At step 408 , read queue controller 212 performs the requested read-type operation and routes the requested data to the appropriate destination. Thereafter, at block 410 , read queue controller 212 de-allocates the entry in read queue 202 allocated to the read-type request. The process then ends at step 412 .
[0029] Returning to step 406 , if read queue controller 212 determines that any pending re-ordered write request exists within write queue 204 having a matching request address, the process will next proceed to step 414 . At step 414 , integrated memory controller 124 will provide a retry partial response to the sender of the read request, which can be any consumer of data on data processing system 10 .
[0030] In an alternative embodiment, at step 406 , if read queue controller 212 determines that any pending re-ordered write request exists within write queue 204 having a matching request address, then the process will proceed to step 416 . At step 416 , will allow read queue control 212 on integrated memory controller 124 will queue and hold the read-type request until any pending re-ordered write request that exists within write queue 204 having a matching request address completes. The process then moves to step 408 , which is described above. As will be apparent to those skilled in the art, source queuing is generally preferred in a memory system. However, those skilled in the art will realize that some specialized applications may require destination queuing, such as is indicated with respect to step 416 . Destination queuing, such as is indicated with respect to step 416 , lies within the scope and spirit of the present invention.
[0031] Turning now to FIG. 5 , a high-level logical flowchart of a process by which write queue 204 services a write-type request in accordance with the preferred embodiment of the present invention is depicted. The process starts at step 500 and moves to step 504 . At step 504 , write queue controller 230 determines whether a write-type request has been received from dispatch logic 200 . If no write request is received at dispatch logic 200 , then the process iterates to step 504 .
[0032] If write queue controller 230 determines that a write-type request has been received from dispatch logic 200 , then the process next moves to step 508 , which depicts write queue controller 230 determining whether any pending re-ordered write-type request exists within write queue 204 having a matching request address. If write queue controller 230 determines that any pending re-ordered write-type request exists within write queue 204 having a matching request address, then the process next proceeds to step 510 .
[0033] At step 510 , write queue controller 230 on integrated memory controller 124 determines whether re-ordering is enabled by inspecting reorder bit 222 . If write queue controller 230 on integrated memory controller 124 determines that reorder bit 222 indicates re-ordering is enabled, then the process next moves to step 512 , which depicts write queue controller 230 on integrated memory controller 124 performing a second subsequent received write request before a first received write request. The process then ends at step 514 .
[0034] Returning to step 508 , if write queue controller 230 determines that no pending re-ordered write-type request exists within write queue 204 having a matching request address, then the process next proceeds to step 516 , which depicts write queue controller 230 determining whether the received write request is the next write-type request to be serviced. Those skilled in the art will realize that while a first-in first-out buffering and queuing system will be common in the art, alternative queuing mechanisms can be used to determine priority of fulfillment of write requests without departing from the spirit and scope of the present invention. If the write request received at step 504 is determined by write queue controller 230 to be the next to be serviced, then the process moves to step 518 , which depicts integrated memory controller 124 performing the write-type request. The process then ends at step 514 .
[0035] Returning to step 516 , if write queue controller 230 determines that the write request received at step 504 is not the next to be serviced, then the process next moves to step 520 , which depicts write queue controller 230 determining by inspecting reorder bit 222 of each entry 220 a - 220 n whether there is a later-received write-type request that is to be re-ordered. If write queue controller 230 determines that there is no later write request to be re-ordered, then the process returns to step 516 . If write queue controller 230 determines that there is a later write request to be re-ordered, then the process proceeds to step 522 , which depicts write queue controller 230 on integrated memory controller 124 performing a second subsequent received write request before a first received write request. The process then returns to step 516 , which is described above.
[0036] An example is provided below. While the example below is explained with respect to an environment with two write requests and one read request, those skilled in the art will quickly anticipate that the present invention applies equally to any set of multiple writes and multiple reads, and that the present invention is substantially scalable. The following example of system behavior illustrates the performance of a preferred embodiment:
1. DMA address A is broadcast by interconnect logic 120 . 2. DMA address B is broadcast by interconnect logic 120 . 3. DMA address A receives a response indicating that the operation must be retried. 4. DMA address B receives a response indicating that the operation is successful. 5. DMA address A is broadcast on interconnect logic 120 . 6. DMA address A receives a response indicating that the operation is successful.
[0043] During the time required to complete step 5 and step 6, if any processor or other consumer of data attempts to read the data from DMA write to address B, I/O controller 128 issues a retry response to prevent the read from completing, thereby restricting read access. By allowing DMA writes to deliver data independently and enforcing coherency by restricting subsequent read access when required, the DMA write ordering rules are met without substantial negative impact to bandwidth and throughput.
[0044] While the present invention is explained with respect to an environment with two write requests and one read request, those skilled in the art will quickly anticipate that the invention applies equally to any set of multiple writes and multiple reads, and that the present invention is substantially scalable. Further, as used with respect to the present invention, the terms second and second subsequent refer to any subsequent write request without regard to how many intervening write requests have accumulated.
[0045] While the invention has been particularly shown as described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. It is also important to note that although the present invention has been described in the context of a fully functional computer system, those skilled in the art will appreciate that the mechanisms of the present invention are capable of being distributed as a program product in a variety of forms, and that the present invention applies equally regardless of the particular type of signal bearing media utilized to actually carry out the distribution. Examples of signal bearing media include, without limitation, recordable type media such as floppy disks or CD ROMs and transmission type media such as analog or digital communication links.
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A method, system and computer program product for handling write requests in a data processing system is disclosed. The method comprises receiving on an interconnect bus a first write request targeted to a first address and receiving on the interconnect bus a subsequent second write request targeted to a subsequent second address. The subsequent second write request is completed prior to completing the first write request, and, responsive to receiving a read request targeting the second address before the first write request has completed, data associated with the second address of the second write request is supplied only after the first write request completes.
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This Nonprovisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 10-2005-0014759 filed in Korea on Mar. 2, 2005, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a refrigerator, and more particularly, to a bottom freezer type refrigerator and container moving system, in which a container of a freezing chamber can be automatically moving along a horizontal or vertical direction.
2. Description of the Related Art
Refrigerators can be classified into several types depending on the locations of a freezing chamber and a chilling chamber. For example, a top mount refrigerator includes a freezing chamber and a chilling chamber that are partitioned up and down, a side-by-side refrigerator includes a freezing chamber and a chilling chamber that are partitioned left and right, and a bottom freezer refrigerator includes a freezing chamber and a chilling chamber that are partitioned down and up.
Although the bottom freezer refrigerator is illustrated to describe the present invention, the present invention is not limited to this particular type of refrigerator.
The bottom freezer refrigerator includes a chilling chamber door and a freezing chamber door. Although the chilling chamber door is a hinged door like other types of refrigerators, the freezing chamber door is a drawer type door because the freezing chamber is relatively small and located at a lower portion of the refrigerator.
Therefore, what is needed is a simple, easy, and convenient way to stow and remove food in the freezing chamber.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a refrigerator and refrigerator container moving system that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a refrigerator and refrigerator container moving system that gives a more convenient way of putting food in the refrigerator and taking food out of the refrigerator.
Another object of the present invention is to provide a refrigerator and refrigerator container moving system that has a simple and effective power supply unit for moving a container along a horizontal or vertical direction.
A further another object of the present invention is to provide a refrigerator and refrigerator container moving system that gives a convenient way of handling a container installed in a drawer type door.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, there is provided a refrigerator including: a main body including at least one chamber; a container disposed in the chamber, the container being movable along a first direction and along a second direction; a door located on the main body, the container being moveable along the first direction by moving the door along the first direction; a motor, the container being movable along the second direction by the motor; and a battery electrically connected to the motor to supply power to the motor.
In another aspect of the present invention, there is provided a refrigerator including: a main body including a chamber; a door for opening and closing the chamber; a container supporter located on a side of the door facing the chamber; a rotary arm connected to the container supporter, the container supporter being movable along a first direction by rotating the rotary arm; a motor for driving the rotary arm; and a power supply unit to supply power to the motor when the door is open.
In a further another aspect of the present invention, there is provided a container moving system for a refrigerator with a door, the system including: a container supporter located on a side of the door; a container seated on the container supporter; a power supply unit, the power supply unit being chargeable when the door is closed; and a motor located on the side of the door to move the container supporter along a first direction.
According to the present invention, food can be more conveniently put in and taken out of the refrigerator.
Further, the power requiring for moving the container can be supplied in a simple, reliable, and convenient way. Therefore, the refrigerator can have an improved outer appearance and it can be conveniently used.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a perspective view of a refrigerator equipped with a container moving system according to an embodiment of the present invention;
FIG. 2 is a sectional view taken along line I-I′ in FIG. 1 ;
FIG. 3 shows a container that is lifted from a position depicted in FIG. 2 ;
FIG. 4 is a rear perspective view of a door according to an embodiment of the present invention;
FIG. 5 is a rear view of a door according to an embodiment of the present invention; and
FIG. 6 is a block diagram of a container moving system for a refrigerator according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. FIG. 1 is a perspective view of a refrigerator equipped with a container moving system according to an embodiment of the present invention. Referring to FIG. 1 , a refrigerator 1 is a bottom freezer type refrigerator that includes a freezing chamber at a lower portion and a freezing chamber door capable of sliding along a horizontal direction, e.g., the forward and backward directions.
In detail, the refrigerator 1 includes a main body 2 , first doors 5 , a second door 6 , a slider 10 , a first chamber (refer to the reference numeral 3 in FIG. 2 ), a second chamber (refer to the reference numeral 4 in FIG. 2 ), drawers 8 , a container supporter 55 , and a power supply terminal 32 . The first doors 5 are hinged on a front upper portion of the main body 2 to open and close the first chamber 3 . The second door 6 is slidably installed at a front lower portion of the main body 2 to open and close the second chamber 4 . The slider 10 is connected between the main body 2 and the second door 6 to enable the sliding of the second door 6 in forward and backward directions. The drawers 8 are formed under the first chamber 3 to store food. The power terminal 32 is formed above or between the drawers 8 to supply power to a container moving system (as will be described later) for lifting the container supporter 55 .
Further, the refrigerator 1 includes a control panel such as control switch buttons 7 at a front side of the second door 6 and a container 62 behind the second door 6 . The control switch buttons 7 are formed at a front side of the second door 6 for controlling the operation of the second door 6 . The container 62 is supported by the container supporter 55 to store food. The container 62 can be vertically lifted by lifting the container supporter 55 . That is, the container 62 may be lifted up for an easy access to food in the container 62 , and it may be lowered down to open and close the second door 6 .
The lifting and lowering of the container 62 will now be described with reference to accompanying drawings. FIG. 2 is a sectional view taken along line I-I′ in FIG. 1 , and FIG. 3 shows a container that is lifted from a position depicted in FIG. 2 . Referring to FIGS. 2 and 3 , a container moving system in the illustrate embodiment includes an actuating unit 40 , a vertical guide unit 20 , and a power supply unit 30 . The actuating unit 40 lifts up and lowers down the container supporter 55 along a rear wall of the second door 6 . The vertical guide unit 20 guides the lifting and lowering of the container supporter 55 . The power supply unit 30 supplies power to the actuating unit 40 . It should be noted that in the illustrated embodiment the container moving system moves the container supporter 55 along the vertical direction. However, the present invention can also be applied to move the container supporter along the horizontal or other directions.
The refrigerator 1 further includes a compartment wall 61 between the first chamber 3 and the second chamber 4 . The drawers 8 are placed under the compartment wall 61 to provide storages at a constant temperature. That is, food and other substances requiring a constant temperature condition can be kept in the drawers 8 .
When the second door 6 is extended outward, the slider 10 stably guides the second door 6 . After the second door is fully extended, the actuating unit 40 operates to lift up the container supporter 55 . Accordingly, the lifting of the container supporter 55 is stably guided by the vertical guide unit 20 . The power supply unit 30 controls power supply to the actuating unit 40 .
The slider 10 includes a pair of horizontal rails 11 . An inner rail is mounted on an inner side of the main body 2 and an outer rail is mounted on an outer side of the second door 6 . The inner rail and the outer rail are slidably engaged with each other such that the outer rail can be slid in and out when the second door 6 is closed and open.
The vertical guide unit 20 is provided to guide the container supporter 55 when the container supporter 55 is lifted up and lowered down. The vertical guide unit 20 includes a vertical rail 21 fixed to the rear surface of the second door 6 . The vertical rail 21 defines a groove (refer to the reference numeral 22 in FIG. 4 ) running its length to receive a protrusion formed on a corresponding side of the container supporter 55 , such that the lifting and lowering of the container supporter 55 can be exactly guided by the vertical rail 21 .
To lift the container supporter 55 , the actuating unit 40 includes an arm support 57 fixed to the rear surface of the second door 6 , an rotary arm 47 hinged on the arm support 57 and extended toward the inside of the refrigerator 1 , a free end 56 of the rotary arm 47 , and a roller 48 rotatably fixed to the free end 56 to make contact with the container supporter 55 at a bottom of the container supporter 55 . The actuating unit 40 further includes a motor (refer to the reference numeral 41 in FIG. 4 ) to rotate the rotary arm. The actuating unit 40 will be further described later.
The power supply unit 30 includes a battery 33 connected to the motor 41 to supply power to the motor 41 . The battery can be located at any place, e.g., within the door 6 as shown in FIG. 3 , on the rear side of the door 6 as shown in FIG. 4 , or on/within the main body 2 with a wiring connection to the motor 41 . The charging terminal 31 is connected to the batter 33 via a wire connection, and the charging terminal 31 comes into contact with the power terminal 32 formed on the main body 2 when the second door 6 is closed.
The lifting of the container 62 will now be described more fully. First, when a user presses a lift-up button of the control switch buttons 7 after the second door 6 is fully open, the battery 33 supplies power to the motor 41 . The battery can be recharged when the second door 6 is closed and the charging terminal 31 and the power terminal 32 are connected.
When the power is on, the motor 41 rotates the rotary arm 47 about the arm support 57 in an upward direction. Thus, the roller 48 as it turns pushes the container supporter 55 upward to lift up the container 62 .
The relationship between the rotary arm 47 and the container supporter 55 can be clearly understood with reference to FIGS. 2 and 3 , which respectively show the container 62 before and after the lifting.
The power supply unit 30 is provided with the battery 33 . When the second door 6 is closed, the battery 33 is charged by receiving power from the main body 2 through the power terminal 32 and the charging terminal 31 . Therefore, the battery 33 can supply power to the motor 41 when the two terminals 32 and 31 are disconnected because of the opening of the second door 6 .
That is, since the power supply unit 30 is provided with the rechargeable battery 33 , in this illustrated embodiment, an additional wire connection is not required between the main body 2 and the second door 6 to supply power to the motor 41 when the second door 6 is open. Therefore, the container moving system can be simply constructed and conveniently used.
FIG. 4 is a rear perspective view of the second door 6 according to an embodiment of the present invention, and FIG. 5 is a rear view of the second door 6 according to an embodiment of the present invention. An operation of the refrigerator with the container moving system will now be more fully described with reference to FIGS. 4 and 5 .
The actuating unit 40 includes the motor 41 installed on the rear surface of the second door 6 , a motor shaft 42 coupled with a rotor of the motor 41 , a driving gear 43 connected to the motor shaft 42 , a driven gear 44 engaged with the driving gear 43 , an arm shaft 46 coupled to a center of the driven gear 44 , and the rotary arm 47 fixed to an end of the arm shaft 46 . A gear support 45 is fixed to the rear surface of the second door 6 to support the driving gear 43 and the driven gear 44 .
In the illustrate embodiment, there are two rotary arm 47 that are respectively coupled to both ends of the arm shaft 46 . Therefore, the container supporter 55 can be supported at both sides by the rotary arms 47 and thus it can be stably lifted.
The gear support 45 includes an arm stopping structure such as a first arm stopper 49 and a second arm stopper 50 that are projected from a surface of the gear support 45 to restrict the rotation of the rotary arm 47 to a predetermined angle range. That is, the container supporter 55 can be limited between the non-lifted and lifted positions. For example, even when the motor 41 is not properly controlled, the arm stoppers 49 and 50 can prevent the rotary arm from over-rotation.
Another stopping structure can be formed on the vertical rail 21 to stop the container supporter 55 . That is, the upper and lower stoppers 51 and 52 may be formed on the upper and lower ends of the vertical rail 21 in order to further limit the container supporter 55 between the non-lifted and lifted positions. Therefore, the container moving system can be more reliably operated.
A sensing unit is provided to detect the up and down motions of the container supporter 55 . For example, the upper and lower sensors 53 and 54 are respectively installed on the upper and lower ends of the vertical rail 21 to detect the lifting and lowering of the container supporter 55 . Both of the contact type sensor and the optical type sensor can be used for the upper and lower sensors 53 and 54 . Based on the detection of the upper and lower sensors 53 and 54 , the power supply to the motor 41 may be controlled.
Operational steps of the container moving system will now be described in detail. When the second door 6 is closed, the power terminal 32 and the charging terminal 31 come into contact with each other so that the battery 33 can be charged. When a user presses a lift-up button of the control switch buttons 7 after the second door 6 is open, the battery 33 supplies power to the motor 41 to drive it. Driving force is transmitted from the motor shaft 42 to the rotary arm 47 through the driving gear 43 , the driven gear 44 , and the arm shaft 46 . Upon the rotation of the rotary arm 47 , the roller 48 on the free end 56 of the rotary arm 47 pushes up the container supporter 55 .
When the container supporter 55 is completely lifted up, the upper sensor 53 detects the container supporter 55 . In response to the detection of the container supporter 55 by the upper sensor 53 , the motor 41 is powered off to stop rotating the rotary arm 47 and lifting the container supporter 55 . Further, when the container supporter 55 is completely lifted up, the container supporter 55 is prevented from being further lifted up by the physical structure of the upper stopper 51 and/or the first arm stopper 49 . Therefore, even if the upper sensor 53 failed to detect the completely lifted container supporter 55 , the container supporter 55 would be prevented from being over-lifted. This increases the reliability of the actuating unit 40 .
The container supporter 55 is lowered down in the same way as it is lifted up. Merely, the motor is rotated in the reverse direction.
FIG. 6 is a block diagram of a container moving system for a refrigerator according to an embodiment of the present invention. Referring to FIG. 6 , a container moving system of the illustrated embodiment includes: a lift-up sensing unit 71 to detect the container 62 when it is completely lifted up; a lowered-down sensing unit 72 to detect the container 62 when it is completely lowered down; a control panel 73 to receive inputs from a user; a controlling unit 70 to output control signals according to signals from the lift-up sensing unit 71 , the lowered-down sensing unit 72 , and the control panel 73 ; an arm driving motor 74 capable of operating under the control of the controlling unit 70 ; and a power source 75 to supply power to the arm driving motor 74 .
The control panel may be the control switch buttons 7 that are formed on the front surface of the second door 6 . The lift-up sensing unit 71 and the lowered-down sensing unit 72 may be respectively the upper sensor 53 and the lower sensor 54 that are installed on the upper and lower ends of the vertical rail 21 . The power source 75 may include the battery 33 to supply power to the arm driving motor 74 .
The lift-up operation of the container moving system is as follows: a lift-up button of the control panel 73 is pressed; the arm driving motor 74 is operated to lift up the container supporter 55 ; the lift-up sensing unit 71 detects the container supporter unit 55 when the container supporter 55 is completely lifted up; and the arm driving motor 74 stops. The lowered-down operation of the container moving system is carried out in a similar way.
As described above, the container is automatically lifted up and lowered down by the container moving system such that users can use the container more easily and conveniently.
Further, the power source (e.g., the battery) is charged when the door is closed and it supplies power to the motor when the door is open, such that an additional power supply unit or a lead wire is not required to supply power to the motor.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A refrigerator and a container moving system for a refrigerator are provided. The refrigerator includes a main body including at least one chamber; a container disposed in the chamber, the container being movable along a first direction and along a second direction; a door located on the main body, the container being moveable along the first direction by moving the door along the first direction; a motor, the container being movable along the second direction by the motor; and a battery electrically connected to the motor to supply power to the motor.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/059,507, filed Jan. 29, 2002, which is a continuation-in-part of U.S. patent application Ser. No. 09/176,481 Oct. 21, 1998, which is a continuation-in-part of U.S. patent application Ser. No. 08/955,590, filed Oct. 22, 1997, which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates generally to an engine that produces energy through a process known as Cavitation and Associated Bubble Dynamics, and specifically to a method and apparatus for a combustion engine that uses bubbles within a fluid as the combustion chamber and for providing the combustion thereof. More particularly, the present invention relates to combustion-type engines that require compression and not spark ignition as part of the combustion process. Even more particularly, the present invention relates to an improved combustion engine that uses a fuel source in the form of a combustible fluid material having been mechanically influenced to provide gas bubbles that are rather small and which bubbles contain a combination of oxygen, water and the burnable fuel matter in vapor form. The term “micro-combustion chamber” as used herein is referring to such small gas bubbles. The bubble combustion process creates an expansion that produces force for driving a pair of rotating members within the chamber. These members have vanes that are so positioned that expansion of the combusting matter contained within the bubbles causes these two particular rotating members to rotate in opposite directions relative to one another, therefore, generating torque that is transmitted to a shaft through a gearing arrangement.
[0006] 2. General Background of the Invention
[0007] Combustion engines are well known devices for powering vehicles, generators and other types of machinery. Some engines require a spark ignition. Some engines such as diesel type engines only require compression for combustion to occur. Combustion diesel engines use one or more reciprocating pistons to elevate the pressure within a corresponding cylinder in order to achieve combustion.
[0008] Among the disadvantages of such engines are inefficiencies caused by heat losses, frictional losses and unharnessed (wasted) work due to the reciprocation of each piston. For example, in a eight cylinder engine, only one cylinder is producing power at any given moment while all eight cylinders are constantly contributing to frictional losses. The reciprocation of each piston also results in unwanted vibration and noise. In addition, due to the relatively low combustion temperatures in such reciprocating piston engines, excessive pollutants such as particulates and carbon monoxide are produced by these engines.
[0009] Furthermore, reciprocating piston engines require refined fuel such as gasoline made from cracking of oil that is performed in refineries and costly to produce. Such engines also require complex fuel injection or carbureation systems, camshafts, electrical systems and cooling systems that can be expensive and difficult to maintain.
[0010] Accordingly, there is a need for more efficient, smoother running and lower emission alternative fuel engines for use in vehicles, generators, and other machinery.
BRIEF SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to overcome one or more of the problems described above.
[0012] In accordance with one aspect of the present invention, a method for increasing the pressure of a fluid in a combustion engine is provided. The method comprises the steps of: creating a bubble of gaseous material within a fluid; elevating the pressure within the bubble to a level such that the temperature inside the bubble reaches a flash point; and obtaining combustion within the bubble.
[0013] In accordance with another aspect of the present invention, a method for generating torque on a rotating shaft is provided. The method comprises the steps of: providing a chamber connected to the shaft for rotation therewith, the chamber having a fluid inlet and a fluid outlet; feeding a fluid into the chamber, the fluid including at least one gaseous bubble; elevating the pressure within the bubble to a level such that the temperature inside the bubble reaches a flash point; and producing combustion within the bubble to elevate the pressure of fluid in the chamber, thereby driving fluid through certain member vanes producing torque and then out through the chamber fluid outlet.
[0014] In accordance with yet another aspect of the present invention, a combustion engine comprises a pump, a fluid reservoir, a drive shaft having a passage therein, and a high pressure chamber fixedly attached to the drive shaft for rotation therewith.
[0015] The high pressure chamber contains a compression drive unit including one or more compression drives blades fixedly attached on the drive shaft, a combustion channel unit rotatably journalled on the drive shaft and containing one or more combustion channels, an impulse drive unit including one or more impulse drives blades rotatable journalled on the drive shaft, and a planetary gear set.
[0016] The planetary gear set includes a ring gear fixedly attached to one of two end plates that are fixedly attached to the drive shaft for rotation therewith, a sun gear fixedly attached to the impulse drive unit for rotation therewith, and one or more planet gears. Each planet gear is rotatable journalled on the combustion channel unit at a location radially intermediate the sun gear and the ring gear and in meshing engagement with the sun gear and the ring gear.
[0017] Therefore, the present invention provides a combustion engine of improved configuration that burns matter contained within small bubbles of a fluid stream, combust these bubbles and produces torque on the shaft.
[0018] The apparatus includes a housing with an interior for containing fluid in a reservoir section. A rotating drive shaft is mounted in the housing and includes a portion that extends inside the housing interior above the fluid reservoir.
[0019] A chamber is mounted on the drive shaft within the housing interior for rotation therewith.
[0020] The chamber includes a power generating system or unit that is positioned within the chamber interior for rotating the drive shaft when fluid flow and bubble combustion take place within the chamber interior. Fluid is provided to the power generating unit via circulation conduit that supplies fluid from the reservoir to the chamber power generating system preferably via a bore that extends longitudinally through the drive shaft and then transversely through a port and into the chamber.
[0021] Within the chamber, the fluid follows a circuitous path through various rotating and non-rotating parts. These parts include at least three rotating members each with vanes thereon, the respective vanes being closely positioned with a small gap therebetween so that when the rotating members are caused to rotate in a given rotational direction, the bubbles are compressed and combustion of the material in the small bubbles occurs and torque is produced.
[0022] A starter is used to preliminarily rotate the shaft and initiate fluid flow. The fluid flow centrifugally causes the respective internal chamber members to rotate. The respective rotating members are so configured and geared, that when they are rotated, they will rotate at different speeds and in relative opposite rotational directions due to the force cause by the fluid flow, however, they will try to rotate in the same direction due to the force cause by the gearing. These conflicting forces configure a fluid flow design that provides a high pressure zone and produces bubble compression. Bubble combustion occurs when two things happen. First, the bubble critical compression produces a sufficiently high temperature in the bubble nucleus to initiate burn. Second, the bubble pressure is lowered. These two steps define one complete combustion cycle. The bubble high pressure and low pressure points occur at the interface between two of the rotating members. The bubble combustion occurs just before the bubble leaves the compression pressure zone. The bubble combustion will apply force in two different fields of direction. This combustion process produces a net expansion force that causes the blades of the two interfacing members to separate and, thereby, causes the two interfacing members proper to rotate in opposite rotational directions.
[0023] A gear mechanism is used to transfer the rotary power from both of the two rotating members to the drive shaft.
[0024] It is to be understood that both the foregoing generally description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. Additional features and advances of the invention will be set forth in the description which follows, and in part will be apparent from the description or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the apparatus and method particularly pointed out in the written description and claims hereof, as well as, the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] For a further understanding of the nature, objects, and advantages of the present invention, reference should be made to the following detailed description and read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0026] [0026]FIG. 1 is a perspective view of the preferred embodiment of the apparatus of the present invention;
[0027] [0027]FIG. 2 is another perspective view of the preferred embodiment of the apparatus of the present invention;
[0028] [0028]FIG. 3 is a partially cutaway front elevational view of the preferred embodiment of the apparatus of the present invention;
[0029] [0029]FIG. 4 is a partial top view of the preferred embodiment of the apparatus of the present invention illustrating the chamber, flinger plate, and drive shaft;
[0030] [0030]FIG. 5 is a sectional view taken along lines 5 - 5 of FIG. 4;
[0031] [0031]FIG. 6 is a sectional view taken along lines 6 - 6 of FIG. 5;
[0032] [0032]FIG. 7 is a sectional view taken along lines 7 - 7 of FIG. 5;
[0033] [0033]FIG. 8 is a sectional view taken along lines 8 - 8 of FIG. 5;
[0034] [0034]FIG. 9 is a fragmentary enlarged view of the vane and combustion interface, an enlargement of a portion of FIG. 7 that is encircled in phantom lines;
[0035] [0035]FIG. 10 is a partial perspective exploded view of the preferred embodiment of the apparatus of the present invention illustrating the combustion channels unit and impulse drive unit portions thereof;
[0036] [0036]FIG. 11 is a perspective fragmentary view of the preferred embodiment of the apparatus of the present invention illustrating the compression drive unit;
[0037] [0037]FIG. 12 is a perspective exploded partially cutaway view of the preferred embodiment of the apparatus of the present invention illustrating the working parts mounted on the drive shaft;
[0038] [0038]FIG. 13 is a perspective view of a second embodiment of the apparatus of the present invention;
[0039] [0039]FIG. 14 is another perspective view of the second embodiment of the apparatus of the present invention;
[0040] [0040]FIG. 15 is a partially cut away front elevational view of the second embodiment of the apparatus of the present invention;
[0041] [0041]FIG. 16 is a partial top view of the second embodiment of the apparatus of the present invention illustrating the chamber, flinger plate, and drive shaft;
[0042] [0042]FIG. 17 is a sectional view taken along lines 17 - 17 of FIG. 16;
[0043] [0043]FIG. 18 is a sectional view taken along lines 18 - 18 of FIG. 17;
[0044] [0044]FIG. 19 is a sectional view taken along lines 19 - 19 of FIG. 17;
[0045] [0045]FIG. 20 is a sectional view taken along lines 20 - 20 of FIG. 17;
[0046] [0046]FIG. 21 is a sectional view taken along lines 21 - 21 of FIG. 17;
[0047] [0047]FIG. 22 is a sectional view taken along lines 22 - 22 of FIG. 17;
[0048] [0048]FIG. 23 is an enlarged fragmentary view of the second embodiment of the apparatus of the present invention showing an enlargement of a portion of FIG. 20 and combustion that takes place at an interface between the torque drive blades and combustion channel blades;
[0049] [0049]FIG. 24 is a partial exploded perspective view of the second embodiment of the apparatus of the present invention;
[0050] [0050]FIG. 25 is a fragmentary sectional elevational view of the alternate embodiment of the apparatus of the present invention illustrating fluid flow and combustion at the interface between torque drive blades and combustion channel blades;
[0051] [0051]FIG. 26 is a perspective view of the third embodiment of the apparatus of the present invention;
[0052] [0052]FIG. 27 is another perspective view of the third embodiment of the apparatus of the present invention;
[0053] [0053]FIG. 28 is a partially cut away front elevation view of the third embodiment of the apparatus of the present invention;
[0054] [0054]FIG. 29 is a schematic view of the third embodiment of the apparatus of the present invention;
[0055] [0055]FIG. 30 is a partial, sectional view of the third embodiment of the apparatus of the present invention;
[0056] [0056]FIG. 31 is a sectional view taken along lines 31 - 31 of FIG. 30;
[0057] [0057]FIG. 32 is a sectional view taken along lines 32 - 32 of FIG. 30;
[0058] FIGS. 33 - 33 A are sectionals view taken along lines 33 - 33 of FIG. 30, FIG. 33A being a partial enlargement of FIG. 33;
[0059] [0059]FIG. 34 is an exploded perspective view of the third embodiment of the apparatus of the present invention;
[0060] [0060]FIG. 35 is a sectional view of a fourth embodiment of the apparatus of the present invention;
[0061] [0061]FIG. 36 is a sectional view taken along lines 36 - 36 in FIG. 35;
[0062] [0062]FIG. 37 is a perspective view of a fifth embodiment of the apparatus of the present invention;
[0063] [0063]FIG. 38 is another perspective view of the fifth embodiment of the apparatus of the present invention;
[0064] [0064]FIG. 39 is a partial sectional elevation view of the fifth embodiment of the apparatus of the present invention taken along lines 39 - 39 of FIG. 1;
[0065] [0065]FIG. 40 is a fragmentary elevation view of the fifth embodiment of the apparatus of the present invention;
[0066] [0066]FIG. 41 is a sectional view of the fifth embodiment of the apparatus of the present invention;
[0067] [0067]FIG. 42 is a sectional view taken along lines 42 - 42 of FIG. 41.
[0068] [0068]FIG. 43 is a partial sectional view of the fifth embodiment of the apparatus of the present invention;
[0069] [0069]FIG. 44 is a fragmentary view of the fifth embodiment of the apparatus of the present invention;
[0070] [0070]FIG. 45 is a sectional view taken along lines 45 - 45 of FIG. 41;
[0071] [0071]FIG. 46 is a sectional view taken along lines 46 - 46 of FIG. 41; and
[0072] [0072]FIG. 47 is an exploded, partial perspective view of the fifth embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0073] FIGS. 1 - 4 show generally the preferred embodiment of the apparatus of the present invention designated generally by the numeral 10 in FIGS. 1, 2, and 3 . Combustion engine 10 has an enlarged housing 11 with an interior 14 . The housing 11 is comprised of upper and lower sections including a lower reservoir section 12 and an upper cover section 13 .
[0074] Fluid 15 is contained in the lower portion of reservoir section 12 as shown in FIG. 3, the fluid 15 having a fluid level 16 that is well below chamber 28 and drive shaft 24 . The fluid can be most any combustible fluid including automatic transmission fluid, hydraulic fluid, vegetable oil, corn oil, peanut oil, for example. A plurality of feet 17 can be used to anchor housing 11 to a pedestal, mount, concrete base, or like structural support. A pair of sealing mating flanges 18 , 19 can be provided respectively on housing sections 11 , 12 to form a closure and seal that prevents leakage during use.
[0075] A pair of spaced apart transversely extending beams 20 , 21 such as the I-beams shown, can be welded to housing reservoir section 12 providing structural support for supporting drive shaft 24 and its bearings 22 , 23 . The drive shaft 24 is to be driven by a rotating member contained within chamber 28 as will be described more fully hereinafter. For reference purposes, drive shaft 24 has a pair of end portions including starter end portion 25 and fluid inlet end portion 26 . Drive shaft 24 carries chamber 28 and flinger plate 27 .
[0076] In FIG. 4, the chamber 28 including its cylindrically-shaped wall portion 50 and its circular end walls 51 , 52 is mounted integrally to and rotates with shaft 24 . Similarly, flinger plate 27 is connected integrally to and rotates with shaft 24 . The flinger plate 27 is used to aerate the liquid 15 after it has been transmitted to chamber 28 and exists therefrom through a plurality of jets 90 (see FIG. 5). The fluid exits via jets 90 and 15 strikes the flinger plate 27 which is rotating with shaft 24 during use. Plate 27 throws the fluid 15 radially away from plate 27 due to the centrifugal force of plate 27 as it rotates with shaft 24 .
[0077] The circulation of fluid 15 through the apparatus 10 begins at reservoir section 12 wherein a volume of liquid 15 is contained below fluid surface 16 as shown. The complete travel of fluid 15 through the apparatus 10 is completed when fluid exits chamber 28 and strikes flinger plate 27 , being thrown off flinger plate 27 as shown by arrow 61 in FIG. 5 to strike housing 11 and then drain to reservoir section 12 of housing 11 . This exiting of fluid 15 from chamber 28 so that it strikes flinger plate 27 creates very small bubbles in fluid 15 that will be the subject of combustion when that aerated fluid 15 again enters chamber 28 via shaft 24 bore 55 as will be described more fully herein.
[0078] In FIGS. 1 - 3 , fluid 15 from reservoir section 12 is first pumped with pump 33 to flow outlet line 32 . This is accomplished initially with a starter motor 42 that rotates shaft 24 . The rotating shaft 24 then rotates pump 33 using power take off 36 .
[0079] Fluid is transferred from reservoir section 12 via outlet port 35 to suction line 34 . Fluid flows from suction line 34 to pump 33 and then to flow outlet line 32 . The fluid then flows through control valve 31 to flow inlet line 30 . A bypass line 40 enables a user to divert flow at control valve 31 so that only a desired volume of fluid enters flow inlet line 30 and hollow bore 55 of shaft 24 at rotary coupling 29 . Once fluid 15 is transmitted to bore 55 , it flows into the interior 71 of chamber 28 for use as a source of combustion as will be described more fully hereinafter. Shaft 24 is connected to flow inlet line 30 with a rotary fluid coupling 29 . Power take off 36 can be in the form of a pair of sprockets 37 , 38 connected to pump 33 and drive shaft 24 respectively as shown in FIG. 2. A chain drive 39 can be used to connect the two sprockets 37 , 38 . Rotation of the drive shaft 24 thus effects a rotation of the pump 33 so that fluid will be pumped from reservoir section 12 of housing 11 via lines 30 , 32 to bore 53 of shaft 24 once starter motor 42 is activated. If fluid 15 is to be bypassed using bypass 40 , it is simply returned to reservoir section 12 via bypass line 40 and port 41 .
[0080] Starter motor 42 can be an electric or combustion engine for example. The motor 42 is mounted upon motor mount 43 . Shaft 24 provides a sheave 44 . Motor drive 42 has a sheave 45 . A sheave 46 is provided on clutch 53 . The sheaves 44 , 45 , 46 are interconnected with drive belt 49 . Clutch 53 also includes a sheave support 47 and a lever 48 that is pivotally attached to mount 43 and movable as shown by arrow 54 in FIG. 1.
[0081] In order to initiate operation, fluid is pumped using pump 33 and motor 42 from reservoir 15 into bore 55 of shaft 24 and then into transverse port 56 . Fluid 15 is picked up by compression drive blades 76 and is centrifugally thrown around and across to combustion channel blades 83 (see arrows 80 , 81 ). Fluid at arrow 81 strikes combustion channel blades 83 and rotates them clockwise in relation to starter 24 end of drive shaft 24 . Continued fluid flow in the direction of arrow 81 causes fluid 15 to hit vanes 63 of impulse drive unit 60 , rotating unit 60 counter clockwise in relation to the starter end 24 of shaft 24 .
[0082] Fluid then returns along the impulse drive unit 60 to exit channels 101 (see arrow 84 ). Since there are only two channels 101 , some fluid 15 recirculates to blades 76 . Fluid exiting channels 101 enters reservoir 102 and then exits chamber 28 at outlet jets 90 to strike flinger plate 27 . At plate 27 the liquid 15 is thrown by centrifugal force to housing 11 where it drains into reservoir section 12 .
[0083] In order to start the engine 10 , the user cranks the starter motor 42 until drive shaft 24 rotates to a desired RPM. On an actual prototype apparatus 10 , the starter motor 42 is cranked until the drive shaft 24 reaches about 1600 RPM's. At that time, the small air bubbles (containing oxygen and vapor from the fluid 15 ) begin to burn at the combustion site designated as 62 in FIG. 9 so that the shaft 26 is driven. When the matter in these bubbles begins to burn, the bubbles expand. In FIG. 9, vanes 63 , 83 on two rotary parts 60 , 65 capture this expansion. The vanes 63 , 83 are so positioned and shaped that the rotary parts 60 , 65 rotate in opposite directions. These two rotary parts are the impulse drive unit 60 and the combustion channels unit 65 . These rotary parts 60 and 65 are part of a mechanism contained within chamber 28 .
[0084] The inner workings of chamber 28 are shown more particularly in FIGS. 4 - 8 . Shaft 24 supports chamber 28 . The chamber 28 end plates 51 , 52 are rigidly fastened to shaft 24 and rotate therewith. In FIG. 5, the starter end 25 of shaft 24 has an externally threaded portion 66 that accepts lock nut 67 . Lock ring 68 bolts to end plate 52 at bolted connections 69 . Key 70 locks lock ring 68 and thus end plate 52 to shaft 24 . Such a lock ring 68 and lock nut 67 arrangement is used to affix end plate 51 to the fluid inlet end portion 26 of shaft 24 .
[0085] The combination of end plates 51 , 52 and cylindrical canister 50 define an enclosure with an interior 71 to which fluid is transmitted during use for combustion. Fluid that enters shaft bore 55 passes through transverse passageway 56 in the direction of arrow 57 to interior 71 of chamber 28 . Bearing 72 is mounted on shaft 24 in between end plates 51 , 52 . Sleeve 73 is mounted on bearing 72 . Transverse openings through shaft 24 , bearing 72 and sleeve 73 define transverse flow passage 56 .
[0086] Impulse drive unit 60 (FIGS. 5 and 10) is rotatably mounted with respect to shaft 24 , being journalled on shaft 24 at transverse passageway 56 . A plurality of preferably four radially extending flow outlet openings 74 enable flow to continue on a path extending radially away from shaft 24 as shown by arrows 75 in FIG. 5. The flow the passes through blades or vanes 76 of compression drive unit 77 , a part that is affixed to end plate 51 at bolted connections 78 . Bearings 79 can form a load transfer interface between compression drive unit 77 and sleeve 73 . The fluid 15 passes over vanes 76 of compression drive unit 77 and radially beyond vanes 76 as shown by arrow 80 in FIG. 5 due to centrifugal force as shaft 24 and chamber 28 are rotated (initially by starter motor 42 ). Bearing 96 rotatably mounts compression channels unit 65 to sleeve 59 .
[0087] Fluid 15 travels from compression drive blades 76 across cavity 82 in the direction of arrows 80 , 81 to combustion channel blades 83 of combustion channels unit 65 . Continued fluid flow brings fluid 15 to and through the blades or vanes 63 of impulse drive unit 60 .
[0088] Combustion occurs at the interface of combustion channel blades 83 and the impulse drive blades 63 . These respective blades 63 and 83 are very close together (see FIGS. 7 and 9) so that severe turbulence causes rapid compression of these bubbles 79 and combustion of their contents (fluid 15 vapor and oxygen). The combustion of the matter within these bubbles 79 causes rapid expansion. This combination of expansion and the shapes of the blades 63 , 83 drives the impulse drive unit 60 and combustion channel unit in opposite rotary directions (see FIG. 9).
[0089] When viewed from the starter end 25 of shaft 24 (see FIGS. 7 and 9) the impulse drive unit 60 rotates counter clockwise and the combustion channels unit 65 rotates counter clockwise. A mix of incoming fluid (arrow 76 in FIG. 5) and outgoing fluid (arrow 84 in FIG. 5) occurs at 85 before fluid 15 exits chamber 28 at fluid outlet jets 90 in plate 51 as shown by arrows 91 .
[0090] Combustion channel unit 65 is bolted to combustion channel inner housing 84 and rotates with it. This assembly of unit 65 and housing 84 are bolted to planet gear mounting plate 85 and rotates therewith. Bolted connection 86 affixes planet gear mounting plate 85 , combustion unit inner housing 84 and combustion channels unit 65 together.
[0091] A plurality (preferably four) planet gears 87 are rotatably mounted ninety degrees (90°) apart to planet gear mounting plate at rotary bushings 95 . Ring gear 89 is bolted at connections 94 to end plate 52 and rotates therewith.
[0092] When viewed from the starter end 25 of shaft 24 , the planet gear mounting plate 85 rotates clockwise (see FIG. 12) during combustion as do the combustion channel unit 65 and combustion channel inner housing 84 all bolted together as an assembly. However, because of the planetary gearing 87 , 88 , 89 these parts 65 , 84 , 85 rotate slower than shaft 24 .
[0093] Sun gear 88 is mounted to impulse drive unit 63 with sleeve 59 . Sun gear 88 can connect to sleeve 59 at bolted connections 92 . A splined connection 93 can connect sleeve 59 to impulse drive unit 63 . Thus, combustion at the impulse drive unit blades 63 (see FIG. 9) rotates the impulse drive unit 60 counter clockwise (relative to shaft 24 starter end 25 ) and sleeve 59 connects that counter clockwise rotation to sun gear 88 .
[0094] Power to drive shaft 24 is generated as follows. Rotational directions are in relation to the starter end 25 of shaft 24 (see FIG. 12). Impulse drive unit 60 and combustion channels unit 65 rotate in opposite rotational directions once the starter motor generates rotation of shaft 24 and initiates fluid flow to a rotational speed of about 1600 rpm. Fluid pumped with pump 33 enters shaft bore 57 and chamber 28 interior via transverse passageway 56 . Fluid 15 flow travels over blades 76 of compression drive unit 77 (see arrows 79 , 80 , 81 ) to the interface between blades 63 and 83 (see FIG. 9). Initially, fluid flow generated by pump 33 causes fluid 15 flow in the direction of arrows 81 (FIGS. 5, 8, and 9 ) to rotate impulse drive unit 60 in a counter clockwise direction and combustion channels unit 65 in a clockwise direction. Once rotational speed of shaft 24 reaches about 1600 rpm, the material in bubbles 79 in between blades 63 of impulse drive unit 60 and blades 83 of combustion channel unit 65 burns.
[0095] Compression of the bubbles 79 at this interface 62 between blades 63 and 83 causes combustion of the fluid vapor-oxygen mixture inside each bubble 79 much in the same way that compression causes ignition and combustion in diesel type engines without the necessity of a spark. In FIG. 9, the gap 100 in between blades 63 and 83 is very small, being about 40 mm.
[0096] Fluid 15 return to reservoir section 12 is via flow channels 101 in drive unit 60 and then to annular reservoir 102 that communicates with jets 90 . Reservoir 102 is defined by generally cylindrically shaped receptacle 103 bolted at 104 to end wall 51 . A loose connection is made at 105 in between receptacle 103 and impulse drive unit 60 . Arrows 106 show fluid flow through impulse drive unit 60 flow channels 101 to reservoir 102 .
[0097] If impulse drive unit 60 and sun gear 88 rotate counter clockwise and the planet gears 87 (and the attached planet gear mounting plate 85 , combustion unit inner housing 84 and combustion channels unit 65 ) rotate clockwise, the ring gear 89 and right end plate 52 (mounted rigidly to shaft 24 ) rotate clockwise at a faster rotary rate than impulse drive unit 60 and sun gear 88 due to the planetary gear ( 87 , 88 , 89 ) arrangement. This can be a 3-1 gear ratio.
[0098] The engine 10 of the present invention is very clean, not having an “exhaust” of any appreciable amount. Residue of combustion is simply left behind in the fluid 15 .
[0099] FIGS. 13 - 25 show a second embodiment of the apparatus of the present invention designated generally by the numeral 110 in FIGS. 13, 14, and 15 . Combustion engine 110 has an enlarged housing 111 with an interior 114 . The housing 111 is comprised of upper and lower sections including a lower reservoir section 112 and an upper cover section 113 .
[0100] Fluid 115 is contained in the lower portion of reservoir section 112 as shown in FIG. 15, the fluid 115 having a fluid level 116 that is well below chamber 128 and drive shaft 124 . The fluid can be any combustible fluid including automatic transmission fluid, hydraulic fluid, vegetable oil, corn oil, or peanut oil, for example. A plurality of feet 117 can be used to anchor housing 111 to a pedestal, mount, concrete base, or like structural support. A pair of sealing mating flanges 118 , 119 can be provided respectively on housing sections 112 , 113 to form a closure and seal that prevents leakage during use.
[0101] A pair of spaced apart transversely extending beams 120 , 121 such as the I-beams shown, can be welded to housing reservoir section 112 providing structural support for supporting drive shaft 124 and its bearings 122 , 123 . The drive shaft 124 is to be driven by a rotating member contained within chamber 128 as will be described more fully hereinafter. For reference purposes, drive shaft 124 has a pair of end portions including starter end portion 125 (right end portion) and fluid inlet end portion 126 (left end portion). Drive shaft 124 carries chamber 128 and flinger plate 127 .
[0102] In FIGS. 15 - 16 , the chamber 128 including its cylindrically-shaped wall portion 150 and its circular end walls 151 , 152 is mounted integrally to and rotates with shaft 124 . Similarly, flinger plate 127 is connected integrally to and rotates with shaft 124 . The flinger plate 127 is used to aerate the liquid 115 after it has been transmitted to interior 171 of chamber 128 and exits therefrom through a plurality of jets 190 (see FIGS. 15, 16, 17 ). The fluid 115 exits via jets 190 and strikes the flinger plate 127 which is rotating with shaft 124 during use. Plate 127 throws the fluid 115 radially away from plate 127 due to the centrifugal force of plate 127 as it rotates with shaft 124 .
[0103] The circulation of fluid 115 through the apparatus 110 begins at reservoir section 112 wherein a volume of liquid 115 is contained below fluid surface 116 as shown. The complete travel of fluid 115 through the apparatus 110 is completed when fluid exits chamber 128 and strikes flinger plate 127 , fluid 115 being thrown off flinger plate 127 as shown by arrows 161 in FIG. 17 to strike housing 111 and then drain to reservoir section 112 of housing 111 . This exiting of fluid 115 from chamber 128 so that it strikes flinger plate 127 creates very small bubbles in fluid 115 that will be the subject of combustion when that aerated fluid 115 again enters chamber 128 via shaft 124 bore 155 as will be described more fully herein.
[0104] In FIGS. 13 - 15 , fluid 115 from reservoir section 112 is first pumped with pump 133 to flow outlet line 132 . This pumping is accomplished initially with a starter motor 142 that rotates shaft 124 . The rotating shaft 124 then rotates pump 133 using power take off 136 .
[0105] Fluid is transferred from reservoir section 112 via outlet port 135 to suction line 134 . Fluid flows from suction line 134 to pump 133 and then to flow outlet line 132 . The fluid 115 then flows through fluid control valve 131 to flow inlet line 130 . A bypass flow line 140 enables a user to divert flow at control valve 131 so that only a desired volume of fluid enters flow inlet line 130 and hollow bore 155 of shaft 124 at swivel or rotary fluid coupling 129 . Once fluid 115 is transmitted to bore 155 , it flows into the interior 171 of chamber 128 for use as a source of combustion.
[0106] Shaft 124 is connected to flow inlet line 130 with rotary fluid coupling 129 . Power take off 136 can be in the form of a pair of sprockets 137 , 138 connected to pump 133 and drive shaft 124 respectively as shown in FIG. 14. A chain drive 139 can be used to connect the two sprockets 137 , 138 . Rotation of the drive shaft 124 thus effects a rotation of the pump 133 so that fluid will be pumped from reservoir section 112 of housing 111 via lines 130 , 132 to bore 155 of shaft 124 once starter motor 142 is activated. If fluid 115 is to be bypassed using bypass 140 , it is simply returned to reservoir section 112 via bypass line 140 and flow port 141 . In this manner, the quantity of fluid 115 flowing to interior 171 can be controlled.
[0107] The configuration and inner workings of chamber 128 are shown more particularly in FIGS. 15 - 17 . Shaft 124 supports chamber 128 . The chamber 128 end wall plates 151 , 152 and canister wall 150 are rigidly fastened to shaft 124 and rotate therewith. In FIG. 17, the starter end 125 of shaft 124 has an external threads 167 that accepts lock nut 168 . Lock ring 169 bolts to end plate 152 at bolted connections 161 . Key 165 locks lock ring 169 and thus end plate 152 to shaft 124 . Such a lock ring 169 and lock nut 168 arrangement is also used to affix end plate 151 to the fluid inlet end portion 126 of shaft 124 .
[0108] Starter motor 142 can be an electric or combustion engine for example. The motor 142 is mounted upon motor mount 143 . Shaft 124 provides a sheave 144 . Motor drive 142 has a sheave 145 . A sheave 146 is provided on clutch 153 . The sheaves 144 , 145 , 146 are interconnected with drive belt 149 . Clutch 153 also includes a sheave support 147 and a lever 148 that is pivotally attached to mount 143 and movable as shown by arrow 154 in FIG. 13.
[0109] When motor 142 is started and clutch 153 engaged, shaft 124 rotates sprocket 138 and (via chain 139 ) sprocket 137 . The sprocket 137 activates and powers pump 133 to pump fluid 115 from outlet line 134 to line 132 and through line 130 to swivel (e.g. a deublin swivel) fluid coupling 129 mounted on shaft 124 . Fluid 115 enters bore or fluid flow channel 155 to port 156 and then to an accumulation or pre-ignition chamber 172 . Chamber 172 is preferably always filled with fluid 115 .
[0110] In order to initiate operation, fluid is pumped using pump 133 and motor 142 from reservoir 115 into bore 155 of shaft 124 and then into transverse port 156 as shown by arrows 157 . Fluid discharged from port 156 enters annular chamber 160 . Fluid then enters chamber 171 via port 188 .
[0111] Fluid at arrows 180 , 181 strikes compression-impulse drive blades 183 and the fluid rotates with them counterclockwise in relation to starter end 125 of drive shaft 124 . Continued fluid flow in the direction of arrow 181 , 182 causes fluid 115 to hit combustion channel blades 163 and then torque blades 166 . As shown in FIG. 25 fluid 115 carries a large number of small bubbles 179 to blades 183 , 163 , 166 . The compression-impulse drive blades 183 are so angled (i.e. blade pitch), that they act as a pump to pitch up fluid in chamber 172 and drive it into combustion channel blades 163 that are a part of and rotate with combustion channel blades housing 170 (see arrows 180 , 181 , 182 in FIG. 17).
[0112] In order to start the engine 110 , the user cranks the starter motor 142 until drive shaft 124 rotates to a desired r.p.m. On an actual prototype apparatus 110 , the starter motor 142 is cranked until the drive shaft 124 reaches about 1500-1600 r.p.m. At that time, the small air bubbles 179 (containing oxygen and vapor from the fluid 115 ) begin to burn at the combustion site, designated as 162 in FIGS. 17 and 23 so that the shaft 124 can be driven.
[0113] When the matter contained in these bubbles 179 begins to burn, the bubbles 179 expand. In FIGS. 17, 23 and 25 , blades or vanes 163 , 166 on two rotary parts capture this expansion. The blades or vanes 163 , 166 are so positioned and so shaped that two rotary parts rotate at different rotational speeds to compress and ignite the bubbles as one vane 163 closely engages another vane. These two rotary parts are the drive sleeve 164 carrying blades 166 and the combustion channels blade housing 170 carrying blades 163 . These rotary parts 164 and 170 are part of the mechanism contained within chamber 28 . The blades 163 and housing 170 are connected to a set of planet gears 174 (i.e. left planet gears) and a ring gear 173 (i.e. right ring gear).
[0114] The concept of the apparatus 110 of the present invention is to provide an internal energy source (i.e. combustion at site 162 in FIGS. 23 - 25 ) in order to put torque on the main drive shaft 124 so that the engine apparatus 110 continues to run from the generated energy of internal combustion. Because of the gearing provided by the assembly of ring gears 173 , 186 and planet gears 174 , 176 and sun gears 175 , 185 the blades 166 rotate faster than blades 163 . The close spacing between blades 163 , 166 (about 0.030 inches) compresses bubbles 179 at combustion site 162 as each bubble 179 is pinched and compressed in between passing blades 163 , 166 . Ignition is thus a function of compression of each bubble 179 , somewhat analogous to the compressive ignition of a diesel engine.
[0115] The right ring gear 173 and right sun gear 175 on the output side (right side) rotate at a faster speed than the output (right side) planet gear 176 . The right planet gears are connected to right end wall 152 . The wall 152 is attached rigidly to shaft 124 .
[0116] On the left side, planet gear 174 is rotatably mounted to mounting plate 177 with shaft 184 . Plate 177 is rigidly mounted to (e.g. bolted) and rotates with combustion channel blades housing 170 (see FIG. 25). Note that the housing 170 thus carries both the left planet gears 184 using plate 177 and the right (output) ring gear 173 using plate 189 . When the left planet gear 184 is driven, the right ring gear 173 is simultaneously driven.
[0117] When the left sun gear 185 is driven, the right sun gear 175 is also driven, because the sun gears 175 , 185 are connected to and rotate with the drive sleeve 164 that rotates independently of main drive shaft 124 . The left ring gear 186 runs at same speed of shaft 124 because it is bolted to thrust wall 206 and thus to chamber 128 at canister wall 150 . Bushing 207 is positioned in between thrust wall 206 and drive sleeve 164 .
[0118] Plant gear (right) 176 and compression-impulse drive blades 183 run at the same rotational speed as drive shaft 124 . If the shaft 124 is rotating at an index speed of 1 r.p.m., the left ring gear 186 and right planet gear 170 also rotate at 1 r.p.m. If the ring gear 186 is rotating at 1 r.p.m., the left planet gear 174 will rotate about the shaft at 33% slower rotational speed i.e. 0.66 r.p.m. The planet gear 174 will rotate several times about its own rotational axis as it rotates 0.66 r.p.m. relative to the rotational axis of the shaft. Stated differently, the planet gear mounting plate 177 carrying left planet gears 174 will rotate 0.66 r.p.m. for each 1.0 r.p.m. of shaft 124 .
[0119] The result of this gearing is that sun gears 175 , 185 connected together with drive sleeve 164 will rotate at about 1.5 r.p.m. for each 1.0 r.p.m. of shaft 124 when planet mounting plate 177 is caused by fluid flow to rotate at about the same speed as shaft 124 .
[0120] Fluid 115 carries small bubbles 179 that will burn at combustion site 162 . The interface at combustion site 162 is a very small dimension of about 0.030 inches of spacing between blades 163 and 166 , that designated spacing indicated by arrow 178 in FIG. 23.
[0121] Once the starter motor reaches about 1600 r.p.m., a stream of fluid 115 containing bubbles 179 which have been impulsed by blades 183 is introduced at interface 162 (combustion site) to generate combustion. The combustion produces an expansion that rotates blades 166 (and everything connected to blades 166 ) counterclockwise (see arrow 159 in FIG. 17) when looking at the starter end 125 of drive shaft 124 . These additional parts that rotate with blades 166 include drive sleeve 164 and sun gears 175 , 185 .
[0122] Combustion channel blades housing 170 is a rotary member that is fastened at bolted connection 205 to plate 189 (see FIGS. 17 and 25). Plate 189 is bolted to ring gear 173 at bolted connection 192 as shown in FIG. 17. The assembly of combustion channel blades housing 170 , the combustion channel blades 163 , plate 189 , and ring gear 173 rotate as a unit. The compression-impulse drive blades 183 are mounted to and rotate with rotary member 191 that is mounted for rotation upon cylindrical sleeve 193 that is also connected for rotation to right planet gear mounting plate 194 . Thrust bearing assembly 195 forms an interface in between the two afore described rotating assemblies. One such assembly includes rotating member 191 , sleeve 193 , and planetary gear mounting plate 194 . The other rotating assembly includes combustion channel blades housing 170 , plate 189 , and ring gear 173 . Each of the planet gears 174 , 176 provides a planet gear shaft 184 that attaches it to an adjacent mounting plate 177 or 194 .
[0123] As fluid 115 reaches the combustion site 162 (see FIGS. 23 and 25), the fluid 115 continues movement in the direction of arrows 196 from blades 163 to combustion site 162 . Fluid 115 then flows through and below blades 166 in FIG. 23. After combustion occurs, the fluid 115 enters annular chamber 197 and port 198 . Flow divider 158 separates chambers 160 , 200 . Some of the fluid flows through port 199 into annular chamber 200 as shown in FIG. 25. Other flow, as indicated by arrow 201 , returns to chamber 172 . One or more longitudinally extending channels 202 are provided in drive sleeve 164 for channeling fluid from annular chamber 200 into reservoir 187 as shown in FIGS. 17 and 25. This flow of fluid from torque blades 166 to jets 190 is shown by arrows 203 in FIG. 17. Fluid exiting reservoir 187 is dispensed by jets 190 against flinger plate 127 as indicated by arrows 204 in FIG. 17.
[0124] FIGS. 26 - 34 show a third embodiment of the apparatus of the present invention designated generally by the numeral 210 . Combustion engine 210 includes a housing 211 having a reservoir section 212 and a cover 213 that is removably attached to the reservoir section 212 . The interior 214 of housing 211 is partially filled with fluid 215 , the fluid level being indicated by arrow 216 . Housing 211 can be provided with a plurality of feet 217 .
[0125] In order to perfect a fluid seal between reservoir section 212 and cover 213 , a pair of peripheral mating flanges 218 , 219 are provided. The flange 218 is on the reservoir section 212 . The flange 219 is on the cover section 213 .
[0126] In FIG. 28, a pair of beams 220 , 221 support bearings 222 , 233 respectively. Bearings 222 , 223 support drive shaft 224 . Drive shaft 224 has a starter end portion 225 and a fluid inlet end portion 226 . In this application, directions of rotations of various parts will be referred to as either clockwise rotation or counterclockwise rotation. These rotations are always in reference to a viewer standing at the starter end portion 225 of shaft 224 and looking at the machine from the starter end portion 225 .
[0127] Flinger plate 227 is attached to shaft 224 and rotates therewith. The flinger plate 227 receives fluid that exits cylindrical cannister 250 via nozzles 280 . As the fluid exits the chamber 228 , it strikes flinger plate 227 and is hurled against the walls of housing 11 because of centrifugal force. Fluid is added to housing 211 at rotary fluid coupling 229 as shown in FIGS. 28 and 29. In FIG. 29, a flow chart of the fluid flow is schematically shown. The fluid 215 is first screened and/or filtered at screen filter 240 and then enters one of the flow outlet pipes 232 A or 232 B. Hydraulic pumps 233 A, 233 B pump fluid to flow divider 234 . Valves 231 A, 231 B control the amount of fluid that enters flow lines 230 or 235 . The flow lines 232 B, 235 define a recirculation flow line that simply routes fluids back to the reservoir section 212 . The valve 231 A determines the amount of fluid that is routed via flow line 230 to rotary coupling 229 and then to chamber 228 .
[0128] Hydraulic pumps 233 A, 233 B are preferably hydraulically driven using power takeoff 236 . Power takeoff 236 includes sprockets 237 A, 237 B and chain drive 239 . Vertical support 238 carries flow divider 234 and valves 231 A, 231 B. Flow ports 241 A, 241 B transmit fluid to and from housing 211 . Port 241 A communicates with flow line 232 A. Port 241 B communicates with flow line 232 B.
[0129] In FIGS. 26 and 28, starter motor 242 is shown contained upon motor mount 243 . A plurality of sheaves 244 , 245 , 246 are connected by belt 249 as shown. Lever 248 is provided for tightening the belt 249 . Sheave support 247 interconnects lever 248 with sheave 246 . A user pulls upon the lever 248 in the direction of arrow 254 in order to tighten the belt 249 and impart energy from starter motor 242 to shaft 224 , rotating the shaft until combustion occurs within chamber 228 .
[0130] Chamber 228 includes an outer enclosure defined by cylindrical cannister wall 250 and circular end walls 251 , 252 . The chamber 228 is connected to shaft 224 and rotates therewith when the clutch 253 comprised of starter motor 242 , sheaves 244 - 246 and belt 249 is engaged. When the shaft 224 is rotated, the power takeoff 236 engages the pumps 233 A, 233 B to begin pumping fluid 215 . The fluid enters shaft flow channel 255 and transverse passageway 256 , fluid flowing in the direction of arrow 257 . In FIG. 30, the connection between chamber 228 and shaft 224 is shown as including an externally threaded portion 266 of shaft 224 that receives lock nut 267 and lock ring 268 . A bolted connection 269 fastens lock ring 268 to end plate 252 . A similar connection is formed between end plate 251 and shaft 224 next to flinger plate 227 . Chamber 228 and shaft 224 rotate clockwise (viewed from starter motor 242 ) as one fixed assembly. The shaft 242 is set in bearings 222 , 223 (FIG. 28).
[0131] In FIG. 34, an exploded view of the chamber 228 is shown with the cylindrical cannister wall 250 removed for clarity. FIG. 30 shows the internal parts of chamber 228 .
[0132] In the exploded view of FIG. 34, and in the sectional view of FIG. 30, the left end plate 251 and right end plate 252 are shown attached to shaft 224 . Left planet gears 262 are rotatably mounted to left end plate 251 at shafts 281 using fasteners 282 . Right ring gear 263 is fastened (eg. bolted) to right end plate 252 .
[0133] The left ring gear 260 drives the right planet gears 264 . The left sun gear 261 rotates counter clockwise as shown in FIG. 34. The left end plate 251 rotates clockwise as shown in FIG. 34 with shaft 224 . The left sun gear 261 rotates counter clockwise and is connected to the reaction blades 265 . The left ring gear 260 rotates faster than shaft 224 , and is connected to the pump blades 270 . The pump blades 270 are connected to left ring gear 260 and rotate faster than shaft 224 .
[0134] Reaction blades 265 are connected to left sun gear 261 with sleeve 288 and rotate counter clockwise to shaft 224 . Pump blades wall 292 is mounted to pump blades 270 (see FIG. 30). The wall 292 acts as a baffle for fluid flow so that fluid traveling from shaft bore 294 through port 293 travels to pump blades 270 and then follows arrows 296 to the periphery of pump blades 270 , around the periphery of wall 292 to the periphery of turbine blades 273 , in between turbine blades 273 (see FIG. 33A) to reaction blades 275 . Sleeve 228 has annular space 313 that collects return fluid exiting reaction blades 265 and transmits such effluent fluid to nozzles 280 via reservoir 298 .
[0135] Left sun gear 261 can be integrally connected to reaction blades 265 at sleeve 288 as shown in the sectional view of FIG. 30. Bearing 287 forms an interface between sleeve 288 and clam shell housing 259 . Turbine 271 is a rotating structure that includes turbine blades 273 and sleeve 283 . Bearing 284 forms a rotary interface between sleeve 283 and clamshell housing 259 . Clamshell 259 can be comprised of left clamshell half 285 and right clamshell half 286 . The halves 285 and 286 are connected together (eg. welded) at their respective peripheries. Right sun gear 289 is fastened (eg. bolted) to right clamshell half 286 using fasteners (eg. bolts) 290 .
[0136] When filled with fluid, the mere rotation of the chamber 228 will cause the pump blades 270 to centrifugally drive the turbine 271 , which is connected to the right planet gears via plate 272 . The right planet gears 264 will in turn drive the right ring gear 263 that is mounted on the right end plate 252 which is connected to the shaft 224 . The aforementioned rotations result when the reaction blades 265 rotate counter clockwise.
[0137] In FIGS. 30 and 31- 34 , fluid enters bore 294 of shaft 224 and flows to lateral flow port 293 (see FIGS. 30 - 31 ). Flow then passes from port 293 via channel 295 (see arrows 296 ) in sleeve 288 to pump blades 270 and in between clamshell 259 left half 285 and plate 292 that is fastened to blades 270 .
[0138] Following arrows 296 in FIG. 30, fluid travels to pump the periphery of blades 270 , then to the periphery of turbine blades 273 and then to reaction blades 265 . As shown in FIG. 34, turbine blades 273 and reaction blades 265 travel in opposite rotational directions so that micro-bubbles 274 traveling with the fluid are combusted at the interface, such combustion designated by the reference numerals 275 in FIG. 34.
[0139] By causing the micro bubbles 274 to combust at 275 on the leading edge of the reaction blades 265 (see FIG. 34), the fluid will accelerate down the pitch of the reaction blades 265 toward the shaft 224 turning the reaction blades 265 counter clockwise as shown by arrow 277 in FIG. 34. The fluid then exits reaction blades 265 through ports 314 to annular space 313 to thrust jets 280 going from a high pressure containment to a low pressure zone, striking flinger plate 227 . Hence, the chamber 228 is driven by micro-bubble 274 combustion at 275 and thrust.
[0140] The micro-combustion chamber heat engine 210 needs no outside mechanical grounding. The turbine blades 273 rotate in the direction of arrow 278 and eventually rotate right end plate 252 . The reaction blades 265 rotate in the direction of arrow 277 to rotate pump blades 270 . The centrifugal force produced by the rotation of the chamber 228 causes the fluid to flow over the different blades inside the chamber. The fluid moves the blades 273 and 265 and the blades 273 , 265 move the connected gears (planet and sun).
[0141] By adding a net energy gain through micro-bubble combustion, the apparatus 210 continually energizes the fluid through a continuous stream of bubble 274 burn 275 . In addition, since the bubble 274 is the combustion chamber, engine size can be scaled down to micro technology without compromising power output and without producing any noticeable amount of CO or CO 2 .
[0142] Fluid exiting reaction blades 265 flows through ports 314 to annular space 313 to channel 291 and then to reservoir 298 that is surrounded by reservoir wall 297 and then exits chamber 228 at nozzle jets 280 , striking flinger plate 227 to aerate the fluid and produce micro-bubbles. Additional micro-bubbles form in the fluid when it travels from flinger plate 227 and strikes the canister wall 250 .
[0143] FIGS. 35 - 36 show a fourth embodiment of the apparatus of the present invention, wherein the chamber 300 replaces the chamber 228 of the third embodiment 210 . In FIGS. 35 - 36 , certain parts attached to left end plate 251 are provided that redirect fluid flow exiting chamber 228 . Otherwise, the working parts of chamber 228 are the same as those shown in FIG. 30. In FIG. 35, the new parts are those to the left of left sun gear 261 and include generally plate 301 , bearing 302 , rotating member 303 and peripheral member 310 .
[0144] Rotating member 303 is preferably integral with sleeve 288 . Thus, member 303 replaces reservoir wall 297 of the embodiment of FIG. 30. Jets 280 and reservoir 298 are also eliminated. Planet gears 262 are now (FIG. 35) mounted upon plate 301 at planet gear mounts 299 instead of to end wall 251 . End wall 251 and plate 301 are affixed together using bolted connections 308 .
[0145] Expander plate 303 rotates with sleeve 288 and sun gear 261 . Plate 301 is bolted to end plate 251 (eg. with bolted connections 311 ) and with peripheral member 310 being positioned as shown in FIG. 35 in between end plate 251 and plate 301 . Bearing 302 defines an interface between sleeve 288 and plate 301 .
[0146] During use, fluid flows via ports 304 to channels 302 in expander plate 303 (see FIG. 30). Fluid then enters chamber 306 . Because plate 303 rotates in the direction of arrow 313 and member 310 rotates in the direction of arrow 313 , fluid entering chamber 306 builds up back pressure until chambers 306 align with chambers 307 . Once fluid from chamber 306 mixes with chamber 307 , rotational speeds of members 303 , 310 increase. Fluid then exits chamber 297 via channels 308 , tube 309 and nozzles 312 .
[0147] FIGS. 37 - 47 show generally the fifth embodiment of the apparatus of the present invention, designated generally by the numeral 315 in FIGS. 37, 38, and 39 . Combustion engine 315 has an enlarged housing 316 with an interior 319 . The housing 316 is comprised of upper and lower sections including a lower reservoir section 317 and an upper cover section 318 .
[0148] Fluid 320 is contained in the lower portion of reservoir section 317 as shown in FIG. 39, the fluid 320 having a fluid level 321 that is well below chamber 333 and drive shaft 329 . The fluid 320 can be most any combustible fluid including automatic transmission fluid, hydraulic fluid, vegetable oil, corn oil, peanut oil, for example.
[0149] A plurality of feet 322 can be used to anchor housing 316 to a pedestal, mount, concrete base, or like structural support. A pair of sealing mating flanges 323 , 324 can be provided respectively on housing sections 317 , 318 to form a closure and seal that prevents leakage during use.
[0150] A pair of spaced apart transversely extending beams 325 , 326 such as the I-beams shown, can be welded to housing reservoir section 317 providing structural support for supporting drive shaft 329 and its bearings 327 , 328 . The drive shaft 329 is to be driven by a rotating member contained within chamber 333 as will be described more fully hereinafter. For reference purposes, drive shaft 329 has a pair of end portions including starter end portion 330 and fluid inlet end portion 331 .
[0151] In FIGS. 39 - 40 , the chamber 333 including its cylindrically-shaped wall portion 355 and its circular end wall plates 356 , 357 is mounted integrally to and rotates with shaft 329 . Cylindrically shaped wall portion 355 has a plurality of fluid outlet jets 332 that enable fluid to exit chamber 333 . The fluid 320 that exits chamber 333 via jets 332 strikes the inside surface 366 . The fluid 320 is thrown radially away from wall portion 355 due to the centrifugal force of wall portion 355 as it rotates with shaft 329 .
[0152] The circulation of fluid 320 through the apparatus 315 begins at reservoir section 317 wherein a volume of fluid 320 is contained below fluid level 321 as shown in FIG. 39. The travel of fluid 320 through the apparatus 315 is completed when fluid 320 exits chamber 333 via jets 332 and is thrown against inner surface 366 of housing 316 and then draining to reservoir section 317 of housing 316 . This exiting of fluid 320 from chamber 333 so that it strikes housing 316 inner surface 366 creates very small bubbles in fluid 320 that will be the subject of combustion when that aerated fluid 320 again enters chamber 333 via shaft 329 flow channel 360 and radial passageway 361 as will be described more fully herein.
[0153] In FIGS. 37 - 41 , fluid 320 from reservoir section 317 is first pumped with positive displacement rotary fluid pump 338 to flow outlet line 337 . Pumping of fluid 320 is accomplished initially with a starter motor 347 that rotates shaft 329 . The rotating shaft 329 then rotates pump 338 using power take off 341 .
[0154] Fluid 320 is transferred from reservoir section 317 via outlet port 340 to suction line 339 . Fluid 320 flows from suction line 339 to pump 338 and then to flow outlet line 337 . The fluid 320 then flows through control valve 336 to flow inlet line 335 . A bypass line 345 enables a user to divert flow at control valve 336 so that only a desired volume of fluid 320 enters flow inlet line 335 and hollow bore 360 of shaft 329 at rotary coupling 334 . Once fluid 320 is transmitted to bore 360 , it flows via radial passageway 361 into the interior 319 of chamber 333 for use as a source of combustion as will be described more fully hereinafter.
[0155] Shaft 329 can be connected to flow inlet line 335 with a rotary fluid coupling 334 . Power take off 341 can be in the form of a pair of sprockets 342 , 343 connected to pump 338 and drive shaft 329 respectively as shown in FIG. 38. A chain drive 344 can be used to connect the two sprockets 342 , 343 . Rotation of the drive shaft 329 thus effects a rotation of the pump 338 so that fluid 320 will be pumped from reservoir section 317 of housing 316 via lines 335 , 337 to channel 360 of shaft 329 once starter motor 347 is activated. If fluid 320 is to be bypassed using bypass 345 , it is simply returned to reservoir section 317 via bypass line 345 and port 346 .
[0156] Starter motor 347 can be an electric motor or internal combustion engine for example. The motor 347 is mounted upon motor mount 348 . Shaft 329 provides a sheave 349 . Motor drive 347 has a sheave 350 . A sheave 351 is provided on clutch 358 . The sheaves 349 , 350 , 351 are interconnected with drive belt 354 . Clutch 358 also includes a sheave support 352 and a lever 353 that is pivotally attached to mount 348 and movably as shown by arrow 359 in FIG. 37.
[0157] To start the engine 315 , the user cranks the starter motor 347 until drive shaft 329 rotates to a desired RPM. On an actual prototype apparatus 315 , the starter motor 347 is cranked until the drive shaft 329 reaches about 1000-1600 RPM's. The starter motor 347 thus initiates operation, by activating pump 338 to pump fluid 320 from reservoir 317 into flow channel 360 of shaft 329 and then into transverse passage way 361 .
[0158] Radial passageway 361 communicates with annular chamber 362 of hub 363 . Hub 363 has a central opening 364 that receives shaft 329 so that hub 363 closely fits shaft 329 , but spins with respect to, shaft 329 . Hub openings 365 are circumferentially spaced, radially extending openings in hub 363 that enable fluid 320 to flow from annular chamber 363 of hub 363 to the annular chamber 373 that is radially positioned away from hub openings 365 and that is sandwiched between clamshell housing 371 and hub 363 .
[0159] Clamshell housing 371 is rotatably mounted to hub 363 using bearings 374 , 375 . Compression drive blades 369 are fixedly attached to clamshell housing 371 . Sun gear 376 attaches to hub 377 . Hub 377 has central opening 378 that is sized and shaped to closely fit shaft 329 . Hub 377 also carries reaction blades 379 . Hub 368 connects planet gears 381 to combustion channel blades 380 . Hub 368 has central opening 382 that is sized and shaped to fit the outer surface 383 of hub 377 .
[0160] In FIGS. 45 and 47 each planet gear 381 attaches to hub 368 with a planet gear shaft 384 . Each planet gear 381 is engaged by sun gear 376 and ring gear 385 . Ring gear 385 is attached to and rotates with chamber 333 . Ring gear 385 can be attached (e.g. bolted) to plate wall 357 .
[0161] Angled thrust tube 370 is mounted on clamshell housing 371 next to combustion site 367 . As shown in FIGS. 41, 42, 43 , 44 and 47 , the thrust tube 370 is angled so that when combustion occurs in the small bubbles that are carried in fluid 320 at combustion site 367 , expanding fluid exits tube 370 as schematically illustrated by arrow 386 in FIG. 44, rotating clamshell housing 371 in the direction of arrow 372 in FIG. 42. Small air bubbles (containing oxygen and vapor from the fluid 320 ) are conveyed to and begin to burn at combustion site 367 in FIG. 41. When the matter in these bubbles begins to combust, the bubbles expand. In FIG. 41, a thrust tube (or tubes) 370 capture this expansion. The thrust tube 370 is so positioned and shaped that it rotates clamshell housing 371 in the direction of arrow 372 .
[0162] Using starter motor 347 , shaft 329 is initially rotated in a clockwise direction as indicated by arrow 387 in FIG. 37. Rotation of shaft 329 also rotates housing 333 and ring gear 385 in the same clockwise direction as viewed in FIG. 37. In the sectional view of FIG. 45, the rotation of ring gear 385 is indicated by arrow 388 . Arrow 389 shows the direction of rotation for each planet gear 381 .
[0163] Arrow 390 shows the rotation of sun gear 376 . When shaft 329 is driven by starter motor 347 , sun gear 376 drives the reaction blades 379 to rotate in the same direction as sun gear rotation arrow 390 . Combustion channel blades 380 rotate in the same direction as ring gear 385 and in an opposite direction from reaction blades 379 (see FIGS. 42, 43 and 44 ).
[0164] Fluid 320 that flows through bore 360 to radial passageway 361 divides into two flow components, (see arrows 391 , 392 in FIG. 41) following the path of least resistance so that some fluid 320 flows to reaction blades 379 and some fluid 320 flows to compression drive blades 369 (see FIGS. 41, 42).
[0165] Once the chamber 333 is filled with fluid 320 , the fluid 320 becomes pressurized because pump 338 tries to transmit more fluid 320 into chamber 333 than can be discharged from chamber 333 , and the pressurized fluid 320 begins to push on the blades 379 , 380 . The pitch of the blades 379 , 380 attempt to channel the fluid 320 as it flows between the blades 379 and then 380 (see FIGS. 43, 44). The sun gear 376 rotates in the direction of arrow 390 as compared to arrow 388 of ring gear 388 . As fluid 320 leaves compression drive blades 369 , it collides with fluid 320 exiting combustion channel blades 380 . These colliding fluid streams carry very tiny bubbles filled with a combination of vapor of the fuel (fluid 320 ) and oxygen. They are compressed sufficiently to cause combustion inside each bubble. The expanding gas produced by combustion of the tiny bubbles in fluid 320 attempts to exit clamshell housing 371 via angled thrust tube 370 , rotating clamshell housing 371 in the same direction as chamber 333 (see arrow 393 in figure 46 ).
[0166] As combustion of small bubbles occurs at combustion site 367 , motor 347 is no longer needed as the sole drive for shaft 329 . Rather, the rotating clamshell housing 371 and its drive blades 369 rotate as the bubble combustion causes expanding gas to exit tube 370 .
[0167] Because of the gearing of FIG. 45, the combustion channel blades 380 rotate at a slower speed. The faster rotating compression drive blades 369 attempt to pump fluid back across the combustion site 367 in the direction of the combustion channel blades 380 . However, fluid 320 continues to inflow via channel 360 , passageway 361 and annular chamber 362 to blades 379 and 380 . The fluid 320 that is pumped by rotating blades 369 on clamshell housing 371 pumps against blades 380 and rotates them in the same direction as arrow 393 (see FIGS. 41, 42, and 46 ). Blades 380 are connected to planet gears 381 . As the planet gears move in the direction of arrow 388 , sun gear 376 rotates in the direction of arrow 390 . The ring gear 385 is driven by planet gears 381 to rotate and drive shaft 329 that is attached to ring gear 385 via chamber 333 and wall plate 357 .
[0168] The following table lists the parts numbers and parts descriptions as used herein and in the drawings attached hereto.
PARTS LIST Part Number Description 10 combustion engine 11 housing 12 reservoir section 13 cover 14 interior 15 fluid 16 fluid level 17 feet 18 flange 19 flange 20 beam 21 beam 22 bearing 23 bearing 24 drive shaft 25 starter end portion 26 fluid inlet end portion 27 flinger plate 28 chamber 29 rotary fluid coupling 30 flow inlet line 31 fluid control valve 32 flow outlet line 33 pump 34 suction line 35 flow port 36 power take off 37 sprocket 38 sprocket 39 chain drive 40 bypass flow line 41 flow port 42 starter motor 43 motor mount 44 sheave 45 sheave 46 sheave 47 sheave support 48 lever 49 belt 50 cylindrical canister 51 circular end wall plate 52 circular end wall plate 53 clutch 54 arrow 55 shaft flow channel 56 transverse passageway 57 arrows 58 bushing 59 sleeve 60 impulse drive unit 61 arrow 62 combustion site 63 impulse drive blades 65 combustion channels 66 externally threaded portion 67 lock nut 68 lock ring 69 bolted connection 70 key 71 interior 72 bearing 73 sleeve 74 flow outlet opening 75 arrow 76 blades 77 compression drive unit 78 bolted connection 79 bubbles 80 arrow 81 arrow 82 cavity 83 combustion channel blades 84 combustion channel unit inner housing 85 planet gear mounting plate 86 bolted connection 87 planet gear 88 sun gear 89 ring gear 90 fluid outlet jet 91 arrow 92 bolted connection 93 splined connection 94 bolted connection 95 rotary bushing 96 bearing 100 gap 101 flow channel 102 reservoir 103 receptacle 104 bolted connection 105 connection 106 arrow 110 combustion engine 111 housing 112 reservoir section 113 cover 114 interior 115 fluid 116 fluid level 117 feet 118 flange 119 flange 120 beam 121 beam 122 bearing 123 bearing 124 drive shaft 125 starter end portion 126 fluid inlet end portion 127 flinger plate 128 chamber 129 rotary fluid coupling 130 flow inlet line 131 fluid control valve 132 flow outlet line 133 pump 134 suction line 135 outlet port 136 power take off 137 sprocket 138 sprocket 139 chain drive 140 bypass flowline 141 flow port 142 starter motor 143 motor mount 144 sheave 145 sheave 146 sheave 147 sheave support 148 lever 149 drive belt 150 cylindrical canister wall 151 circular end wall plate 152 circular end wall plate 153 clutch 154 arrow 155 shaft flow bore 156 transverse port 157 arrow 158 flow divider 159 shaft rotation arrow 160 annular chamber 161 bolted connection 162 combustion site 163 combustion channel blade 164 drive sleeve 165 key 166 torque blade 167 external threads 168 lock nut 169 lock ring 170 combustion channel blades housing 171 interior 172 pre-ignition chamber 173 right ring gear 174 left planet gear 175 right sun gear 176 right planet gear 177 planet gear mounting plate 178 arrow 179 bubbles 180 arrow 181 arrow 182 arrow 183 compression-impulse drive blade 184 planet gear shaft 185 left sun gear 186 left ring gear 187 reservoir 188 port 189 plate 190 jets 191 rotary member 192 bolted connection 193 sleeve 194 planetary gear mounting plate 195 thrust bearing assembly 196 arrows 197 chamber 198 port 199 port 200 annular chamber 201 arrow 202 channels 203 arrow 204 arrow 205 bolted connection 206 thrust wall 207 bushing 210 combustion engine 211 housing 212 reservoir section 213 cover 214 interior 215 fluid 216 fluid level 217 feet 218 flange 219 flange 220 beam 221 beam 222 bearing 223 bearing 224 drive shaft 225 starter end portion 226 fluid inlet end portion 227 flinger plate 228 chamber 229 rotary fluid coupling 230 flow inlet line 231A fluid control valve 231B fluid control valve 232A flow outlet pipe 232B flow outlet pipe 233A pump 233B pump 234 flow divider 235 recirculation line 236 power takeoff 237A sprocket 237B sprocket 238 vertical support 239 chain drive 240 screen filter 241A flow port 241B flow port 242 starter motor 243 motor mount 244 sheave 245 sheave 246 sheave 247 sheave support 248 lever 249 belt 250 cylindrical canister wall 251 circular end wall 252 circular end wall 253 clutch 254 arrow 255 shaft flow channel 256 transverse passageway 257 arrow 258 turbine 259 clam shell 260 left ring gear 261 left sun gear 262 planet gear 263 right ring gear 264 right planet gear 265 reaction blade 266 externally threaded portion 267 lock nut 268 lock ring 269 bolted connection 270 pump blade 271 turbine 272 planet gear plate 273 turbine blade 274 micro-bubble 275 combustion of bubble 276 arrow 277 arrow 278 arrow 279 pump blade wall 280 nozzle thrust jet 281 planet gear shaft 282 fastener 283 sleeve 284 bearing 285 left clamshell half 286 right clamshell half 287 bearing 288 sleeve 289 right sun gear 290 fastener 291 flow channel 292 plate 293 flow port 294 bore 295 channel 296 arrow 297 reservoir wall 298 reservoir 299 planet gear mount 300 chamber 301 plate 302 bearing 303 expander plate 304 port 305 channel 306 chamber 307 chamber 308 channel 309 tube 310 peripheral member 311 bolted connection 312 nozzle 313 annular space 314 ports 315 combustion engine 316 housing 317 reservoir section 318 cover 319 interior 320 fluid 321 fluid level 322 feet 323 flange 234 flange 325 beam 326 beam 327 bearing 328 bearing 329 drive shaft 330 starter end portion 331 fluid inlet end portion 332 fluid outlet jet 333 chamber 334 rotary fluid coupling 335 flow inlet line 336 fluid control valve 337 flow outlet line 338 pump 339 suction line 340 outlet port 341 power take off 342 sprocket 343 sprocket 344 chain drive 345 bypass flow line 346 flow port 347 starter motor 348 motor mount 349 sheave 350 sheave 351 sheave 352 sheave support 353 lever 354 belt 355 cylindrical wall 356 circular end wall plate 357 circular end wall plate 358 clutch 359 arrow 360 shaft flow channel 361 radial passageway 362 annular chamber 363 hub 364 central opening 365 opening 366 housing inner surface 367 combustion site 368 hub 369 compression drive blades 370 angled thrust tube 371 clamshell housing 372 arrow 373 annular chamber 374 bearing 375 bearing 376 sun gear 377 hub 378 hub central opening 379 reaction blades 380 combustion channel blades 381 planet gear 382 central opening 383 outer surface 384 planet gear shaft 385 ring gear 386 arrow 387 arrow 388 arrow 389 arrow 390 arrow 391 arrow 392 arrow 393 arrow
[0169] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A combustion engine is provided having a rotating drive shaft and planetary gear sets that are linked to a rotating chamber, keyed to the drive shaft, to turbomachinery within the chamber. Fluid is fed to the chamber through an axial passage in the drive shaft and is compressed by a number of mechanisms, including set of pump blades, turbine and reaction blades initially driven by the drive shaft and its starter motor. Bubbles within the fluid are subjected to high pressures causing combustion to occur within the bubbles. Additional pressure created by the combustion of the bubbles drives the fluid to exert a net torque on the drive shaft through the gearing mechanism, thereby generating power.
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BACKGROUND OF THE INVENTION
This invention relates in general to applying size to a yarn product, and in particular to improved apparatus and method for high pressure squeezing in the application of size.
Size is a product and is a treatment for reducing the friction and abrasive action of a loom on the warp or longitudinal yarn bundles, in preparing for a subsequent weaving process. The commonplace application of size takes place by passing the warp yarns through a size bath to saturate the yarns with size, and then removing excess size solution by squeezing the warp between a pair of rolls. The moisture remaining in the warp yarns after the squeezing operation must be removed by passing the warp through a dryer, which typically includes a number of heated drying drums around which the warp passes to remove the remaining moisture by evaporation. The maximum speed of the sizing operation, measured in terms of lineal warp distance per unit time, is limited by the need to completely dry the sized warp, which is rewound for subsequent weaving.
The term "% add-on" is used to describe the amount of sizing product applied to the warp yarn, and this term is usually expressed as the product of the "wet pick-up" (the weight of size bath liquid applied to a unit weight of yarn) times the % solids (the proportion of size bath liquid made up of actual sizing products). The need to provide at least a desired minimum % add-on to the warp yarn has, in the past, conflicted with the desire to minimize the water evaporation requirement of the yarn immediately after passing through the squeeze rolls. The water evaporation requirement is the weight of water to be evaporated per unit weight of yarn, and reducing the water evaporation requirement decreases the amount of energy required to remove that water from a unit length of yarn.
The squeeze rolls of conventional sizing machines typically include a top rubber covered squeeze roll, and a lower stainless steel roll. The lower roll is driven to substantially synchronize its surface speed with the forward movement of the warp yarns, and the rubber covered squeeze roll is held against the bottom roll to provide a squeeze force typically on the order of ten to twenty pounds per lineal inch (PLI) in the "nip" or region of roll contact, in the prior art. While increasing the squeeze pressure theoretically would reduce the water evaporation requirement, the % add-on was reduced below a desirable amount in the past.
Sizing products which can be mixed in higher concentrations (% solids) have become available. These more highly concentrated sizing products permit a greater amount of liquid removal by squeezing, which substantially reduces the water evaporation requirement while still retaining the desired % add-on of sizing product applied to the yarn. In order to obtain the reduced water evaporation requirement, it was initially believed that the squeeze pressure simply could be increased to provide the desired increased liquid removal before the drying operation. Such prior-art attempts to increase size squeezing, however, met with several unanticipated problems. The top rubber-covered squeeze roll of conventional sizing apparatus is driven only by the friction of surface contact with the lower roll, and the combined effects of increased squeeze pressures and inherent slipperyness of sizing solutions caused intermittent or erratic slippage of the top squeeze roll relative to the bottom roll. A substantial amount of relative slippage of the rolls cannot be tolerated, because the warps must be processed under very low limits of longitudinal strain. Moreover, the amount of slippage in rotation of the rubber covered top roll, caused by rubber strain under increased squeeze force, varied as a function of the squeeze loading, so that the degree of warp strain varied depending on the particular selected squeeze loading. Initial attempts to overcome the problem of top squeeze roll slippage, brought on by attempts to decrease the water evaporation requirement by increasing the squeeze loading, thus were not successful.
Moreover, the frequent need to separate the top and bottom squeeze rolls for threading a new warp created problems with producing an effective yet inexpensive top roll drive, problems that were compounded by the need to maintain a selected squeeze loading substantially unaffected by changes in tension of the means for driving the movable top roll. Simply providing the top squeeze roll with a gear to mesh with a gear on the driven bottom roll, according to one prior art proposal, would subject the gears to damage each time the rolls were separated to thread a new warp inasmuch as rotation of either roll while disengaged could cause the gears to misregister and become damaged when re-engaged.
SUMMARY OF INVENTION
According to the present invention, the foregoing and other problems of the prior art are reduced or eliminated by a high pressure sizing apparatus and method including a unique arrangement for driving the rubber covered squeeze roll of a sizing machine by applying drive torque to the roll. Stated in somewhat general terms, one aspect of the present invention is a top roll drive mechanism which remains engaged to the top rubber covered roll as that roll is moved away or toward the bottom non-resilient roll. The drive mechanism for the top roll, in preferred embodiments of the invention, maintains driving engagement with the top roll with variable drive tension applied to the top roll, without affecting the squeeze loading of the rolls. Stated more specifically, preferred embodiments of the present invention utilize mechanical drive of the top roll for compatibility with existing sizing squeeze apparatus, yet permit the top roll to be moved toward or away from the bottom roll without disengaging the drive mechanism and without affecting the driving torque applied to the top roll.
Positive drive of the top roll in a high-pressure sizing apparatus according to the present invention is improved by selecting the top rubber covered roll diameter to be slightly less than the diameter of the bottom non-resilient roll. Because the rubber covered roll is rotationally driven by frictional surface engagement with the non-resilient roll, as well as by a positive drive means according to the present invention, the rubber covered roll can be made to "overdrive" or lead the positive driving connection to that roll during relatively light squeeze loading resulting in relatively little or no surface slippage, and to "underdrive" or be driven by the positive driving connection at increased squeeze loading. A null point between overdriving and underdriving may be obtained, at which point the tendency to overdrive the rubber covered roll is substantially balanced by surface slippage relative to the driven non-resilient bottom roll. At the null point, the positive drive to the top roll applies no torque. This aspect of the present invention permits a high pressure squeeze sizing machine operable over a relatively wide range of operating squeeze force, without experiencing excessive resilient roll driving forces that would possibly damage the drive, or would require relatively expensive drive modifications.
Accordingly, it is an object of the present invention to provide an improved apparatus and method for applying sizing to warp yarns.
It is another object of the present invention to provide an improved high-pressure sizing method and apparatus.
It is yet another object of the present invention to provide a sizing method and apparatus which effectively reduces water evaporation requirement, and thus reduces the amount of energy required to dry the warp yarn.
It is a further object of the present invention to provide an improved sizing method and apparatus which operates at substantially increased squeeze loading pressures, and yet does not impart undesired longitudinal strain to the warp yarns.
Other objects and attendant advantages of the present invention will become more readily apparent from the following description of preferred embodiments.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a pictorial view showing a disclosed embodiment of high pressure sizing apparatus according to the present invention.
FIG. 2 is an elevation view taken from the left side of FIG. 1, with panels removed to show details of the roll drive mechanism according to a first embodiment of the present invention.
FIG. 3 is a partially sectioned and broken-away front elevation view taken along line 3--3 of FIG. 2, showing details of the top roll lifting and loading mechanism.
FIG. 4 is a vertical section view taken along line 4--4 of FIG. 3, showing added details of the mechanism for lifting and loading the top roll.
FIG. 5 is an elevation view showing another disclosed embodiment of drive mechanism, alternative to that shown in FIG. 2.
FIG. 6 is a schematic drawing of an operating control circuit for the top roll loading elements and the variable torque limiter.
DESCRIPTION OF PREFERRED EMBODIMENTS
Looking initially to FIG. 1, there is shown generally at 10 an embodiment of high pressure sizing squeeze apparatus according to the present invention. The sizing apparatus 10 includes a top squeeze roll 11 having a peripheral surface made of an elastomeric material such as rubber or the like, and a bottom squeeze roll 12 having a smooth peripheral surface of a relatively nonresilient and corrosion-resistant material such as stainless steel. Both rolls 11 and 12 are journaled for rotation in a manner described below in greater detail. The top roll 11 is journaled at its ends in a pair of bearing blocks 13a and 13b supported for movement in a vertical direction relative to the fixed end members 14.
The sizing squeeze apparatus 10, including top roll 11 and bottom roll 12, comprises squeezing apparatus through which the warp yarns (not shown) pass after the warp is initially coated with sizing solution. This initial application of liquid sizing to the warp takes place in one or more size boxes through which the warp passes before entering the high pressure sizing squeeze apparatus 10. The size boxes, along with immersion rolls and other related apparatus, are well-known to those skilled in the art, and are typically located immediately behind the squeeze apparatus 10 shown in FIG. 1.
The apparatus 10 includes a control console 16 containing controls for regulating the operation of the overall sizing apparatus. These controls may select the amount of squeeze loading applied to the warp yarns passing between the top and bottom rolls, as described below in greater detail, as well as other variable factors associated with the sizing operation and including control of apparatus (not shown) associated with the size box.
Turning next to FIGS. 3 and 4, it is seen that the bottom roll 12 is supported for rotation on the fixed frame assembly indicated generally at 19, and providing basic structural support for the high pressure squeeze apparatus 10. The fixed end members 14 supporting the bearing blocks 13a and 13b for the top roll are rigidly connected to the frame assembly 19 and are considered to comprise part of the frame assembly, although it will be understood that the frame assembly is fabricated from a number of separate interconnected components. Journals 20 for each end of the bottom roll 12 are supported by the frame assembly 19.
Extending transversely across the apparatus 10 is the load and lift beam 23, best seen in FIGS. 3 and 4. The beam 23 is mounted for a limited extent of vertical movement relative to the frame assembly 19, and to accomplish that result the beam is supported from its underside by a pair of inflatable lifting elements 24, located near the ends of the beam. As best seen in FIG. 4, the lifting elements 24 are supported from below by the base member 25 of the frame assembly 19. Mounted above the beam 23 is a second pair of inflatable elements 26, hereafter known as loading elements. The loading elements 26 are supported from above by the fixed cross beam 27, forming part of the frame assembly 19.
The lifting elements 24 and the loading elements 26 comprise selectably expandable members such as inflatable air bags or the like, which expand in the vertical dimension (as viewed in FIGS. 3 and 4) when connected to a source of pressurized fluid. The pair of lifting elements 24, and the pair of loading elements 26, are separately connected to receive pressurized air through valves controlled at the control console 16, and it will be understood that the beam 23 is either lifted or lowered relative to the frame assembly 19, depending on whether the lifting elements 24 or the loading elements 26 are pressurized.
A separate pair of spaced-apart connecting rods 30a and 30b are attached to each end of the load and lift beam 23, and the connecting rods extend upwardly from that beam to engage the respective bearing blocks 13a and 13b supporting the top roll 11. The bearing blocks 13a and 13b are received within the surrounding fixed end members 14 for slidable vertical movement relative to the support structure. Because the bearing blocks 13a and 13b support the top roll 11, it should now be apparent that the vertical position of the top roll relative to the bottom roll 12 may be selected by controlling the vertical position of the load and lift beam 23. The magnitude of squeeze loading along the nip or contact area 31 of the two rolls is determined by the force exerted downwardly on the beam 23 by the loading elements 26, and that force is determined by the air pressure supplied to the loading elements.
Details of a mechanism for driving the top and bottom rolls 11 and 12 are shown in FIG. 2. The rolls are secured to the respective drive shafts 11' and 12', and sprocket 35 is keyed into driving engagement with the drive shaft 12' for the bottom roll. The drive shaft 11' for the top roll 11 is keyed to the driven element of a variable torque drive such as the air-loaded torque limiter 33 or equivalent. The driving or input element of the torque limiter 33 is driven by the sprocket 34. A drive chain 36 engages the sprocket 34 around approximately 180° at the upper side of the sprocket, as shown in FIG. 2. The drive chain extends downwardly from the sprocket 34, as shown at 37, to engage and wrap around the idler sprocket 38, and returns upwardly at 39 from the idler sprocket to wrap around the top portion of the sprocket 35 driving the bottom roll 12. The idler sprocket 38 is carried by the idler bracket 44, which in turn is attached by the pivot connection 45 to the load and lift beam 23. The idler sprocket 38 thus is raised and lowered by vertical movement of the beam 23, to the same extent and direction that the top roll 11 is raised and lowered.
The chain 36 leaves the sprocket 35 as shown at 40, and extends forwardly and downwardly to engage the drive input sprocket 41 in front of the apparatus 10. The drive input sprocket is connected to any appropriate source of motive power, such as a line shaft drive associated with an overall sizing and drying apparatus, or alternatively may be connected to a separate motor provided with its own control. As seen in FIG. 2, the wrap of the drive chain 36 across the sprockets 34 and 35 imparts counter-rotation to those sprockets and their associated rolls 11 and 12, when the input sprocket 41 is driven.
The drive chain 36, on its return or slack run 46 from the drive input sprocket 41, passes over another idler sprocket 47 mounted at the lower end of the chain tension adjusting arm 48. The adjusting arm 48 is pivotally mounted at 49 to the fixed frame assembly 19. A threaded adjustment member 50 selects the position of the adjusting arm 48, and thus adjusts the position of the idler sprocket 47 relative to the slack chain run 46 leading to the sprocket 34 associated with the top roll 11.
The drive chain 36 is selected to transmit to the top and bottom rolls the maximum drive torque to be encountered in operation for which the apparatus 10 is designed. As pointed out below, the maximum tension anticipated in the drive chain can be reduced by appropriate selection of roll diameters. In a specific embodiment of the present invention with a maximum design squeeze loading of 345 pounds per linear inch (PLI), a top roll triple drive chain having one-half inch pitch is satisfactory.
The variable torque limiter 33 is preferably operated to provide a selectably variable maximum drive torque determined in proportion to the particular squeeze loading of the rolls 11 and 12. One way of accomplishing this variable control is shown in FIG. 6. The variable torque limiter 33 is connected to a control air line 42, which receives air pressure through an adjustable ratio air valve 43. The adjustable ratio air valve 43 is connected to receive and sense air pressure supplied to the loading elements 26 from the squeeze load control valve 16'. The adjustable ratio air valve 43 operates in a manner known to those skilled in the art to apply air pressure to the control line 42 at a pressure in predetermined selected ratio to the air pressure supplied to the loading element 26 by squeeze load control valve 16'. Because the control air pressure supplied to the variable torque limiter 33 determines the maximum amount of torque transmitable from the drive sprocket 34 to the top roll drive shaft 11', this maximum torque to the top roll is automatically varied in response to the amount of squeeze loading. The variable torque limiter 33 thus acts as a variable slip clutch to drive the top roll at a variable maximum torque determined as a function of the selected squeeze loading. The ratio between selected squeeze loading and maximum torque transmission capacity is determined by selectable adjustment of the adjustable ratio air valve 43.
Considering now the operation of the embodiment as described thus far, it will be appreciated that the top roll 11 is raised and lowered as the lift and load beam 23 is raised or lowered by selective inflation of the lifting elements 24 or the loading elements 26. Furthermore, the PLI loading of warp yarns pinched between the rubber covered top roll 11 and the stainless steel bottom roll 12 is determined by the magnitude of downward loading force exerted on the beam 23 by inflation of the loading elements 26. The loading force imparted to the top roll 11, and thus the squeeze loading applied to the warp yarns pinched in the nip 31 between the rolls, is relatively unaffected by the amount of tension in the drive chain 36, inasmuch as the idler sprocket 38 moves vertically with the beam 23 and with the top roll 11. That is, the vertical component of the chain tension applied to the top roll sprocket 34 is approximated balanced in the embodiment of FIG. 2, and fully balanced in the embodiment of FIG. 5, by the idler sprocket 38, the beam 23, and the connecting rods 30a, 30b which are rigidly connected to the bearing blocks 13a, 13b supporting the top roll. Thus, the amount of squeeze loading imparted by the present apparatus 10 is substantially independent of the amount of tension in the drive chain connected to the top and bottom rolls.
The top roll 11, as mentioned previously, is subject to two rotational forces whenever that roll peripherally engages the bottom roll and the drive chain 36 is driven by the drive input sprocket 41. The first of these rotational forces is the torque applied by the drive chain 36 acting on the sprocket 34 associated with the top roll 11. The second rotational force is imparted directly to the top roll 11 by frictional surface engagement with the bottom roll, in much the manner associated with sizing low-pressure squeeze apparatus of the prior art. If the present sizing squeeze apparatus 10 is operated at relatively low squeeze loadings, for example, 10-30 PLI, the amount of frictional slippage in surface drive of the top roll 11, and the change in circumference of the top roll due to rubber deformation, are relatively negligible. As squeeze loading pressures are increased, so does slippage, and an increased amount of torque must be supplied from the drive chain 36 to maintain the desired rotation of the top roll 11. Moreover, the top roll 11 undergoes substantial rubber strain when subjected to relatively high squeeze loading, and the rubber strain distorts the surface of the top roll by increasing the effective circumference of the top roll. This increase in effective circumference of the top roll 11 decreases the axial velocity at which the top roll is rotated by peripheral engagement with the driven bottom roll 12. This underdrive or decrease in the velocity of rotational drive due to the increase in effective circumference, combined with the increased slippage of the surface drive at higher squeeze loadings, causes the velocity of the top roll 11 to lag even further behind the bottom roll 12. With squeeze loadings in the order of 320 PLI or greater, which are theoretically possible while maintaining the desired % add-on with sizing products presently available, the amount of drive torque required to maintain rotation of the top roll 11 may increase beyond the point of practical application, at least with an economical effective circumference of the rubber covered top roll 11 under high squeeze loading affected by the hardness of the rubber, with harder rubber permitting somewhat increased squeeze loading. Rubber having hardness in the range of 65-90 Shore A durometer has been successfully used for the top roll surface, in embodiments of the present invention. The thickness and other characteristics of the warp yarn being squeezed also can affect the maximum possible squeeze loading before substantial changes of effective circumference and slippage occurs.
The maximum drive torque requirements for the top roll 11 at higher squeeze loadings can be minimized by forming the top roll to a diameter slightly less than the diameter of the bottom roll. For example, the uncompressed nominal diameter of the top roll 11 may be selected so that the surface speed of the top roll is 1% less than the surface speed of the lower roll, when both rolls are driven by the drive chain 36 engaging identical sprockets 34 and 35. When these two rolls are brought together at relatively light squeeze loading, the slightly greater surface velocity of the steel bottom roll tends to overdrive the rubber-covered top roll at an angular velocity slightly greater than that at which the sprocket 34 is rotated by the drive chain 36, so that the drive chain is actually slack on the normal driving side 37. As the squeeze loading is increased by increasing the downward load on the beam 23, increased slippage in the surface drive of the top roll 11 reduces the amount of overdrive to a point where the chain is slack on both sides of the top roll sprocket 34, and the power required to drive the top roll is transmitted entirely through friction contact with the bottom roll. This condition is considered a null point, and it is chosen to occur at some point (not necessarily the midpoint) between minimum and maximum squeeze loads for which the particular machine 10 is designed.
When the squeeze load is increased beyond the null point, with a corresponding increase in surface drive slippage between the top and bottom rolls, the chain 36 becomes tight on the driving side 37 and the amount of torque transmitted through the chain to the top roll 11 increases. It will be understood that the amount of driving torque delivered to the top roll by the drive chain at maximum squeeze loading is substantially reduced with the slightly undersize top roll, inasmuch as the drive chain does not commence delivering torque to the top roll at the lower range of squeeze loads.
With the variable torque limiter 33 operating as described above, so as to prevent the top roll 11 from receiving axial torque exceeding the required driving torque for a particular squeeze loading, the drive chain can operate to maintain tension in the driving chain side 37 at all times. The drive chain thus can be said to overdrive the top roll 11, with the variable torque limiter 33 keeping the top roll from receiving axial torque substantially exceeding the torque needed to maintain the top roll velocity notwithstanding slippage and changes in effective circumference of the top roll, at a particular squeeze loading. The variable torque limiter also protects the drive chain 36 and other elements of the rigid drive from damage from excessive torque requirements.
During periodic maintenance of the sizing squeeze apparatus 10, the surface of the rubber top roll 10 is ground to remove degraded surface rubber. This rubber is removed to a predetermined diameter, and a new upper drive sprocket 34 is then substituted to provide the desired surface speed for the refinished top roll. In practical application, each substitute drive sprocket will have one less tooth than the sprocket it replaces, and the amount of surface rubber removed by grinding is calculated to yield the desired relative surface speed with the known substitute drive sprocket.
Turning next to FIG. 5, there is shown an alternative embodiment of the present invention utilizing a somewhat different mechanical drive arrangement to fully compensate for the effect of tension in the drive chain, as the top roll is raised or lowered. The nominally-slack span 46 of drive chain from the drive input sprocket 41 passes over a first idler sprocket 47' mounted on the chain tension adjusting arm 48', somewhat comparable to the correspondingly-numbered elements shown in FIG. 2. Once the chain 36 passes over the idler sprocket 47, however, the chain goes around a second idler sprocket 54, positioned so that the length of chain 55 leaves the second idler sprocket and travels along a substantially horizontal path to engage the drive sprocket 34 of the top roll 11. The second idler sprocket 54 may be mounted concentrically with the pivot 49' of the chain tension adjusting arm 48.
The driven length of chain 37 extending downwardly from the top roll drive sprocket 34 passes around an idler sprocket 38', whose function is similar to that of idler sprocket 38 in FIG. 2. The idler sprocket 38', however, is mounted on the lever 56, pivotably affixed at 57 to the fixed frame assembly 19 and connected at 58 to the lift and load beam 23. The effective length of the lever 56 between its pivot 57 and the beam connection 58, along with the mounting point of the sprocket 38' on the lever, are selected to equalize the vertical component of chain tension as the top roll 11 is raised or lowered by the beam 23. Thus, the squeeze loading of the rolls is unaffected by changes in the tension of the drive chain. It will also be seen that any tension in the horizontal length 55 of drive chain approaching the sprocket 34 does not have a vertical component to affect the squeeze loading of the top roll.
It should be understood that the two disclosed drive arrangements are by way of example, and that alternative drive arrangements may be provided to meet the requirements of this invention and to prevent drive tension from affecting the squeeze loading. It will also be understood that the present invention is not restricted to using chain drive for the rolls, and that other sources of driving torque may be employed where appropriate.
It should also be understood that the foregoing relates only to specific embodiments of the present invention, and that numerous changes and modifications may be made without departing from the spirit and the scope of the invention as defined in the following claims.
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Apparatus and method for high pressure sizing, including sizing squeeze apparatus which effectively utilizes high pressure squeeze loading to remove excess sizing from the warp yarns, and thus to reduce the water evaporation requirement of the yarn. The high pressure sizing squeeze apparatus includes positive drive of the rubber-surface roll as well as the steel roll to prevent slippage which could strain the warp, and maintains a substantially invariant squeeze loading irrespective of variable tension in the roll drive. The surface speed of the rubber-covered squeeze roll may be slightly less than the surface speed of the steel roll, to reduce the torque required to drive the rubber-covered roll at relatively high squeeze pressures where substantial slippage is encountered. A torque limiter controls maximum axial drive torque supplied to the rubber-surface roll, in response to the magnitude of squeeze loading.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to field of user interfaces for computer systems. More specifically, the present invention is directed to a method and an apparatus for combining the user interfaces of a plurality of applications.
BACKGROUND
[0002] User interfaces refers to the methods and devices that are used to accommodate interaction between the machines and the users who use them. The user interfaces allow for communicating information from the machine to the user, and communicating information from the user to the machine.
[0003] Generally, the user interacts with the machine through the user interfaces presented by an application running on the machine. The user interfaces are designed by the software developers with the purpose of allowing the user to take full advantage of the functions of the applications. This may include presenting a finite number of options for the user to choose rather than requiring the user to memorize and manually enter commands from a large number of command options. Furthermore, the user interfaces are generally designed so that they are intuitive and easy to use. This significantly reduces the training to use a new application allowing the user to become productive in a short time.
[0004] Since the user may use applications designed by different groups of software developers from the different software vendors, the user is required to be familiar with multiple user interfaces and to interact with each interface individually. This requirement still exists even though there may be overlapping interfaces among the applications.
[0005] Unless there are collaborations among the software vendors, the user interfaces for each application are designed virtually without any anticipation of being modified by applications from other software vendors. This is because the software vendors want to preserve the carefully designed graphics and layout of their user interfaces. As a result, the user is unable to take advantage of the common user interfaces and data structure among the applications.
SUMMARY OF THE INVENTION
[0006] In one embodiment, a method for combining the user interfaces of several applications is disclosed. Data generated by a first application is extracted from a display buffer. The data is associated with a user interface from the first application. From the extracted data, a layout pattern is recognized. Using the layout, an overlay is created. The overlay is used to display a second data generated by a second application. There is no direct link between the first application and the second application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention is illustrated by way of example in the following drawings in which like references indicate similar elements. The following drawings disclose various embodiments of the present invention for purposes of illustration only and are not intended to limit the scope of the invention.
[0008] FIG. 1A illustrates one embodiment of a computer system.
[0009] FIG. 1B is an exemplary flow diagram of one embodiment of the melded user interfaces.
[0010] FIG. 2 is an exemplary web-based calendar manager illustrating a parent application.
[0011] FIG. 3A is an exemplary layout of the calendar produced by an edge detection operation of a pattern recognition application.
[0012] FIG. 3B is an exemplary layout produced by an edge smoothing operation.
[0013] FIG. 4A is an exemplary layout with the boundaries identified.
[0014] FIG. 4B is the same layout as in FIG. 4A with the corners and intersections identified.
[0015] FIG. 4C is the same lay out as in FIG. 4B with the addition of the information previously compiled about the calendar.
[0016] FIG. 5A illustrates the exemplary calendar parent application with the overlay information from the child application.
[0017] FIG. 5B illustrates an exemplary interaction with the child application.
[0018] FIG. 6 illustrates one embodiment of a computer-readable medium containing various sets of instructions, code sequences, configuration information, and other data used by a computer or other processing device.
DETAILED DESCRIPTION
[0019] A method and apparatus for combining the user interfaces of several applications are disclosed. In the following description, for purposes of explanation, specific nomenclature is set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present invention.
[0020] Some portions of the detailed descriptions that follow are presented in terms of algorithms and symbolic representations of operations on data bits within a computer memory. These algorithmic descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. An algorithm is here, and generally, conceived to be a self-consistent sequence of steps leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
[0021] It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussion, it is appreciated that throughout the description, discussions utilizing terms such as “processing” or “computing” or “calculating” or “determining” or “displaying” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
[0022] The present invention also relates to apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may comprise a general-purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but is not limited to, any type of disk including floppy disks, optical disks, CD-ROMs, and magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, or any type of media suitable for storing electronic instructions, and each coupled to a computer system bus.
[0023] The algorithms and displays presented herein are not inherently related to any particular computer or other apparatus. Various general-purpose systems may be used with programs in accordance with the teachings herein, or it may prove convenient to construct more specialized apparatus to perform the required method steps. The required structure for a variety of these systems will appear from the description below. In addition, the present invention is not described with reference to any particular programming language. It will be appreciated that a variety of programming languages may be used to implement the teachings of the invention as described herein.
Overview
[0024] There is a need for a capability to allow the user interfaces of two or more applications to be combined or merged with one another. This capability allows for the free exchange of information between related applications and allows the context of a user interface from one application to be used by many different applications.
[0025] A method and apparatus for melding user interfaces are described. Melded user interfaces combines the user interfaces of two or more applications and does not require the cooperation or acquiescence from the applications (or their programmers). Using melded user interfaces, the screen layout (e.g., base layout) corresponding to the user interface of one application may be used by one or more other applications to display data associated with that application.
[0026] The application having the base layout is referred to herein as a parent application. The application whose data modifies the base layout of the parent application is referred to herein as a child application. There may be one or more children applications. The parent application provides the context for the displaying of the data from the children applications.
[0027] In one embodiment, an overlay generation mechanism (e.g., application) retrieves raster data associated with the user interface of the parent application from the display buffer of a personal computer video card. The raster data is used to determine a layout so that the child application can overlay the data it wants to display. In one embodiment, in order to make the correct overlay, previously compiled information about the layout of the user interface of the parent application is utilized. For example, when the parent application is an appointment application displaying appointment information in a monthly calendar view, the information that can be compiled from the display includes data such as, for example, the location of the month name, the locations of the day names, the locations of the day numbers, etc. It will be appreciated to note that the parent application's user interface is designed and provided by the software vendor, independent of any child application. This independence of the parent application from the child application is advantageous because it allows a wide range of children applications to be used with the parent application.
[0028] FIG. 1A is exemplary embodiment of a personal computer system that may be used to perform functionality described herein. The various components shown in FIG. 1A are provided by way of example. Certain components of the computer in FIG. 1A can be deleted from the addressing system for a particular implementation of the invention. The computer shown in FIG. 1A may be any type of computer including a general-purpose computer.
[0029] FIG. 1A illustrates a system bus 10 to which various components are coupled. A processor 15 performs the processing tasks required by the computer. Processor 15 may be any type of processing device capable of implementing the steps necessary to perform the operations discussed above. An input/output (I/O) device 20 is coupled to bus 10 and provides a mechanism for communicating with other devices coupled to the computer. A graphics display adapter 25 is connected to the bus to receive display data generated by the processor 15 and store the display data in a display buffer. A read-only memory (ROM) 30 and a random access memory (RAM) 35 are coupled to bus 10 and provide a storage mechanism for various data and information used by the computer, such as, for example, the overlay generation code and the pattern recognition code. Although ROM 30 and RAM 35 are shown coupled to bus 10 , in alternate embodiments, ROM 30 and RAM 35 are coupled directly to processor 15 or coupled to a dedicated memory bus (not shown).
[0030] A video display 40 is coupled to the graphics display adapter 25 and displays various information and data stored in the display buffer to the user of the computer. The data display may include the base layout of the parent application by itself or with the overlay display from the child application. A disk drive 45 is coupled to bus 10 and provides for the long-term mass storage of information. Disk drive 45 may be used to store the parent application, the child application, and the overlay generation application. It may also be used to store data associated with the parent and the child application. A keyboard 50 and a mouse 55 are provided to receive input from the user.
[0031] Initially, the parent application is the active application that controls the information displayed on the video display 40 before the child application is activated. In one embodiment, the child application runs in the background and is activated by pressing a key or a key combination on the PC keyboard 50 . It will be apparent to one skilled in the art that other methods can be used to activate the child application, such as, for example, positioning the pointer of the mouse 55 on an icon representing the child application and pressing the left mouse button. When the child application is activated, the display buffer is read, the pattern recognition operation is applied, and the overlay layout is generated. The user can then interact with the data from the child application in the context of the user interface of the parent application.
[0032] In one embodiment, the child application continuously applies pattern recognition operations to the contents of the display buffer. When it detects the presence of a display format indicative of a known parent application, an indication of this event such as, for example, a beep or a flashing icon, is displayed to the user. This indication can be parameterized by the amount of data the child can display in the current context of the parent. The user can then choose to invoke the child application in the manner described above. In another embodiment, the child application may be invoked automatically after a defined period of inactivity by the user.
[0033] FIG. 1B is a flow diagram illustrating an exemplary embodiment of the present invention. At block 105 , the raster data is read from the PC graphics card. The raster data is analyzed by a pattern recognition operation, as shown in block 110 . The pattern recognition operation looks for patterns in the raster data to identify all or portions of a layout. In one embodiment, information previously compiled about the user interface of the parent application is utilized to identify and locate different sections of the layout, as shown in block 115 . For example, when using a calendar display as the display from the parent application, the information about the calendar may comprise of the format of the calendar, the locations of the day names and the locations of the day numbers on the calendar. As another example, the display from the parent application is the window file system layout, and the information about the window file system may comprise the format of the file tree, the locations of the icons representing the directories, etc.
[0034] The layout and the previously compiled information about the corresponding user interface are used by the overlay generation mechanism (e.g., application) to generate an overlay layout, as shown in block 120 . In one embodiment, the overlay may comprise information from both the parent application and the child application. At block 125 , the overlay is written into the display buffer and presented to the user through a display monitor.
[0035] At block 130 , the user is able to interact with the child application through the melded user interface generated using the overlay. Using the layout of the parent application to display the data from the child application provides the impression that both the parent application and the child application are integrated with one another. In one embodiment, the user of the parent application does not have to learn a new user interface to interact with the child application.
[0036] In one embodiment, when the child application is invoked, it writes data into the display buffer. The child application knows where (e.g., x, y pixel location) in the display buffer each data item was written. It also sets an event mask in the operating system that intercepts events from the user interface devices (e.g., keyboard, mouse, etc.). Such events typically include an identification of the event (e.g., identity of the key pressed, mouse button clicked, or x-y cursor position).
[0037] Based on a combination of event identity, its x-y location, and the locations of the child's data items, the event is either processed by the child application or it is processed by the operating system as it would normally be if the child application were not present. This allows the user to select the data displayed by the child application. For example, the user can move the mouse cursor on top of data items that were written in the display buffer by the child and click a mouse button to display another data item.
[0038] FIG. 2 is an exemplary calendar display that can be used with the present invention. The calendar display is from a web calendar manager which runs as the parent application. Information about the layout of the calendar display includes the knowledge that the calendar manager runs from within a web browser, and the calendar manager typically displays monthly calendar views, characterized by a rectangular grid layout with one grid cell used for each day of a month. Furthermore the month and year are displayed along the top center area 205 , the names of the days are displayed in the first row 210 , centered above a calendar grid cell, and the day number of each day is displayed in the upper right corner 215 of each grid cell.
[0039] Using the knowledge about the parent application, the overlay generation application can generate its overlay on the layout of the parent application without altering the user interface of the parent application or causing the user to learn a new user interface.
[0040] In the calendar display example, the display from the calendar manager can be integrated with information from a child application, such as, for example, a document manager application. The document manager application retrieves documents previously generated and saved in a storage device. The overlay generation mechanism (e.g., application) uses the precompiled knowledge about the calendar manager (e.g., parent application) and generates an overlay for the documents retrieved by the document manager (e.g., child application) in the context of the parent application. For example, all documents to be reviewed by the user on Sep. 15, 1999 are shown on the calendar display within the grid identifying the date Sep. 15, 1999.
[0041] The pattern recognition operation detects whether the display buffer contains data representing a monthly calendar view. It finds out where the calendar is on the display and calculates the coordinates of the grid cell for each day. From the coordinates of the grid cells, a grid layout of the entire calendar can be generated. The pattern recognition operation is performed with a series of standard computer vision or image processing operation, which includes an edge detection operation. FIG. 3A is an exemplary layout result produced by the edge detection operation. Note that the highlighted edges correspond to the edges shown in FIG. 2 . It will be apparent to one skilled in the art that other pattern recognition operations can be used to generate the grid layout without deviating from the invention.
[0042] The edges of the layout result shown in FIG. 3A are filtered through a smoothing operation. This smoothing operation groups the pixels and connects the lines together. FIG. 3B is an exemplary result produced by the smoothing operation. A line detection algorithm is then applied to locate the boundaries of the grid cells, as shown in FIG. 4A . The line intersections and corners are identified using standard techniques, as shown in FIG. 4B . This provides the grid for the calendar display.
[0043] The precompiled information about the calendar display is then used to estimate the locations of the day number, the day names, the months, and the year information in the grid of the calendar, as shown in FIG. 4C . In one embodiment, optical character recognition (OCR) is applied to the raster data in these locations to obtain the day number, the month and the year displayed in the calendar. Contextual post-processing using knowledge about the calendar is applied to verify the character recognition results.
[0044] The overlay generation application uses the grid information and the knowledge about the locations of the day number, the day and the month to generate the overlay corresponding to the lay out of the parent application. FIG. 5A illustrates an exemplary calendar parent application with the overlay information from the child application. In one embodiment, the document manager (i.e., child application) uses icons or thumbnail images to represent the documents. The physical location on the screen where the thumbnail images are placed is determined based on the grid cell locations and dates that were found by the pattern recognition operation. The document thumbnail images 505 are then included in the overlay and displayed in the melded user interface.
[0045] In one embodiment, the user may dynamically adjust the size of the icons. In another embodiment, the overlay generation operation extracts the first few pages of the documents and displays them in the melded user interface. Alternatively, the title or some other information indicative of the documents may be displayed instead of the thumbnail images or icons.
[0046] The overlay generation mechanism (e.g., application) may have to determine the locations of the data displayed by the parent application so that the placements of the thumbnail images from the child application do not overlap with the data from the parent application. In one embodiment, the overlay generation application may display the document thumbnail images on top of the data displayed by the parent application. The user may invoke the overlay mode by pressing a function key on the PC keyboard. This triggers the execution of the child application and displays the thumbnail images on the calendar.
[0047] FIG. 5B illustrates an exemplary interaction with the child application though the melded user interfaces. Through the melded user interface, the user interacts with the child application by selecting the thumbnail images. Clicking on the thumbnail images 510 navigates the user to higher resolution documents represented by the thumbnail images. In one embodiment, the icons are also hotlinked to complete document descriptions 515 so that when the user places the cursor over the icon the complete description is displayed.
[0048] In one embodiment, the thumbnail images displayed in a grid cell show one or more documents that were recorded on that date. The display of the parent application and the child application can be toggled from one to the other. When the display from the child application is toggled on, the information from the parent application may be suppressed or overlapped by the information from the child application.
[0049] Also, when the display from the child application is toggled on, the child application has control of the interaction between the user and the system. On the other hand, when the display from the parent application is toggled on, the information from the parent application reappears and the parent application has control of the interaction between the user and the system.
[0050] When the document thumbnail image is selected, the document is retrieved by the child application. The child intercepts the “selection,” as previously described and retrieves the document based on the event type. For example, clicking on the left mouse button could retrieve (from a document server), a high resolution image of the document depicted in the thumbnail. The child maintains a table of network addresses (e.g., URL's) that correspond to each thumbnail and event type. Those network addresses are accessed and their contents retrieved when the particular event is executed.
[0051] Alternatively, the document can be retrieved by another application outside of the child application. The document may be retrieved from a document server through a network connection. In one embodiment, when there are multiple documents to be displayed in the same grid cell, only the first few pages of the document are shown as representative pages. An indicator such as, for example, a green bar or a number is used to indicate to the user that the document has additional pages to be seen. This enables the user to go and look further.
[0052] In another embodiment, the text displayed by the parent application can be used to initiate a document retrieval request to the document manager. For example, when an appointment in the calendar display is a birth day appointment, the child application may retrieve all documents related to people having birth days on that particular date.
[0053] In another embodiment, the user interface can depend on the information provided by operating system. For example, with the web calendar as the parent application running in a browser, the child application may analyze the uniform resource locations (URL) associated with the web calendar application. The URL may provide information that lets the child application know about the type of calendar view being displayed (e.g., week grid, month grid) without having to use the OCR. In another embodiment, both of the information from the registry and the OCR results may be used.
[0054] In the foregoing discussion, the document manager application is used to illustrate a child application overlaying the display of the calendar display parent application. Other children applications can also be used to take advantage of the present invention. For example, trip information, airline reservation information, and hotel confirmation information can be generated in the overlay by the overlay generation application using the display buffer. It will be apparent to one skilled in the art that other applications can also be used as the parent application.
[0055] FIG. 6 illustrates an embodiment of a computer-readable medium 600 containing various sets of instructions, code sequences, configuration information, and other data used by a computer or other processing device. The embodiment illustrated in FIG. 6 is suitable for use with the melded user interface method described above. The various information stored on medium 600 is used to perform various data processing operations. Computer-readable medium 600 is also referred to as a processor-readable medium. Computer-readable medium 600 can be any type of magnetic, optical, or electrical storage medium including a diskette, magnetic tape, CD-ROM, memory device, or other storage medium.
[0056] Computer-readable medium 600 includes interface code 602 that controls the flow of information between various devices or components in the computer system. Interface code 602 may control the transfer of information within a device (e.g., between the processor and a memory device), or between an input/output port and a storage device. Additionally, interface code 602 may control the transfer of information from one device to another.
[0057] Computer-readable medium 600 also includes the overlay generation application 604 that is used to generate the overlay. Other codes stored on the computer-readable medium 600 may include the pattern recognition code 606 , the edge smoothing code 608 , and the optical character recognition code 612 .
[0058] From the above description and drawings, it will be understood by those of ordinary skill in the art that the particular embodiments shown and described are for purposes of illustration only and are not intended to limit the scope of the invention. Those of ordinary skill in the art will recognize that the invention may be embodied in other specific forms without departing from its spirit or essential characteristics. References to details of particular embodiments are not intended to limit the scope of the claims.
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In one embodiment, a method for combining the user interfaces of several applications is disclosed. Data generated by a first application is extracted from a display buffer. The data is associated with a user interface from the first application. From the extracted data, a layout pattern is recognized. Using the layout, an overlay is created. The overlay is used to display a second data generated by a second application. There is no direct link between the first application and the second application.
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BACKGROUND OF THE INVENTION
This invention relates generally to bore-hole and well mapping and navigation, and more particularly concerns apparatus and method to remotely determine tilt from vertical, in a bore-hole.
At the present time it is customary to employ three-axis accelerometer packages or assemblies to accurately determine tilt in a bore-hole. In general, three accelerometers are required, and are mounted in mutually orthogonal relationship to measure gravity components in the Z-direction of the hole axis, and also in X and Y directions at right angles to one another and also perpendicular to the Z axis. The output of each accelerometer is then measured, and a resultant vector constructed to determine the direction of tilt. For low tilt angles (i.e. near vertical) the outputs from the X and Y direction sensing accelerometers provide the useful signal, whereas for high tilt angles the output from the Z direction sensing accelerometer becomes the most sensitive and accurate.
U.S. Pat. No. 3,753,296 to Donald H. Van Steenwyk describes a technique whereas a single accelerometer is rotated about the Z axis, that accelerometer having its tilt sensitive axis perpendicular to the Z axis and thereby sweeping through the X and Y field directions upon rotation. Such rotation enables one accelerometer to take the place of the two (X and Y direction sensing) accelerometers described above. Besides eliminating fixed errors and bias errors, such a rotary or carouseling arrangement realizes many other advantages inasmuch as, depending upon the speed and accuracy of rotation, statistical leverage can significantly improve tilt determination. Thus, improved accuracy, lower cost and simplified tilt measurement can be realized. However, for very high tilt angles, such accuracy rapidly diminishes, and a significant problem remains.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide a solution to the above described problem. Basically, the invention contemplates use of a single accelerometer to take the place of all three X, Y and Z direction sensing accelerometers referred to above. The single accelerometer is adapted to be carouseled or rotated about an axis defined on a carrier movable lengthwise of the bore-hole; and the tilt sensitive axis of the single accelerometer is oriented in a "cant" direction characterized as having components respectively along the axis of rotation and also along a perpendicular to that axis. Since the accelerometer is rotated, its tilt sensitive axis then effectively has components along the X and Y directions normal to the Z axis, whereby components along all three axes are provided.
Carouseling of a single accelerometer gains the benefits of high accuracy, as will be further discussed; and it also takes the place of two or three accelerometers such as were previously required, to gain a cost advantage. As will also appear, the cant angle should be between about 5° and 40° as measured from the X-Y plane normal to the Z-axis (the axis of rotation).
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following description and drawings in which:
DRAWING DESCRIPTION
FIG. 1 is an elevation taken in section to show use of one form of instrument of the invention, in well mapping;
FIG. 2 is a diagram indicating tilt of the well mapping tool in a slanted well;
FIG. 3 is a wave form diagram;
FIGS. 4 and 4a are schematic showings of a single degree of freedom gyroscope as may be used in the apparatus of FIG. 1; and FIG. 4b is a spin axis component diagram;
FIG. 5 is a diagrammatic showing of the operation of the accelerometer under instrument tilted conditions;
FIG. 6 is a view like FIG. 1, and showing a modified form of the invention;
FIG. 7 is a wave form diagram;
FIG. 8 is a view like FIG. 1, and showing another modified form of the invention;
FIGS. 9-11 are graphs; and
FIG. 12 shows a further modification.
DETAILED DESCRIPTION
In FIG. 1, well tubing 10 extends downwardly in a well 11, which may or may not be cased. Extending within the tubing in a well mapping instrument or apparatus 12 for determining the direction of tilt, from vertical, of the well or bore-hole. Such apparatus may readily be traveled up and down in the well, as by lifting and lowering of a cable 13 attached to the top 14 of the instrument. The upper end of the cable is turned at 15 and spooled at 16, where a suitable meter 17 may record the length of cable extending downwardly in the well, for logging purposes.
The apparatus 12 is shown to include a generally vertically elongated tubular housing or carrier 18 of diameter less than that of the tubing bore, so that well fluid in the tubing may readily pass, relatively, the instrument as it is lowered in the tubing. Also, the lower terminal of the housing may be tapered at 19, for assisting downward travel or penetration of the instrument through well liquid in the tubing. The carrier 18 supports rate gyroscope 20, accelerometer 21, and drive means 22 to rotate the latter, for travel lengthwise in the well. Bowed springs 70 on the carrier center it in the tubing 10.
The drive means 22 may include an electric motor and speed reducer functioning to rotate a shaft 23 relatively slowly about axis 24 which is generally parallel to the length axis of the tubular carrier, i.e., axis 24 is vertical when the instrument is vertical, and axis 24 is tilted at the same angle from vertical as is the instrument when the latter bears sidewardly against the bore of the tubing 10 when such tubing assumes the same tilt angle due to bore-hole tilt from vertical. Merely as illustrative, the rate of rotation of shaft 23 may be within the range 0.5 RPM to 5 RPM. The motor and housing may be considered as within the scope of primary means to support and rotate the gyroscope and accelerometer. The sensitive axis 21a of the accelerometer is shown as tilted at angle φ from a plane 21b which is normal to axis 24.
Due to rotation of the shaft 23, and a lower extension 23a thereof, the frame 25 of the gyroscope and the canted frame 26 of the accelerometer, and tilted axis 21a, are all rotated simultaneously about axis 24, within and relative to the sealed housing 18. The signal outputs of the gyroscope and accelerometer are transmitted via terminals at suitable slip ring structures 25a and 26a, and via cables 27 and 28, to the processing circuitry at 29 within the instrument, such circuitry for example including a suitable amplifier or amplifiers, and multiplexing means, if desired. The multiplexed or non-multiplexed output from such circuitry is transmitted via a lead in cable 13 to a surface recorder, as for example includes pens 34 and 34a of a strip chart recorder 35, whose advancement may be synchronized with the lowering of the instrument in the well. The drivers 60 and 61 for recorder pens 34 and 34a are calibrated to indicate bore-hole azimuth and degree of tilt, respectively, the run-out of the strip chart indicating bore-hole depth along its length.
Turning to FIG. 4, the gyroscope 20 is schematically indicated as having its frame 25 rotated about upward axis 24, as previously described. A sub-frame 36 of the gyroscope has shafts 36a and 36b bearing supported at 37 and 37a by the frame 25, to pivot about output axis OA which is parallel to axis 24. The gyroscope rotor 39 is suitably motor driven to rotate about spin reference axis SRA which is normal to axis OA. The rotor is carried by sub-frame 36, to pivot therewith and to correspondingly rotate the wiper 41 in engagement with resistance wire 42 connected with DC source 43. The sub-frame 36 is yieldably biased against rotation about axis OA and relative to the housing 25, as by compression springs 75 (or their electrical equivalents) carried by the housing and acting upon the arm 76 connected to shaft 36a, as better seen in FIG. 4a.
Accordingly, the current flow via the wiper is a function of pivoting of the sub-frame 36 about axis OA, which is in turn a function of rotary orientation of the frame 25 with respect to a North-South longitudinal plane through the instrument in the well. As seen in FIG. 3, the gyroscope may be rotated about axis 24 so that its signal output 39a is maximized when spin reference axis SRA passes through the North-South longitudinal plane, and is zero when that axis is normal to that plane. One usable gyroscope is model GI-G6, a product of Northrop Corporation.
The accelerometer 21, which is simultaneously rotated with the gyroscope, has an output as represented for example at 45 under instrument tilted conditions corresponding to tilt of axis 24 in North-South longitudinal plane; i.e. the accelerometer output is maximized when the gyroscope output indicates South alignment, and again maximized when the gyroscope output indicates North alignment. FIG. 2 shows tilt of axis 24 from vertical 46, and in the North-South plane, for example. Further, the accelerometer maximum output is a function of the degree of such tilt, i.e. is higher when the tilt angle increases, and vice versa; therefore, the combined outputs of the gyroscope and accelerometer enable ascertainment of the azimuthal direction of bore-hole tilt, at any depth measured lengthwise of the bore-hole, and the degree of that tilt.
FIG. 5 diagrammatically illustrates the functioning of the accelerometer in terms of rotation of a mass 40 about axis 24 tilted at angle φ from vertical 46. As the mass rotates through points 44 at the level of the intersection of axis 24 and vertical 46, its rate of change of velocity in a vertical direction is zero; however, as the mass rotates through points 47 and 48 at the lowest and highest levels of its excursion, its rate of change of velocity in a vertical direction is at a maximum, that rate being a function of the tilt angle φ. A suitable accelerometer is that known as Model 4303, a product of Systron-Donner Corporation, of Concord, California.
Control of the angular rate of rotation of shaft 23 about axis 24 may be from surface control equipment indicated at 50, and circuitry 29 connected at 80 with the motor. Means (as for example a rotary table 81) to rotate the drill pipe 10 during well mapping, as described, is shown in FIG. 1.
Referring to FIGS. 1 and 7, the gyroscope is characterized as producing an output which varies as a function of azimuth orientation of the gyroscope relative to the earth's spin axis, that output for example being indicated at 109 in FIG. 7 and peaking when North is indicated. Shaft 23 may be considered as a motor rotary output element which may transmit continuous unidirectional drive to the gyroscope. Alternatively, the shaft may transmit cyclically reversing rotary drive to the gyroscope. Further, the structure 22 may be considered as including servo means responsive to the gyroscope output to control the shaft 23 so as to maintain the gyroscope with predetermined azimuth orientation, i.e. the axis SRA may be maintained with direction such that the output 109 in FIG. 7 remains at a maximum or any other desired level.
Also shown in FIG. 1 is circuitry 110, which may be characterized as a position pick-off, for referencing the gyroscope output to the case or housing 18. Thus, that circuitry may be connected with the motor (as by wiper 111 on shaft 23a' turning with the gyroscope housing 20 and with shaft 23), and also connected with the carrier 18 (as by slide wire resistance 112 integrally attached to the carrier via support 113), to produce an output signal at terminal 114 indicating azimuthal orientation of the gyroscope relative to the carrier. That output also appears at 115 in FIG. 7. As a result, the outputs at terminal 114 may be processed (as by surface means generally shown at 116 connected to the instrumentation by cable 13) to determine or derive azimuthal data indicating orientation of the carrier relative to the earth's spin axis. Such information is often required, as where it is desired to know the orientation of well logging apparatus being run in the well. Item 120 in FIG. 1 may be considered, for example, as well logging apparatus the output of which appears at 121. Carrier 18 supports item 120, as shown. Merely for purpose of illustration, such apparatus may comprise an inclinometer to indicate the inclination of the bore-hole from vertical, or a radiometer to sense radiation intensity in the hole.
It will be understood that the recorder apparatus may be at the instrument location in the hole, or at the surface, or any other location. Also, the control of the motor 29 may be pre-programmed or automated in some desired manner.
FIG. 8 shows a modified tool, which remains the same as in FIG. 1, except that the gyroscope is eliminated. The motor or drive 22 rotates the accelerometer 21, only. The pick-off for the accelerometer is generally indicated at 200, and includes elements depicted at 110-114 in FIG. 1.
FIGS. 9 and 10 show accelerometer outputs during rotation of the tool (as in FIGS. 1 or 8), and for different conditions. In each graph, the accelerometer cant angle φ is 20°; however, in FIG. 9, the tool axis 24 is very close to vertical (i.e. parallel to the earth's radius) whereas in FIG. 10 the tool axis 24 is horizontal.
Curves A and B in FIG. 11 show accelerometer maximum outputs (peak to peak differences) for different tool axis tilt conditions (abcissa). Curve A is for an accelerometer cant angle φ=20°, and curve B is for φ=30°. Curves C and D show algebraic sum outputs of the accelerometer, for 20° and 30° cant angles, respectively.
In FIG. 11, curves A and B show that, at small tool axis tilt angles, the output sensitivities are close to the sensitivities that would be achieved with an accelerometer mounted to have zero cant of its output axis (i.e. its output axis normal to the tool rotation axis). Indeed, at lower tilt angles, one may measure peak-to-peak voltage output from the accelerometer, as it is rotated, and obtain the phase shift (relative to a plane containing the earth's axis and intersecting the accelerometer) in a useful manner.
For high tool axis tilt angles (in FIG. 11), the peak-to-peak voltage change (change in ordinates of curves A and B), as the tool tilt angle (bore-hole angle relative to vertical) approaches horizontal, becomes smaller and smaller in correspondence to a 1-cosine function, so that output accuracy becomes less and less. However, because of the cant angle φ, the accelerometer output is asymmetrical about the zero "g" level as it is rotated about axis 24. This asymmetric effect has a (1-cos) function effect at low tool axis tilt angle (see FIG. 9) and becomes a sine function effect at high tilt angles (see FIG. 10). Therefore, the average signal from the canted accelerometer provides a good leverage factor to measure high tilt angles accurately.
Referring again to FIG. 1, the invention enables one to look at the complete sine wave generated by a sensor such as a gyro or accelerometer rather than just one point. In addition, since the carouseling rate can be precise, one knows that all data must fit a perfect sine wave of a known period. Additional statistical leverage is gained using filter techniques and by other means. In addition, many error terms from the sensor, such as bias related errors, are eliminated.
Carouseling of a single accelerometer gains all these benefits and permits a lower basic cost single accelerometer to do the same job as two much more accurate fixed accelerometers. Mounting this accelerometer with a cant angle and rotating it accomplishes the same thing as three fixed accelerometers.
The cant angle selected would, in practice, be determined by application factors. For instance, it is very often the case that high tilt angles occur only at the terminal point of a bore-hole. In such cases, high tilt angle error does not propogate as rapidly as does a low tilt angle error at the beginning of the hole. On the other hand, if the hole has a very high tilt angle throughout a large portion of its length, one would be more concerned about high tilt angle accuracy and thus a higher cant angle would be chosen. These considerations illustrate the criticality of cant angle selection between 5° and 40°, relative to a plane normal to the axis of rotation of the accelerometer.
FIG. 6 shows a tilted accelerometer 21 as in FIG. 1, in combination with a gyroscope 25' which is also tilted (relative to axis 24) as and for the purposes described in U.S. Pat. application Ser. No. 924,931 filed July 17, 1978 by Donald H. Van Steenwyk. Thus, the spin rotor of the gyro has spin axis components along travel axis 24 and in a direction normal to axis 24. Accordingly the benefits of both gyroscope and accelerometer tilting or canting are achieved, simultaneously.
In both FIGS. 1 and 6, the gyroscope may take the form of either of the gyroscopes G 1 or G 2 described in U.S. Pat. application Ser. No. 970,625 filed Dec. 18, 1978 by Donald H. Van Steenwyk.
FIG. 12 shows a first tilted accelerometer 121 as in FIG. 1, in combination with a second tilted accelerometer 121, the direction of tilt of 121 being orthogonal to that of 121 (i.e. if 121 is tilted to the right so that its tilt sensitive axis extends to the right and downward in FIG. 12), 122 is tilted toward the viewer with its tilt sensitive axis extending toward the viewer and downwardly. Motor 22 drives both accelerometers about axis 24 of shaft 23 which typically extends in the direction of the borehole. Such use of two orthogonally tilted accelerometers provides greater precision of measurement in that the two simultaneous outputs may be averaged, or the two outputs (or their components) can both be used separately and compared or cross-checked. Thus, for example, the two outputs will be 90° out of phase at any given time, and can be cross-checked. Also, if the drive motor M fails, carrier 18 may be rotated about axis 24, and readings of the outputs of the two accelerometers taken and compared or averaged, for enhanced accuracy. Carrier 18 may be considered as attached to or integral with a drill stem or well pipe that is rotated. The stem or pipe may be successively rotated and stopped, and readings taken during the stop intervals to produce successive points on output curves.
A means to process the outputs of both accelerometers, as described, is indicated at 130 in FIG. 12. Input leads from the two accelerometers are indicated at 131 and 132.
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A borehole mapping and navigational instrument which travels up and down in a well. The instrument includes a housing which supports at least a rate gyroscope, accelerometer, and an electric motor to rotate the accelerometer about an axis which is canted about the axis of the housing. Since the accelerometer is rotated, its tilt sensitive axis then effectively has components along the X and Y directions normal to the Z axis, whereby components along all three axis are provided.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to chemical solvating, degreasing, stripping and cleaning agents. More particularly, this invention relates to cleaning and solvating compositions containing dichloroethylene and six carbon length hydrofluoroethers and/or other agents that improve and enhance the properties of the original mixture.
The present invention was made in response to concerns with ozone depleting materials, and toxicity concerns with non-ozone depleting chlorinated materials. In September 1987, the United States and 22 other countries signed the Montreal Protocol on Substances that Deplete the Ozone Layer (the “Protocol”). The Protocol called for a freeze in the production and consumption of ozone depleting chemicals (“ODP's” or “ODC's”) by the year 2000 for developed countries and 2010 for developing countries. In 1990 the United States enacted the Clean Air act mandating that the use of ozone depleting chemicals be phased out by the year 2000. In September 1991, the U.S. Environmental Protection Agency announced that ozone layer depletion over North America was greater than expected. In response to this announcement, President George H. W. Bush issued an executive order accelerating the phase-out of the production of ozone depleting materials to Dec. 31, 1995. More than 90 nations, representing well over 90% of the world's consumption of ODP's, have now agreed to accelerate the phase-out of production of high ozone depleting materials to Dec. 31, 1995 for developed countries and Dec. 31, 2005 for developing countries pursuant to the protocol.
Historically fluorine and chlorine based solvents were widely used for degreasing, solvating, solvent cleaning, aerosol cleaning, stripping, drying, cold cleaning, and vapor degreasing applications. In the most basic form the cleaning process required contacting a workpiece with the solvent to remove an undesired material, soil or contaminant. In solvating applications these materials were added to dissolve materials in such applications as adhesive or paint formulations.
Cold cleaning, aerosol cleaning, stripping and basic degreasing were simple applications where a number of solvents were used. In most of these processes the soiled item was immersed in the fluid, sprayed with the fluid, or wiped with cloths or similar objects that had been soaked with the fluid. The soil was removed and the item was allowed to air dry.
Drying, vapor degreasing and/or solvent cleaning consisted of exposing a room temperature workpiece to the vapors of a boiling fluid or directly immersing the workpiece in the fluid. Vapors condensing on the workpiece provided a clean distilled fluid to wash away soils and contaminants. Evaporation of the fluid from the workpiece provided a clean item similar to cleaning the same in uncontaminated fluid.
More difficult cleaning of difficult soils or stripping of siccative coatings such as photomasks and coatings required enhancing the cleaning process through the use of elevated fluid temperatures along with mechanical energy provided by pressure sprays, ultrasonic energy and or mechanical agitation of the fluid. In addition these process enhancements were also used to accelerate the cleaning process for less difficult soils, but were required for rapid cleaning of large volumes of workpieces. In these applications the use of immersion into one or more boiling sumps, combined with the use of the above mentioned process enhancements was used to remove the bulk of the contaminant. This was followed by immersion of the workpiece into a sump that contained freshly distilled fluid, then followed by exposing the workpiece to fluid vapors which condensed on the workpiece providing a final cleaning and rinsing. The workpiece was removed and the fluid evaporated. Vapor degreasers suitable in the above-described process are well known in art.
In recent years the art was continually seeking new fluorocarbon based mixtures which offered similar cleaning characteristics to the chlorinated and chlorofluorocarbon (CFC) based mixtures and azeotropes. In the early 1990's materials based on the compounds of hydrochlorofluorocarbons (HCFC) began to appear. Three molecules in particular 1,1-dichloro-1-fluoro ethane (HCFC-141b), dichloro trifluoro ethane (HCFC-123), and dichloro pentafluoro propane (HCFC-225) were proposed as replacements for methyl chloroform and CFC blends. As more highly fluorinated materials these materials were less ozone depleting than current ODP's however these materials were weaker solvents and in order to properly clean required the use of co-solvents through the use of blends and azeotropes. Later toxicity studies performed on these materials, however, showed them to have unacceptable character for broad commercial use in cleaning applications. Consequently HCFC-123 was immediately limited in cleaning use, and HCFC-141b was phased out in the U.S. by Apr. 1, 1997. HCFC-225 is still used, however the material is scheduled for phase out by the Clean Air Act after the year 2010. Toxicity concerns with HCFC-225 exist to some users and the recommended commercial exposure level of blends of the various isomers of the material is 100 ppm.
In the mid 1990's another art emerged through the use of brominated solvents similar in structure to ozone depleting chlorofluorocarbons. Three molecules were proposed as viable products to replace ODP's, bromochloromethane (BCM), isopropyl bromide (iBP) and n-propyl bromide (nPB). Although all three materials have excellent cleaning solvency for many soils, the first two materials BCM and iBP have been eliminated due to potential health risks. The third candidate nPB has undergone a number of toxicity tests with the results being inconclusive. Currently most reputable producers of nPB are indicating a safe 8-hour TLV level of 25 ppm, which is of some concern to some users.
The art in the mid 1990's changed as aqueous and semi-aqueous materials became the major choice of replacement for ODP's. The shift to these materials however had two drawbacks for some users. First was the requirement for new cleaning apparatus and machinery capable of handling and drying water. The second was the fact that certain niche applications in the marketplace could not tolerate the use of water in the cleaning process due to damage to the workpiece. This damage was caused by either incompatibility of water with the workpiece, or residual water remaining on the workpiece due to the geometry of the workpiece. This second factor resulted in the art shifting to processes cleaning with solvents and either rinsing with volatile flammable solvents such as acetone hexane, cyclohexane and isopropanol, or rinsing with highly fluorinated materials called perfluorocarbons (PFC's).
These PFC rinsing agents were investigated by some users. Other solvents such as low molecular weight alcohols, ketones and alkanes, were also evaluated since they provided users with acceptable rinsing and cleaning, however they were flammable and concerns were raised about their use in production applications. Systems that operated with these inexpensive solvents were very expensive and required explosion-proof machinery and buildings. Perfluorocarbons were deemed to be viable replacements in that they could potentially be operated in inexpensive vapor degreasing equipment such as was used for CFC's. Additionally these materials were inert, inflammable, and had very low toxicity. However, being inert these materials had no solvency, i.e., they did not dissolve the soils they were meant to remove from the workpieces, and were found to be poor cleaning materials. Other perceived drawbacks with these rinsing agents were that they were extremely expensive and required the use of modified vapor degreasers. Later work conducted by the U.S. EPA deemed PFC's to be unacceptable materials due to the fact that they had huge global warming potentials and would remain in the environment for thousands of years.
The art then evolved today to seeking materials for these specialty applications that required PFC like materials that had lower global warming potentials. Highly fluorinated materials such as hydrofluorocarbons (HFC's) and hydrofluoroethers (HFE's) and other highly fluorinated compounds are the result of the most recent disclosures. Like PFC, HFC's and HFE's exhibit the same characteristics, with the exception they are slightly less expensive than PFC's but are still orders of magnitude more expensive than CFC's and chlorinated solvents. Primarily used as rinsing, drying and inerting agents these materials exhibit poor solvency for the soils commonly encountered in most cleaning applications, and will require the use of solvent blends, co-solvent systems, and azeotrope like blends in order to effectively clean.
As a replacement for CFC compounds and mixtures in cleaning applications, the use of highly fluorinated materials HFE's or HFC's have been described in a number of patents in combination with dichloroethylenes and other halogenated solvents. Most of the disclosed blends contain mixtures with highly fluorinated materials containing two to six carbon atoms. In industrial practice blends containing little or no dichloroethylene or halogenated solvents are only useful in cleaning light oils and particulates since the highly fluorinated materials have little cleaning efficacy. Mixtures having dichloroethylene or halogenated solvents as the major component are known to be more effective in cleaning a broader array of soils and thus are preferred.
The use of an HFC, decafluoropentane,(a 5 carbon highly fluorinated material) is disclosed in U.S. Pat. No. 5,196,137. This patent discloses the binary azeotrope of 1,1,1,2,3,4,4,5,5,5-decafluoropentane (HFC-4310 mee) with cis- or trans-1,2-dichloroethylene. U.S. Pat. No. 5,064,560 discloses the ternary azeotropes of HFC-4310 mee with trans-1,2-dichloroethylene and with methanol or ethanol. U.S. Pat. No. 5,759,986 discloses the ternary azeotrope of HFC-4310 mee with trans-1,2-dichloroethylene (trans DCE) and cyclopentane, and the quaternary azeotrope of the three materials plus methanol. All the above listed mixtures produce non-flammable, azeotrope-like mixtures with the highest claimed level of dichloroethylene in any of the patents being 50%.
The use of an HFE is disclosed in a number of patents. U.S. Pat. No. 5,827,812 discloses a number of binary azeotrope-like mixtures with two isomers of perfluorobutyl methyl ether (HFE-7100), a highly fluorinated 5 carbon molecule. Included in disclosed binary azeotropes are trans and cis 1,2-dichloroethylene, methylene chloride, nPB and HCFC-225. U.S. Pat. No. 6,008,179 discloses binary azeotrope-like mixtures between HFE-7100 and methanol, ethanol, 1-propanol, 2-butanol, isobutanol, and tert-butanol. In addition it names ternary azeotrope-like mixtures between HFE-7100, trans DCE and methanol, ethanol, 1-propanol, 2-propanol (IPA), and tert-butanol. Further the patent discloses other ternary azeotrope-like mixtures between HFE-7100, HCFC-225 (a hydrofluorinated-chlorinated solvent) and methanol or ethanol. Most of the combinations with HFE-7100 described in these patents are non-flammable and show acceptable flammability character when high levels of HFE-7100are present. Ternary azeotrope like combinations with halogenated solvents are not as flammable but like HFC-4310, form azeotrope-like mixtures at dichloroethylene levels of near and/or less than 50 wt % of the mixture.
The use of another HFE material, perfluorobutyl ethyl ether (HFE-7200, a six carbon highly fluorinated material) is described U.S. Pat. Nos. 5,814,595, 6,235,700 and in 6,288,018. These patents describe a number of binary azeotrope-like mixtures with two isomers of the perfluorobutyl ethyl ether. All binary combinations are shown to be flammable with the exception of azeotropes with the following halogenated solvents: hexafluoro-2-propanol, 1,2-dichloropropane and trans DCE. The combination with trans DCE is the most interesting aspect of this patent because the material forms an azeotrope-like product at 62.7 to 68.8 wt % trans DCE depending on the HFE-7200 isomer mixture.
The family of HFE materials are fully described in U.S. Pat. No. 6,291,417. This patent teaches the use of highly fluorinated ethers described in general as alkoxy-substituted perfluorocompounds in combination at least one co-solvent selected from a group of multiple chemical families. The patent claims that the fluorinated ether component must be at least 30% by weight of the composition and more preferred to be at least 50% of the mixture (a majority of the mixture) and most preferred to be greater than 60%.
Dichloroethylene compositions are described in U.S. Pat. No. 5,851,977. The patent discloses the use of 1,2-dichloroethylene in combination with a specific group of selected 3 and 4 carbon halogenated alkanes and alcohols. In the described patent the halogenated alkanes and alcohols are used to retard the flash point of the dichloroethylene.
U.S. Pat. Nos. 5,654,129 and 5,902,412 describe non-azeotrope mixtures of dichloroethylene and perchloroethylene that can be used to clean photographic films and other general substrates. The perchloroethylene is used in the formulation to retard the flash point of the dichloroethylene.
There currently is a need for azeotrope or azeotrope like compositions that are able to clean difficult soils and fluxes that are not effectively cleaned today by current art. Preferably these compositions would be non-flammable, effective cleaning, have little or no ozone depletion potential and have relatively short atmospheric lifetime so that they do not contribute to global warming.
The present invention provides a solvent mixture which can be used in solvating, vapor degreasing, photoresist stripping, adhesive removal, aerosol, cold cleaning, and solvent cleaning applications including defluxing, dry-cleaning, degreasing, particle removal, metal and textile cleaning. Non-limiting examples of the soils and contaminants that are removed by the composition of the present invention are oil, grease, coatings, flux, resins, waxes, rosin, adhesives, dirt, fingerprints, epoxies, polymers, and other common contaminants found in the art.
The present cleaning and solvating compositions comprise dichloroethylene compounds and alkoxy-substituted perfluoro compounds that contain six carbon atoms (HFE6C). The compositions also include highly fluorinated materials to retard flammability and/or other enhancement agents that improve and enhance the properties of the original mixture. The addition of these agents to the composition will modify the physical and/or cleaning characteristics of the dichloroethylene/HFE6C mixture to accomplish its desired cleaning or solvating task. The highly fluorinated material is any fluorinated hydrocarbon material in which the number of fluorine atoms exceeds the number of hydrogen atoms on the molecule. The enhancement agents are one or more of the following materials: alcohols, esters, ethers, cyclic ethers, ketones, alkanes (including cyclic alkanes), aromatics, amines, siloxanes, terpenes, dibasic esters, glycol ethers, pyrollidones, or low or non ozone depleting halogenated hydrocarbons. These mixtures are useful in a variety of solvating, vapor degreasing, photoresist stripping, adhesive removal, aerosol, cold cleaning, and solvent cleaning applications including defluxing, dry cleaning, degreasing, particle removal, metal and textile cleaning. In particular, the composition comprising the dichloroethylene compounds and alkoxy-substituted perfluoro compounds that contain six carbon atoms (HFE6C), with highly fluorinated materials to retard flammability and/or other enhancement agents that improve and enhance the properties of the mixture can be used to replace highly ozone depleting materials such as chlorofluorocarbons, methyl chloroform, hydrochlorofluorocarbons or chlorinated solvents. In addition these mixtures will be more robust cleaning agents versus present art that uses HFC's and HFE's.
In the novel cleaning compositions of the present invention, dichloroethylene materials include 1,1-dichloroethylene, 1,2-cis-dichloroethylene and 1,2-trans-dichloroethylene.
Alkoxy-substituted perfluoro compounds that contain six-carbons (HFE6C) include all isomers of perfluorobutane ethyl ether (C 4 F 9 —O—C 2 H 5 ) and all isomers of perfluoropentane methyl ether (C 5 F 11 —O—CH 3 ).
Highly fluorinated materials used in this invention are compounds of the formula C a F b H c X d where a is an integer from 2 to 8, b is an integer greater than a but less than 2a+2, d is 0,1, or 2, and c is less than or equal to 2a+2−b−d. X can be O, N, halogen, or Si, in any possible combination as long as the number of F atoms exceeds the number of H atoms in the molecule. Throughout this specification and claims, by “halogen” is meant Cl, Br, and I.
Suitable enhancement agents are one or more of the following materials: alcohols, esters, ethers, cyclic ethers, ketones, alkanes, aromatics, amines, siloxanes, terpenes, dibasic esters, glycol ethers, pyrollidones, or low-or non ozone depleting-halogenated hydrocarbons.
The addition of the fluorinated compounds to the mixture will reduce and/or eliminate the flammability measured as the closed and/or open cup flash points of the mixture. In addition the proper selection of the materials in the mixture may create an azeotrope or azeotrope-like blend which is desirable. Furthermore, those skilled in the art would be aware of other additives such as surfactants, colorants, dyes, fragrances, indicators, inhibitors, and buffers as well as other ingredients which modify the properties of the mixture.
The dichloroethylene component of the mixture contains effective amounts of 1,1-dichloroethylene, 1,2-cis-dichloroethylene and 1,2-trans-dichloroethylene. They are usable either singly or as a mixture of two or more. Among the most preferred are 1,2-trans- and 1,2-cis-dichloroethylene.
The alkoxy-substituted perfluoro compounds that contain six carbon atoms (HFE6C) are all isomers of perfluorobutane ethyl ether (C 4 F 9 —O—C 2 H 5 ) and perfluoropentane methyl ether (C 5 F 11 —O—CH 3 ). Examples of these compounds are n-perfluorobutane ethyl ether, iso-perfluorobutane ethyl ether, tert-perfluorobutane ethyl ether, n-perfluoropentane methyl ether, 2-trifluoromethyl perfluorobutyl 1-methyl ether, 2-trifluoromethyl perfluorobutyl 2-methyl ether, 2-trifluoromethyl perfluorobutyl 3-methyl ether, 2-trifluoromethyl perfluorobutyl 4-methyl ether, 2,2-trifluoromethyl perfluoropropyl 1-methyl ether.
The highly fluorinated materials of this invention are compounds of the formula C x F y H z X a where x is 2-8, y>x and z<y; and a can be 0 or greater. X can be O, N, halogen, or Si, in any possible combination as long as the number of F atoms exceeds the number of H atoms in the molecule. Examples of suitable fluorinated materials are tetrafluoroethane, pentafluoroethane, perfluoroethane, pentafluoropropane, hexafluoropropane, heptafluoropropane, perfluoropropane, hexafluorobutane, heptafluorobutane, octafluorobutane, nonafluorobutane, perfluorobutane, heptafluoropentane, octafluoropentane, nonafluoropentane, decafluoropentane, undecafluoropentane, perfluoropentane, octafluorohexane, nonafluorohexane, decafluorohexane, undecafluorohexane, dodecafluorohexane, tridecafluorohexane, and perfluorohexane. Other commercially available fluorinated compounds are: 3-chloro-1,1,1-trifluoropropane (HCFC-253fb); 1,1,1,3,3,5,5,5-octafluoropentane (HFC-458mfcf); 4-trifluoromethyl-1,1,1,2,2,3,3,5,5,5-decafluoropentane (HFC-52-13); 4-trifluoromethyl-1,1,1,2,2,5,5,5-octafluoropentane (HFC-54-11); 4-trifluoromethyl-1,1,1,2,2,3,5,5,5-nonafluoropentane (HFC-53-12); 1,1,1,2,3,4,4,5,5,5-decafluoropentane (HFC-43-10mee); 1,1,1,2,2,3,3,4,4,5,6-undecafluorohexane (HFC-54-11qe); 1,1,2,2,3,3,4,4-octafluorobutane (HFC-338pcc); 1,1,1,2,2,3,3,4,4-nonafluorobutane-4-methyl ether (HFE-7100); 1,1,1,2,2,3,4,4,4-nonafluoroisobutane-3-methyl ether (HFE-7100); 1,1,1,2,2,3,3,4,4-nonafluorobutane-4-ethyl ether (HFE-7200); 1,1,1,2,2,3,4,4,4-nonafluoroisobutane-3-ethyl ether (HFE-7200); 1,1,2,2,3,3,4,5-octafluorocyclopentane; pentafluoroethane (HFC-134); dichloro-trifluoroethane (HCFC-123); trichloro-tetrafluoropropane (HCFC-224); dichloro-pentafluoropropane (HCFC-225); dichloro-tetrafluoropropane (HCFC-234); chloro-pentafluoropropane (HCFC-235); chloro-tetrafluoropropane (HCFC-244); chloro-hexafluoropropane (HCFC-226); pentachloro-difluoropropane (HCFC-222); tetrachloro-trifluoropropane (HCFC-223); trichloro-trifluoropropane (HCFC-233) pentafluoropropane (HFC-245) nonafluorobutylethylene (PFBET) and 1-bromopropane. Fluoroalcholos such as trifluoroethanol can also be used. They can be used either singly or as a mixture of two or more. Among the most preferred are HFE-7100, HFC 43-10, HCFC-225, PFBET, 1-bromopropane and octafluorocyclopentane.
Other compounds may be added to the mixture to vary the properties of the cleaner or solvent to fit various applications. The addition of these other compounds may also assist in the formation of useful azeotropic compositions. An azeotropic composition is defined as a constant boiling mixture of two or more substances that behaves like a single substance. Azeotropic compositions are desirable because they do not fractionate upon boiling. This behavior is desirable because mixtures may be used in vapor degreasing equipment and or the material may be redistilled.
Since achieving a perfect azeotrope is not practical in industrial use, all mixtures are described as “azeotrope-like”. The term “azeotrope-like composition” means a constant boiling or substantially constant boiling mixture of two or more substances that behave as a single substance, which therefore can distill without substantial compositional change. Constant boiling compositions, which are characterized as “azeotrope-like” will exhibit either a maximum, or minimum boiling point compared to non azeotropic mixtures of two substances at a given pressure.
As used herein, the terms azeotrope, azeotrope-like and constant boiling are intended to mean also essentially azeotropic or essentially constant boiling. In other words, included within the meaning of these terms are not only the true azeotropes, but also other compositions containing the same components in different proportions, which are true azeotropes or are constant boiling at other temperature and pressure. As is well recognized in this art, there is a range of compositions which contain the same components as the azeotrope, which will not exhibit essentially equivalent properties for cleaning, solvating and other applications, but will exhibit essentially equivalent properties as the true azeotropic composition in terms of constant boiling characteristics or tendency not to separate or fractionate on boiling.
The alcohol useful as an enhancement agent is of the formula C x H y O z where x is 1 to 12, preferably 1 to 8, more preferably 1 to 6, y is greater than x but less than 2x+2, and z is 1 to 3 provided that at least one O is a hydroxyl oxygen. Examples of these alcohols are methyl alcohol, ethyl alcohol, propyl alcohol, isopropyl alcohol, n-butyl alcohol, 2-butyl alcohol, t-butyl alcohol, 1-pentanol, 2-pentanol, 3-pentanol, allyl alcohol, 1-hexanol, 2-hexanol, 3-hexanol, 2-ethyl hexanol, 1-octanol, 1-decanol, 1-dodecanol, cyclohexanol, cyclopentanol, benzyl alcohol, furfuryl alcohol, tetrahydrofurfuryl alcohol, bis-hydroxymethyl tetrahydrofuran, ethylene glycol, propylene glycol, and butylene glycol. They can be used either singly or in the form of a mixture of two or more. Among the most preferred are methanol, ethanol, n-propanol, isopropanol, and tert butyl alcohol.
The ester useful as an enhancement agent is of the formula R 1 —COO—R 2 where R 1 and R 2 could be the same or different, R 1 is hydrogen, C 1 -C 20 alkyl, C 5 -C 6 cycloalkyl, benzyl, furanyl or tetrahydrofuranyl, preferably C 1 to C 8 alkyl, more preferably C 1 to C 4 alkyl; R 2 is C 1 -C 8 alkyl, preferably C 1 to C 4 alkyl, C 5 -C 6 cycloalkyl, benzyl, phenyl, furanyl or tetrahydrofuranyl. Examples of these esters are methyl formate, methyl acetate, methyl propionate, methyl butyrate, ethyl formate, ethyl acetate, ethyl propionate, ethyl butyrate, propyl formate, propyl acetate, propyl propionate, propyl butyrate, butyl formate, butyl acetate, butyl propionate, butyl butyrate, methyl soyate, isopropyl myristate, propyl myristate, and butyl myristate. Among the most preferred are methyl formate, methyl acetate, ethyl acetate and ethyl formate.
The ether useful as an enhancement agent is of the formula R 3 —O—R 4 where R 3 is C 1 -C 10 alkyl or alkynl, C 5 -C 6 cycloalkyl, benzyl, phenyl, furanyl or tetrahydrofuranyl, R 4 is C 1 -C 10 alkyl or alkynyl, C 5 -C 6 cycloalkyl, C 1 -C 4 ether, benzyl, phenyl, furanyl or tetrahydrofuranyl. Examples of these ethers are ethyl ether, methyl ether, propyl ether, isopropyl ether, butyl ether, methyl tert butyl ether, ethyl tert butyl ether, vinyl ether, allyl ether, methylal, ethylal and anisole. In the composition listed R 3 and R 4 , which can be the same or different, can be C 1 to C 10 alkyl or alkynyl, preferably C 1 to C 6 alkyl or alkynyl, more preferably C 1 to C 4 alkyl. Among the most preferred are isopropyl ether, methylal and propyl ether.
The preferred cyclic ethers are: 1,4-dioxane, 1,3-dioxolane, tetrahydrofuran (THF), methyl THF, dimethyl THF and tetrahydropyran (THP), methyl THP, dimethyl THP, ethylene oxide, propylene oxide, butylene oxide, amyl oxide, and isoamyl oxide. Most preferred is THF.
The ketone component of the mixture is of the formula: R 5 —C═O—R 6 where R 5 is C 1 -C 10 alkyl or alkynyl, C 5 -C 6 cycloalkyl, benzyl, furanyl or tetrahydrofuranyl, R 6 is C 1 -C 10 alkyl, C 5 -C 6 cycloalkyl, benzyl, phenyl, furanyl or tetrahydrofuranyl. Examples of these ketones are acetone, methyl ethyl ketone, 2-pentanone, 3-pentanone, 2-hexanone, 3-hexanone, and methyl isobutyl ketone. R 5 and R 6 , which can be the same or different, can be are, preferably C 1 to C 6 alkyl, more preferably C 1 to C 4 alkyl. Among the most preferred are acetone, methyl ethyl ketone, 3-pentanone and methyl isobutyl ketone.
The alkane useful as an enhancement agent is of the formula: C n H n+2 where n is 1-20, or C 4 -C 20 cycloalkanes. Examples of these alkanes are butane, methyl propane, pentane, isopentane, methyl butane, cyclopentane, hexane, cyclohexane, isohexane, heptane, methyl pentane, dimethyl butane, octane, nonane and decane, n is preferably 4 to 9, more preferably 5 to 7. Among the most preferred are cyclopentane, cyclohexane, hexane, methyl pentane, and dimethyl butane.
The aromatic compound useful as an enhancement agent is of the formula: C 6 H n —X 6−n where n is 0 to 6. X can be hydroxyl, halogen or any of the alkane, alcohol, ether groups listed above. Examples of these aromatics are benzene, toluene, xylene, ethylbenzene, cumene, mesitylene, hemimellitine, pseudocumene, butylbenzene, phenol and benzotrifluoride. Among the most preferred are toluene, xylene and mesitylene.
The amine useful as an enhancement agent is of the formula: NR 7 R 8 R 9 where R 7 , R 8 and R 9 can be hydrogen, hydroxyl, C 1 -C 10 alkyl, C 1 -C 10 alcohol. R 7 , R 8 and R 9 can all be the same or independently different. Examples of these amines are methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine, triethylamine, n-propylamine, di-n-propylamine, tri-n-propylamine, isopropylamine, di-isopropylamine, tri-isopropylamine, n-butylamine, isobutylamine, sec-butylamine, tert-butylamine, ethanolamine, diethanolamine, triethanolamine, amino methyl propanol and hydroxylamine. Most preferred are butylamines and triethylamine.
The siloxane useful as an enhancement agent is a volatile methyl siloxane. Three examples of these are hexamethyl disiloxane, octamethyl trisiloxane and decamethyl tetrasiloxane. Most preferred is hexamethyl disiloxane.
The terpene useful as an enhancement agent contains at least one isoprene group of the general formula:
The molecule may be cyclic or multicyclic. Preferred examples are d-limonene, pinene, terpinol, turpentine and dipentene.
The dibasic ester which can be used as an enhancement agent is of the formula: R 10 —COO—R 11 —COO—R 12 where R 10 is C 1 -C 20 alkyl, C 5 -C 6 cycloalkyl, benzyl, furanyl or tetrahydrofuranyl, R 1 l is C 1 -C 20 alkyl, C 5 -C 6 cycloalkyl, benzyl, phenyl, furanyl or tetrahydrofuranyl, R 12 is C 1 -C 20 alkyl, C 5 -C 6 cycloalkyl, benzyl, furanyl or tetrahydrofuranyl. Examples of these dibasic esters are dimethyl oxalate, dimethyl malonate, dimethyl succinate, dimethyl glutarate, dimethyl adipate, methyl ethyl succinate, methyl ethyl adipate, diethyl succinate, diethyl adipate. In the formula, R 10 , R 11 , and R 12 , which can be the same or different, are preferably C 1 to C 6 alkyl or alkynyl, more preferably C 1 to C 4 alkyl. Among the most preferred are dimethyl succinate, and dimethyl adipate.
The glycol ether component which can be used as an enhancement is of the formula: R 13 —O—R 14 —O—R 15 where R 13 is C 2 -C 20 alkyl, C 5 -C 6 cycloalkyl, benzyl, furanyl or tetrahydrofuranyl, R 14 is C 1 -C 20 alkyl, C 5 -C 6 cycloalkyl, benzyl, phenyl, furanyl or tetrahydrofuranyl, R 15 is hydrogen or an alcohol as defined above. Examples of these glycol ethers are ethylene glycol methyl ether, diethylene glycol methyl ether, ethylene glycol ethyl ether, diethylene glycol ethyl ether, ethylene glycol propyl ether, diethylene glycol propyl ether, ethylene glycol butyl ether, diethylene glycol butyl ether, propylene glycol methyl ether, dipropylene glycol, dipropylene glycol methyl ether, propylene glycol propyl ether, dipropylene glycol propyl ether, methyl methoxybutanol, propylene glycol butyl ether, and dipropylene glycol butyl ether. Among the most preferred are propylene glycol butyl ether, dipropylene glycol methyl ether, dipropylene glycol, methyl methoxybutanol, dipropylene glycol butyl ether and diethylene glycol butyl ether.
The pyrrolidone enhancement agent is substituted in the N position of the pyrrolidone ring by hydrogen, C 1 to C 8 alkyl, or C 1 to C 8 alkanol. Examples of these pyrrolidones are pyrrolidone, N-methyl pyrrolidone, N-ethyl pyrrolidone, N-propyl pyrrolidone, N-hydroxymethyl pyrrolidone, N-hydroxyethyl pyrrolidone, and N-hexyl pyrrolidone. Among the most preferred are N-methyl pyrrolidone and N-ethyl pyrrolidone.
The halogenated hydrocarbon enhancement agent is of the formula: R 16 —X y where R 16 is C 1 -C 20 alkyl, C 4 -C 10 cycloalkyl, C 2 -C 20 alkenyl benzyl, phenyl, fluoroethyl, and X is chlorine, bromine fluorine or iodine and y is not 0, and the Ozone Depletion Potential (ODP) of the molecule <0.15. Examples of these chlorinated materials are methyl chloride, methylene chloride, ethyl chloride, dichloro ethane, propyl chloride, n-propyl bromide, isopropyl chloride, propyl dichloride, butyl chloride, isobutyl chloride, sec-butyl chloride, tert-butyl chloride, pentyl chloride, and hexyl chloride. Among the most preferred are methylene chloride, and n-propyl bromide.
The inventive compositions are intended to be used in a similar manner as CFC's and chlorinated solvents, which have been widely used in the past in cleaning applications. These mixtures may be used in various techniques of cleaning which would be apparent to one skilled in the art such as spraying, spray under immersion, vapor degreasing/cleaning, immersion at either the boiling point or below the boiling point, wiping with cloths and brushes, immersion with ultrasonics, immersion with tumbling and spraying into air. These techniques were used to clean hard surfaces of items and were also used to clean textiles.
The compositions are also intended to be used in a similar manner as CFC's and chlorinated solvents, which have been widely used in past solvating applications. These mixtures may be used as a solvent in adhesives, paints, chemical processes, and other applications in which the solubility parameter of the solvent dissolved the solid or liquid, and/or exhibited appropriate volatility for the application.
The key to the success of these mixtures as solvents and cleaning agents is the fact that it is desirable for these mixtures to be formulated to have no flash point. This is important because it allows the solvent to be used safely without the threat of flammability as was found in similar solvents, which had the same volatility. As such the highly fluorinated material described becomes necessary in most mixtures to retard the closed cup flash point of the mixture.
Although not required it is desirable that the mixture forms an azeotrope-like mixture. This is desirable because it allows for a consistent flash point and allows the product to be distilled and recovered.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the invention, novel compositions have been formulated comprising dichloroethylene and alkoxy-substituted perfluoro compounds that contain six carbon atoms (HFE6C) with, if required, highly fluorinated materials to retard flammability and/or with other enhancement agents that improve and enhance the properties.
The resultant composition can be formulated to have acceptable low ozone depletion potential, and will have some or all of the similar desirable characteristics of CFC's and chlorinated solvents of: cleaning ability, compatibility, volatility, viscosity, solvating ability, drying ability, low or no VOC, and/or surface tension character. In addition, desired blends will exhibit no flash points in keeping in character with the CFC and chlorinated based solvents.
The content of the enhancement components in the mixture of the present invention is not particularly limited, but for the addition of an effective amount necessary to improve or control solubility, volatility, boiling point, flammability, surface tension, viscosity, reactivity, and material compatibility.
Preferably the level of the dichloroethylene component will exceed 50% by weight of the mixture and the HFE6C will be less than 30% by weight of the mixture. The amount of dichloroethylene is 50-99.9 weight percent, preferably 50-99 weight percent, more preferably 50-90 weight percent, and still more preferably 60-80 weight percent. The amount of highly fluorinated ether is 0.1-30 weight percent, preferably 10-30 weight percent, and more preferably 15-25 weight percent. Addition of the highly fluorinated material is required to modify physical properties of the mixture such as flash point, and the addition of other optional materials is required to improve the efficacy of the mixture or to assist in creating an azeotrope or an azeotrope-like mixture which is preferred.
As used in this specification and claims, effective amounts for azeotropes is defined as the amount of each component of the inventive compositions that, when combined, results in the formation of an azeotropic or azeotrope-like composition. This definition includes the amounts of each component, which amounts vary depending on the pressure applied to the composition, so long as the azeotropic or azeotrope-like, or constant boiling or substantially constant boiling compositions continue to exist at different pressures, but with possible different boiling points. Therefore, effective amount includes the weight percentage of each component of the composition of the instant invention, which forms azeotropic or azeotrope-like, or constant boiling or substantially constant boiling, compositions at pressures other than atmospheric pressure.
It is possible to characterize, in effect, a constant boiling mixture, which may appear under many guises, depending on the conditions chosen, by any of several criteria:
A composition can be defined as an azeotrope of A, B, and C, since the term “azeotrope” is at once both definitive and limitative, and requires that effective amounts of A, B, and C form this unique composition of matter, which is a constant boiling mixture.
It is well known by those skilled in the art that at different pressures, the composition of a given azeotrope will vary, at least to some degree, and changes in pressure will also change, at least to some degree, the boiling point. Thus an azeotrope of A, B, and C represents a unique type of relationship but with a variable composition which depends on temperature and/or pressure. Therefore compositional ranges rather than fixed compositions are often used to describe azeotropes.
The composition can be defined as a particular weight percent relationship or mole percent relationship of A, B, and C, while recognizing that such specific values point out only one particular such relationship and that in actuality, a series of such relationships, represented by A, B, and C actually exist for a given azeotrope, varied by the influence of pressure.
Azeotrope A, B, and C can be characterized by defining the composition as an azeotrope characterized by a boiling point at a given pressure, thus giving identifying characteristics without unduly limiting the scope of the invention by a specific numerical composition which is limited by and is only as accurate as the analytical equipment available.
The following ternary compositions are characterized as azeotropic or azeotrope-like in that compositions within these ranges exhibit substantially constant boiling point at constant pressure. These ternary azeotrope like compositions being substantially constant boiling, the compositions do not tend to fractionate to any great extent upon evaporation at standard conditions. After evaporation, only a small difference exists between the composition of the vapor and the composition of the initial liquid phase. This difference is such that the composition of the vapor and liquid phases are considered substantially the same and are azeotropic or azeotrope like in their behavior.
1) 50-80 weight percent 1,2-trans-dichloroethylene (TDCE), 10-30 weight percent nonafluorobutane ethyl ether (HFE-7200), and 0.1-10 weight percent methanol.
2) 50-80 weight percent TDCE, 10-30 weight percent HFE-7200, and 0.1-7 weight percent ethanol.
3) 50-80 weight percent TDCE, 10-30 weight percent HFE-7200, and 0.1-5 weight percent 1-propanol.
4) 50-80 weight percent TDCE, 10-30 weight percent HFE-7200, and 0.1-5 weight percent 2-propanol (IPA).
5) 50-80 weight percent TDCE, 10-30 weight percent HFE-7200, and 0.1-2.5 weight percent t-butanol.
6) 50-80 weight percent TDCE, 10-30 weight percent HFE-7200, and 0.1-5 weight percent methylal.
7) 50-80 weight percent TDCE, 10-30 weight percent HFE-7200, and 0.1-2.5 weight percent methyl acetate.
8) 50-80 weight percent TDCE, 10-30 weight percent HFE-7200, and 0.1-7 weight percent acetone.
9) 50-80 weight percent TDCE, 10-30 weight percent (FE-7200, and 1-40 weight percent methylene chloride.
The following ternary compositions have been established, within the accuracy of successive distillation methods, as true ternary azeotropes at substantially atmospheric pressure.
1) 66 weight percent TDCE, 26.5 weight percent HFE-7200, and 7.5 weight percent methanol, boiling point of about 106° F. (about 41° C.).
2) 68.5 weight percent TDCE, 27 weight percent HFE-7200, and 4.5 weight percent methanol, boiling point of about 116° F. (about 47° C.).
3) 71 weight percent TDCE, 28.5 weight percent HFE-7200, and 0.5 weight percent 1-propanol, boiling point of about 116° F. (about 47° C.).
4) 70.5 weight percent TDCE, 27.5 weight percent HFE-7200, and 2 weight percent IPA boiling point of about 116° F. (about 47° C.).
5) 72 weight percent TDCE, 27.5 weight percent HFE-7200, and 0.5 weight percent t-butanol, boiling point of about 116° F. (about 47° C.).
6) 69.5 weight percent TDCE, 28 weight percent HFE-7200, and 2.5 weight percent methylal, boiling point of about 116° F. (about 47° C.).
7) 72 weight percent TDCE, 27.5 weight percent HFE-7200, and 0.5 weight percent methyl acetate, boiling point of about 116° F. (about 47° C.).
8) 72 weight percent TDCE, 26 weight percent HFE-7200, and 2 weight percent acetone, boiling point of about 115° F. (about 47° C.).
9) 52 weight percent TDCE, 23.5 weight percent HFE-7200, and 24.5 weight percent methylene chloride, boiling point of about 110° F. (about 43° C.).
The following multicomponent compositions are characterized as azeotropic or azeotrope-like in that compositions within these ranges exhibit substantially constant boiling point at constant pressure. These mixtures were selected as a result of adding a material from a final group of selected highly fluorinated compounds to the ternary azeotrope-like blend. In most instances the purpose of its addition was to retard the flashpoint. However, the addition of the highly fluorinated compound in many ways formed unique mixtures in creating two ternary azeotrope-like mixtures that overlapped each other and had similar boiling points and compositions. Being substantially constant boiling, the compositions do not tend to fractionate to any great extent upon evaporation up to 50% of the mass. Since the mixtures are not easily fractionated, they are useful commercially in standard cleaning apparatuses for cold cleaning and vapor degreasing. After evaporation of half the mass, small differences of less than 10% exist between the composition of the vapor and the composition of the initial liquid phase. This difference is such that the composition of the vapor and liquid phases are considered substantially the same and are either azeotropic or azeotrope like in their behavior. This is a blend that is suitable for commercial use.
1) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-10 weight percent methanol, and 1-25 weight percent 1,1,1,2,3,4,4,5,5,5-decafluoropentane (HFC-43-10mee).
2) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent ethanol, and 1-25 weight percent HFC-43-10mee.
3) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-5 weight percent 2-propanol, and 1-25 weight percent HFC-43-10mee.
4) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-10 weight percent acetone, and 1-25 weight percent HFC-43-10mee.
5) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-8 weight percent methylal, and 1-25 weight percent HFC-43-10mee.
6) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent methanol, 0.1-4 weight percent ethanol. and 1-25 weight percent HFC-43-10mee.
7) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent methanol, 0.1-4 weight percent 2-propanol, and 1-25 weight percent HFC-43-10mee.
8) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent methanol, 0.1-4 weight percent methylal, and 1-25 weight percent HFC-43-10mee.
9) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent methanol, 0.1-4 weight percent cyclopentane, and 1-25 weight percent HFC-43-10mee.
10) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent ethanol, 0.1-4 weight percent 2-propanol. and 1-25 weight percent HFC-43-10mee.
11) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-10 weight percent methanol, and 1-25 weight percent HFE-7100.
12) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent ethanol, and 1-25 weight percent HFE-7100.
13) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-5 weight percent 2-propanol, and 1-25 weight percent HFE-7100.
14) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-10 weight percent acetone, and 1-25 weight percent HFE-7100.
15) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-8 weight percent methylal, and 1-25 weight percent HFE-7100.
16) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent methanol, 0.1-4 weight percent ethanol, and 1-25 weight percent HFE-7100.
17) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent methanol, 0.1-4 weight percent 2-propanol, and 1-25 weight percent HFE-7100.
18) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent methanol, 0.1-4 weight percent methylal, and 1-25 weight percent (HFE-7100.
19) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-6 weight percent methanol, 0.1-4 weight percent cyclopentane, and 1-25 weight percent HFE-7100.
20) 50-88 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent ethanol, 0.1-4 weight percent 2-propanol, and 1-25 weight percent HFE-7100.
The following multicomponent compositions have been established, within the accuracy of simple one plate distillation methods, as azeotrope-like blends that are preferred. The compositions are characterized by having no flash points and have stable compositions upon distillation of approximately 50% of the original mixture. The noted boiling point range is at atmospheric pressure.
1) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-7 weight percent methanol, and 1-15 weight percent HFC-43-10mee, boiling point range of 108-116° F. (42-47° C.).
2) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent ethanol and 1-15 weight percent HFC-43-10mee, boiling point range of 116-119° F. (47-48° C.).
3) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent 2-propanol, and 1-15 weight percent HFC-43-10mee, boiling point range of 116-119° F. (47-48° C.).
4) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent acetone, and 1-15 weight percent HFC-43-10mee, boiling point range of 114-119° F. (46-48° C.).
5) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent methylal, and 1-15 weight percent HFC-43-10mee, boiling point range of 116-119° F. (47-48° C.).
6) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent methanol, 0.1-2 weight percent ethanol, and 1-15 weight percent HFC-43-10mee, boiling point range of 113-117° F. (45-47° C.).
7) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent methanol, 0.1-2 weight percent 2-propanol, and 1-15 weight percent HFC-43-10mee, boiling point range of 113-117° F. (45-47° C.).
8) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent methanol, 0.1-3 weight percent methylal, and 1-15 weight percent HFC-43-10mee, boiling point range of 116-119° F. (47-48° C.).
9) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent methanol, 0.1-2 weight percent cyclopentane, and 1-15 weight percent HFC-43-10mee, boiling point range of 106-115° F. (41-46° C.).
10) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent ethanol, 0.1-4 weight percent 2-propanol, and 1-15 weight percent HFC-43-10mee, boiling point range of 116-119° F. (47-48° C.).
11) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-5.5 weight percent methanol, and 1-18 weight percent HFE-7100, boiling point range of 105-111° F. (41-44° C.).
12) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-3.5 weight percent ethanol, and 1-18 weight percent HFE-7100, boiling point range of 115-119° F. (46-48° C.).
13) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent 2-propanol, and 1-18 weight percent HFE-7100, boiling point range of 116-118° F. (47-48° C.).
14) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-3 weight percent acetone, and 1-18 weight percent HFE-7100, boiling point range of 113-116° F. (45-47° C.).
15) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-3 weight percent methylal, and 1-18 weight percent HFE-7100, boiling point range of 116-119° F. (47-48° C.).
16) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-3 weight percent methanol, 0.1-2 weight percent ethanol, and 1-20 weight percent HFE-7100, boiling point range of 113-116° F. (45-47° C.).
17) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-3 weight percent methanol, 0.1-2 weight percent 2-propanol, and 1-20 weight percent HFE-7100, boiling point range of 113-117° F. (45-47° C.).
18) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-3 weight percent methanol, 0.1-2 weight percent methylal, and 1-20 weight percent HFE-7100, boiling point range of 113-117° F. (45-47° C.).
19) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-3 weight percent methanol, 0.1-2 weight percent cyclopentane, and 1-20 weight percent HFE-7100, boiling point range of 105-110° F. (41-43° C.).
20) 60-78 weight percent TDCE, 10-30 weight percent HFE-7200, 0.1-4 weight percent ethanol, 0.1-4 weight percent 2-propanol, and 1-20 weight percent HFE-7100, boiling point range of 116-119° F. (47-48° C.).
It is preferred that inhibitors be added to the compositions to inhibit decomposition, react with undesirable decomposition products of the compositions, and/or prevent corrosion of metal surfaces. Any and all of the following classes of inhibitors may be employed in the invention, some of which may serve a dual purpose as suitable components for cleaning and solvating. Preferred are alkanols having 4 to 7 carbon atoms, nitroalkanes having 1 to 3 carbon atoms, 1,2 epoxyalkanes having 2 to 7 carbon atoms, acetylene alcohols having 3 to 9 carbon atoms, phosphite esters having 12 to 30 carbon atoms, ethers having 3 to 6 carbon atoms, unsaturated hydrocarbon compounds having 4 to 7 carbon atoms, triazoles, acetals having 4 to 7 carbon atoms, ketones having 3 to 5 carbon atoms, and amines having 6 to 8 carbon atoms. Other suitable inhibitors will be readily apparent to those skilled in the art.
Inhibitors may be used alone or in mixtures in any proportions. Typically less than 5 weight percent and, preferably, less than 2 weight percent of inhibitor based on thertotal weight of the mixture may be used.
In addition, the composition of the present invention may further contain surfactants, emulsifying agents, wetting agents, water, perfumes, indicators, or colorants.
The compositions of the invention are useful for solvating, vapor degreasing, photoresist stripping, adhesive removal, aerosol, cold cleaning, and solvent cleaning applications including defluxing, dry cleaning, degreasing, particle removal, metal and textile cleaning.
EXAMPLES 1-10
The azeotropic mixtures of this invention were initially identified by screening mixtures of dichloroethylene HFE6C and various organic solvents. The selected mixtures were distilled in a Kontes multistage distillation apparatus using a Snyder distillation column. The distilled overhead composition was analyzed using a Hewlett-Packard Gas Chromatograph using a FID detector and a HP-4 column. The overhead composition was compared to the feed composition to identify the azeotropic composition. If the feed and overhead compositions differed then the overhead material was collected and re-distilled until successive distillation compositions were within 2% of the feed composition, indicating an azeotrope. The method was also supplemented by recording temperatures of the feed at boiling at approximately 1 atmosphere (room pressure). The presence of an azeotrope was also indicated when the test mixture exhibited a lower boiling point than the boiling point of the subsequent feed mixture. Results obtained are summarized in Table 1.
TABLE 1
Azeotrope-like Compositions
Alkoxy-substituted
Other
Azeotrope
perfluoro
Material
Weight Percent
Boiling Point
Example/
Dichloroethylene
compounds
Component
Weight Percent
Weight Percent
Other Material
° F./° C.
Flash
Mixture
Component (I)
Component (II)
A&B
Component (I)
Component (II)
Component A&B
@ 1 atm
Point
1
TDCE
HFE-7200
None
68%
32%
0%
118/48
None
2
TDCE
HFE-7200
Methanol
66%
26.5%
7.5%
106/41
Yes
3
TDCE
HFE-7200
Ethanol
68.5%
27%
4.5%
116/47
Yes
4
TDCE
HFE-7200
1-Propanol
71%
28.5%
0.5%
116/47
None
5
TDCE
HFE-7200
2-Propanol
70.5%
27.5%
2%
116/47
Yes
6
TDCE
HFE-7200
t-Butanol
72%
27.5%
0.5%
116/47
None
7
TDCE
HFE-7200
Methylal
69.5%
28%
2.5%
116/47
Yes
8
TDCE
HFE-7200
Methyl
72%
27.5%
0.5%
116/47
None
Acetate
9
TDCE
HFE-7200
Acetone
72%
26%
2%
115/47
Yes
10
TDCE
HFE-7200
Methylene
52%
23.5%
24.5%
110/43
None
Chloride
EXAMPLE 11
The ten azeotrope-like compositions given in Table 1 were tested to determine the cleaning and solvating of the compositions on three soils, two types of flux and machine oil. The soils were applied to a test FR-4 substrate and then were immersed into a beaker of the mixture at room temperature with minimal agitation. All 10 mixtures easily cleaned the soils from the substrates in less than 5 minutes. The cleaning was observed to be faster with those blends that contained the addition of component B from the previously mentioned candidates. This was observed to be true when cleaning no-clean flux residues.
The results of this example were encouraging based on the fact that when dichloroethylene compositions are greater than 50% by weight in a mixture, the blend was usually found to be effective on difficult soils such as no-clean flux residues. A drawback of this example is that over half of the mixtures cited exhibited flash points which is not preferred. Usually flash points were the result of the addition of a component B at levels greater than 0.1% weight percent which gave the mixture better cleaning properties but at the expense of creating a flash point.
EXAMPLES 12-21
Cleaning/solvating compositions were made using dichloroethylene compounds (I) with alkoxy-substituted perfluoro compounds that contain six carbons (HFE6C)(II), with highly fluorinated materials (A) to retard flammability and with other enhancement agents that improve and enhance the properties of the original mixture were tested (B). Tests were conducted to determine the cleaning and solvating of the solvent mixtures using the same method as previously discussed. Flash points were also observed in checking the ability to light the mixture in a beaker at room temperature and pressure in a modified open cup flash point test.
TABLE 2
Multicomponent Compositions Testing
Alkoxy-substituted
perfluoro
Other Material
Weight
Weight
Example/
Dichloroethylene
compounds
Highly Fluorinated
Component
Percent
Percent
Mixture
Component (I)
Component (II)
Material (A)
(B)
(I)
(II)
12
(TDCE)
HFE-7200
HFC-43-10 mee
Methanol
70%
18%
13
TDCE
HFE-7200
HFC-43-10 mee
Methanol
66%
22%
Ethanol
14
TDCE
HFE-7200
HFC-43-10 mee
2-Propanol
72%
16%
15
TDCE
HFE-7200
HFC-43-10 mee
Methylal
66%
21%
16
TDCE
HFE-7200
HFC-43-10 mee
Methanol
69%
18%
Cyclopentane
17
TDCE
HFE-7200
HFE-7100
Methanol
68%
19%
18
TDCE
HFE-7200
HFE-7100
Methanol
66%
22%
Ethanol
19
TDCE
HFE-7200
HFE-7100
2-Propanol
66%
20%
Ethanol
20
TDCE
HFE-7200
HFE-7100
2-Propanol
71.5%
18%
t-Butanol
21
TDCE
HFE-7200
HFE-7100
Methanol
67%
20%
Cyclopentane
Cleans
Weight
Weight
Cleans
No-
Example/
Percent
Percent
Cleans
Rosin
Clean
Mixture
(A)
(B)
Oil
Fluxes
Fluxes
Flammable
12
8%
4%
Yes
Yes
Yes
No
13
9%
1%
Yes
Yes
Yes
No
2%
14
9%
3%
Yes
Yes
Yes
No
15
10%
3%
Yes
Yes
Yes
No
16
9%
3%
Yes
Yes
Yes
No
1%
17
10%
3%
Yes
Yes
Yes
No
18
9%
1%
Yes
Yes
Yes
No
2%
19
10%
2%
Yes
Yes
Yes
No
2%
20
8%
2%
Yes
Yes
Yes
No
0.5%
21
10%
2%
Yes
Yes
Yes
No
1%
It should be apparent from the foregoing detailed description that the objects set forth at the outset to the specification have been successfully achieved. Moreover, while there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.
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Chemical solvating, degreasing, stripping and cleaning agents. The agents are cleaning and solvating mixtures of dichloroethylene and alkoxy-substituted perfluoro compounds that contain six carbon atoms, with optionally highly fluorinated materials to retard flammability and/or other enhancement agents that improve and enhance the properties of the composition to accomplish its desired cleaning or solvating task. These other agents are one or more of the following materials: alcohols, esters, ethers, cyclic ethers, ketones, alkanes, aromatics, amines, siloxanes terpenes, dibasic esters, glycol ethers, pyrollidones, or low- or non-ozone depleting halogenated hydrocarbons. These mixtures are useful in a variety of solvating, vapor degreasing, photoresist stripping, adhesive removal, aerosol, cold cleaning, and solvent cleaning applications including defluxing, dry-cleaning, degreasing, particle removal, metal and textile cleaning.
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FIELD OF THE INVENTION
[0001] The invention is generally related to the field of CMOS transistors and more specifically to a sidewall process for a CMOS transistor.
BACKGROUND OF THE INVENTION
[0002] As semiconductor devices are scaled to smaller dimensions, generally in the sub-0.1 μm region, it becomes more difficult to fabricate transistors with high drive current and small short-channel effects (i.e., reduced threshold voltage rolloff). To this end, pocket implant processes have been implemented to reduce the threshold voltage (Vt) rolloff, reduce the nominal Vt, and thus improve the nominal drive current. The pocket implant process is a process whereby a region of dopants (referred to herein as a pocket region) opposite to the type used for source/drain (and/or source/drain extension) regions is formed adjacent to the source/drain (and/or source/drain extension) regions. The lateral extent of the pocket region is typically less than the channel length of the MOSFET such that the formation of the pocket results in a laterally non-uniform dopant region from the source and/or drain and/or drain extension to the interior of the channel region. While the pocket implant may reduce short-channel effects, it may also increase the channel surface doping nearest the drain extension (and/or source extension) tip to a significant lateral extent to the interior of the channel region. This, in turn, lowers surface mobility due to dopant scattering. So, while drive current is improved by the pocket implant due to lower nominal Vt, the drive current is not as improved as it could be due to enhanced dopant scattering.
[0003] Additionally, source and/or drain extension region (referred to hereafter as “drain extension region”) doping processes have been implemented to reduce the source and/or drain extension region parasitic resistance and to reduce the Vt rolloff and thus improve the nominal drive current. To achieve both low parasitic resistance and low Vt rolloff, the drain extension regions should be of sufficient junction depth to allow for low parasitic resistance but with small gate overlap of the drain extension regions.
[0004] It is desired therefore to provide for a structure with improved pocket implant process for high drive current. It is additionally desired to have a structure allowing for use of moderate drain extension implant energies for formation of drain extension regions which have low parasitic resistance with sufficiently low gate overlap of the drain extension regions.
SUMMARY OF THE INVENTION
[0005] A transistor and method for forming a transistor using an edge blocking material is disclosed herein. The edge blocking material may be located adjacent a gate or disposable gate or may be part of a gate or disposable gate. During an angled pocket implant, the edge blocking material limits the implant range of dopants to be less than that in the semiconductor body and the dopant placed under the edge blocking material is in part located at a given distance below the surface of the semiconductor body. The edge blocking material in part may limit the portion of the angled pocket implant that penetrates through a gate electrode to the underlying channel region in the semiconductor body.
[0006] An advantage of the invention is providing a transistor having reduced short channel effects as well as improved surface mobility due to a pocket placed with peak doping below the surface of the channel and/or due to a reduced length of high pocket doping at the channel surface extending laterally from the drain extension regions inwards to the channel region.
[0007] Another advantage of the invention is providing a transistor having reduced gate-to-drain and gate-to source capacitance.
[0008] Another advantage of the invention is providing a method of forming a transistor using a sidewall spacer that is relatively insensitive to clean-up processes.
[0009] These and other advantages will be apparent to those of ordinary skill in the art having reference to the specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the drawings:
[0011] [0011]FIG. 1 is a cross-sectional diagram of a transistor having a pocket implant spaced below a surface of the substrate and/or having a reduced length of high pocket doping at the channel surface extending laterally from the drain extension regions inwards to the channel region according to the invention;
[0012] FIGS. 2 A- 2 C are cross-sectional diagrams of the transistor of FIG. 1 at various stages of fabrication;
[0013] [0013]FIG. 3 is a cross-sectional diagram of a transistor having raised source/drain regions according to the invention;
[0014] [0014]FIG. 4 is a cross-sectional diagram of a transistor according to a second embodiment of the invention; and
[0015] FIGS. 5 A- 5 C are cross-sectional diagrams of the transistor of FIG. 4 at various stages of fabrication.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0016] The invention will now be described in conjunction with a tenth micron n-type transistor using a CMOS process. It will be apparent to those of ordinary skill in the art that the benefits of the invention may be applied to other CMOS processes (as well as NMOS and PMOS), and transistor sizes. It will also be apparent to those of ordinary skill in the art that the invention may be applied to p-type transistors by reversing the conductivity types.
[0017] A first embodiment of the invention is shown in FIG. 1. Transistor 30 is located in p-type substrate 10 . Substrate 10 may alternatively refer to a p-type epitaxial layer formed on a substrate or a p-type well region formed in a substrate or epitaxial layer. Transistor 30 is isolated from other devices (not shown) by isolation regions 12 . Isolation regions 12 are shown as field oxide regions. However, other types of isolation, such as shallow trench isolation, may also be used. Regions 16 are highly doped regions (n-type) commonly referred to as drain extensions. Transistor 30 may also include deep source/drain regions 14 . As will be discussed further hereinbelow, transistor 30 may additionally or alternatively include raised source/drain regions.
[0018] Pocket regions 18 are doped oppositely to drain extension regions 16 . In the case of the n-type transistor, regions 18 are p-type. Peak concentration of the pocket regions 18 are spaced from the surface of the substrate 10 to a greater extent and/or the lateral extent of a high pocket concentration at the channel surface, extending from the drain extension inwards to the channel region, is reduced as will be described. Thus, the benefits of traditional pocket regions, i.e., reduced threshold voltage rolloff, reduced nominal Vt, and improved nominal drive current, are maintained. In addition, drawback of conventional pockets, i.e., enhanced dopant scattering due to enhanced dopant concentration over a large lateral extent near the channel surface, is significantly reduced. Because the pocket regions 18 do not have a peak concentration to a significant lateral extent at the surface and/or are spaced from the surface of the substrate, the dopant concentration at the surface of the channel is not significantly enhanced by the pocket as compared to conventional methods of forming transistors.
[0019] Gate electrode 22 is located on a gate dielectric 20 . Gate dielectric 20 may be any suitable gate dielectric known in the art. Typically, gate dielectric 20 will comprise an oxide. Gate electrode 22 comprises a conductive material such as polysilicon, silicide, metal, or a combination thereof.
[0020] A thin sidewall spacer 24 preferably of thickness 10-25 nanometers is located on the sidewalls of gate electrode 22 . Spacer 24 comprises a material or a composite of materials that reduces the implant range of dopants thus preventing dopants from reaching the surface of substrate 10 under the spacer 24 during an angled implant and/or reducing the lateral extension of dopants from the drain extension edge inwards to the channel at the surface of substrate 10 during an angled implant. The material chosen for spacer 24 has a smaller implant range than the underlying substrate and may include in part silicon nitride or silicon carbide. Additionally, silicon nitride and silicon carbide are materials which are not significantly reduced in thickness by standard wet chemical cleaning or stripping processes as compared to other materials as deposited oxides.
[0021] A method for forming the first embodiment of the invention will now be described. The substrate 10 is processed through the formation of isolation regions 12 and any well implants and threshold adjust implants as is well known in the art.
[0022] Referring to FIG. 2A, a gate structure 32 is formed on substrate 10 . Gate structure 32 may comprise a gate electrode and gate dielectric or a disposable gate structure as is known in the art. If the gate electrode and dielectric are formed at this point (as opposed to a disposable gate), the gate dielectric may be a remote-plasma nitrided oxide for smaller (˜0.1 micron) transistors. Other gate dielectric materials suitable include oxide or nitrided oxide by means other than remote-plasma nitridation. The gate pattern/etch may be accomplished with a deep UV surface-imaging lithography with linewidth reduction etch to achieve a short gate length.
[0023] Thin sidewall spacers 24 are then formed on the sidewalls of gate structure 32 . Prior to formation of sidewall spacers 24 , a thin thermal oxide of thickness 3-6 nanometers may be formed during a gate sidewall-reoxidation process to in part repair any gate etch damage to the underlying gate oxide. This thin thermal oxide from the sidewall re-oxidation process is not shown in FIG. 2A. Similarly, after formation of sidewall spacers 24 , a thin thermal oxide of thickness ˜2-3 nm may be formed if desired as a screen oxide before any subsequent implantation processes. Spacers 24 are formed prior to the highly doped drain (HDD) extension implant. This is done to reduce the gate to drain capacitance and thus the minimum gate length that the transistor can operate without excessive leakage between source and drain regions. Spacers 24 comprise a blocking material, preferably silicon nitride or silicon carbide. However, they may comprise any material having a smaller implant range than the substrate. The material is chosen to reduce the implant range of dopants thus preventing dopants from reaching the surface of substrate 10 under the spacer 24 during a subsequent angled implant and/or reducing the lateral extension of dopants from the drain extension edge inwards to the channel at the surface of substrate 10 during a subsequent angled implant. Another advantage of using silicon nitride or silicon carbide for spacers 24 , is that the thickness of spacer 24 will not substantially decrease during subsequent clean-up or resist stripping processes. In contrast, the thickness of currently used oxide spacers is affected by these subsequent processes. As transistors continue to scale to smaller dimensions, slight variations or uncontrolled reductions in spacer thicknesses have greater impact on transistor characteristics.
[0024] Referring to FIG. 2B, the NMOS and PMOS HDD implants are performed (The PMOS HDD region is not shown.) Preferably, a reduced energy implant of arsenic (n-type) or BF2 (p-type) at 10 keV-20 keV is used. A pre-amorphization implant (such as a low energy Sb, non-counterdoping implant for low diode leakage current) may be utilized prior to the PMOS HDD implant for shallower junctions. The HDD implant is shown as non-angled. However, angled HDD implants may be used if desired. For HDD implant at sufficiently reduced energies (such as less than 10 keV), it may be that the HDD implants can be performed prior to spacers 24 if the gate-source and gate-drain capacitance is acceptable. A typical HDD implant dose for arsenic of BF 2 is in the range of 2E14-1.2E15/cm 2 .
[0025] Next, angled pocket implants (of opposite conductivity to the HDD implant) are performed and the structure may then subjected to a rapid thermal anneal (RTA), as shown in FIG. 2C. Preferably, an implant energy of 10-20 keV for B at an implant angle of 15-45 degrees is utilized for NMOS pocket implant although other pocket implant species as BF2 and Indium can be used with an appropriate change in energy dependent in part on the mass of the species. For example, Indium may be implanted at energies of 60-170 keV. Implant dose for each angled pocket implant may be in the range of 5E12-1.5E13 cm−2. Preferably, an implant energy of 30-70 keV for P at an implant angle of 15-45 degrees is utilized for PMOS pocket implant although other pocket implant species as As and Sb can be used with an appropriate change in energy dependent in part on the mass of the species. For example, Sb (or As) may be implanted at energies of 60-180 keV. Implant dose for each angled pocket implant may be in the range of 6E12-1.7E13 cm−2. Spacers 24 reduce the implant range of dopants thus preventing dopants from reaching the surface of substrate 10 and/or reduce the lateral extension of pocket dopants from the drain extension edge inwards to the channel at the surface of substrate 10 during an angled pocket implant. Dopant is placed below spacers 24 due to the angling of the implant. A pocket implant range distance on the order of 20-80 nanometers below the surface of the substrate is desired. It is noted that the order of the HDD implant and the pocket implant can be reversed if desired.
[0026] Next, a second sidewall spacer 34 is formed followed by deep source/drain regions 14 being implanted and annealed if desired. Alternatively or additionally, raised source/drain regions 36 may be formed at this point as shown in FIG. 3. Method for forming raised source/drain regions are known in the art. For example, raised source/drain regions 36 may be formed by selective epitaxial growth. The raised source/drain regions 36 may then be implanted and annealed if desired. Subsequent salicidation or metal cladding over the source/drain and or gate regions can be performed if desired. Additionally, a dielectric layer may be formed over the source/drain regions or over the raised source/drain regions if present. The dielectric layer may be planarized to expose the top of gate structure 32 such that the disposable gate structure 32 is removed and replaced with a gate dielectric 20 and gate dielectric 22 . Conventional backend processing as is well known in the art may then be utilized to complete device fabrication.
[0027] A second embodiment of the invention is shown in FIG. 4. Transistor 40 is located in p-type substrate 10 . Substrate 10 may alternatively refer to a p-type epitaxial layer formed on a substrate or a p-type well region formed in a substrate or epitaxial layer. Transistor 40 is isolated from other devices (not shown) by isolation regions 12 . Isolation regions 12 are shown as field oxide regions. However, other types of isolation, such as shallow trench isolation, may also be used. Regions 16 are highly doped regions (n-type) sometimes referred to as drain extensions. Transistor 40 may also include deep source/drain regions (not shown). Transistor 40 includes raised source/drain regions 36 .
[0028] Pocket regions 18 are doped oppositely to drain extension regions 16 . In the case of the n-type transistor, regions 18 are p-type. Peak concentration of the pocket regions 18 are spaced from the surface of the substrate 10 to a greater extent and/or the lateral extent of a high pocket concentration at the channel surface, extending from the drain extension inwards to the channel region, is reduced as will be described. Thus, the benefits of traditional pocket regions, i.e., reduced threshold voltage rolloff, reduced nominal Vt, and improved nominal drive current, are maintained. In addition, drawback of conventional pockets, i.e., enhanced dopant scattering due to enhanced dopant concentration over a large lateral extent near the channel surface, is significantly reduced. Because the pocket regions 18 do not have a peak concentration to a significant lateral extent at the surface and/or are spaced from the surface of the substrate, the dopant concentration at the surface of the channel is not significantly enhanced by the pocket as compared to conventional methods of forming transistors.
[0029] Gate electrode 22 is located on a gate dielectric 20 . Gate dielectric 20 may be any suitable gate dielectric known in the art. Typically, gate dielectric 20 will comprise an oxide. Gate electrode 22 comprises a conductive material such as polysilicon, silicide, metal, or a combination thereof.
[0030] A method for forming the second embodiment of the invention will now be described. The substrate 10 is processed through the formation of isolation regions 12 and any well implants and threshold adjust implants as is well known in the art.
[0031] Referring to FIG. 5A, a disposable gate structure 32 is formed on substrate 10 . Disposable gate structure 32 may, for example, comprise a thin oxide with an overlying non-oxide material. The overlying non-oxide material is a blocking material, preferably silicon nitride or silicon carbide. However, it may comprise any material having a smaller implant range than the substrate. The material is chosen to reduce the implant range of dopants thus preventing dopants from reaching the surface of substrate 10 under the disposable gate structure 32 during a subsequent angled implant and/or reducing the lateral extension of dopants from the drain extension edge inwards to the channel at the surface of substrate 10 during a subsequent angled implant.
[0032] Still Referring to FIG. 5A, the NMOS and PMOS HDD implants are performed (The PMOS HDD region is not shown.) Preferably, a reduced energy implant of arsenic (n-type) or BF2 (p-type) at 10 keV or less is used. A pre-amorphization implant (such as a low energy Sb, non-counterdoping implant for low diode leakage current) may be utilized prior to the PMOS HDD implant for shallower junctions. The HDD implant is shown as non-angled. However, angled HDD implants may be used if desired. A typical HDD implant dose for arsenic of BF 2 is in the range of 2E14-1.2E15/cm 2 .
[0033] Next, angled pocket implants (of opposite conductivity to the HDD implant) are performed and the structure may then subjected to a rapid thermal anneal (RTA), as shown in FIG. 5B. Preferably, an implant energy of 10-20 keV for B at an implant angle of 15-45 degrees is utilized for NMOS pocket implant although other pocket implant species as BF2 and Indium can be used with an appropriate change in energy dependent in part on the mass of the species. For example, Indium may be implanted at energies of 60-170 keV. Implant dose for each angled pocket implant may be in the range of 5E12-1.5E13 cm−2. Preferably, an implant energy of 30-70 keV for P at an implant angle of 15-45 degrees is utilized for PMOS pocket implant although other pocket implant species as As and Sb can be used with an appropriate change in energy dependent in part on the mass of the species. For example, Sb (or As) may be implanted at energies of 60-180 keV. Implant dose for each angled pocket implant may be in the range of 6E12-1.7E13 cm−2. The blocking layer of disposable gate structure 32 reduce the implant range of dopants thus preventing dopants from reaching the surface of substrate 10 and/or reduce the lateral extension of pocket dopants from the drain extension edge inwards to the channel at the surface of substrate 10 during an angled pocket implant. Dopant is placed below disposable gate structure 32 due to the angling of the implant. An implant range distance on the order of 20-80 nanometers below the surface of the substrate is desired. It is noted that the order of the HDD implant and the pocket implant can be reversed if desired.
[0034] Referring to FIG. 5C, raised source/drain regions 36 are formed. Methods for forming raised source/drain regions are known in the art. For example, raised source/drain regions may be formed by selective epitaxial. After raised/source/drain regions 32 are formed an overlying dielectric layer 38 is deposited and planarized with disposable gate 32 . Disposable gate 32 is then removed and replaced with a gate dielectric 20 and gate electrode 22 .
[0035] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is therefore intended that the appended claims encompass any such modifications or embodiments.
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A transistor ( 30 ) and method for forming a transistor using an edge blocking material ( 24 ) is disclosed herein. The edge blocking material ( 24 ) may be located adjacent a gate ( 22 ) or disposable gate or may be part of a disposable gate. During an angled pocket implant, the edge blocking material ( 24 ) blocks some dopant from entering the semiconductor body ( 10 ) and the dopant ( 18 ) placed under the edge blocking material is located at a given distance below the surface of the semiconductor body ( 10 ).
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TECHNICAL FIELD
[0001] The present invention relates to the field of traction transformers for electric railway vehicles. It refers to a traction transformer as described in the preamble of claim 1 and 2 .
RELATED ART
[0002] In electric railway propulsion vehicles such as locomotives or rail coaches, the traction transformer is a crucial piece in the traction chain. If the traction transformer fails, the train is immobilised and a track section is blocked. The traction transformer is the main transformer on the railbound vehicle and provides energy from the catenary to the propulsion motor and for all on board systems. Traction transformers have to accommodate different input frequencies and voltage (ranging from as high as 50 Hz down to 16.7 Hz and rated up to 25 kV) while being suitable for multiple AC asynchronous motor and DC converters and motors with varying harmonics mitigation filtering requirements. To provide high-power conversion the traction transformer need to be designed with a substantial size and weight. A traction transformer is designed to withstand all occurring mechanical vibrations, shocks and acceleration forces of a railway propulsion vehicle.
[0003] The traction transformer is usually placed outside the main casing of the traction vehicle, i.e. underfloor or on the roof top where space is limited because of the maximal allowable vehicle height or the available space between underfloor and rail. Tractions transformers may also be placed inside the main casing end prevail similar space limitations. Further, due to considerable weight of the transformer care has to be taken if roof top or underfloor installations are demanded.
[0004] The first traction transformers have been constructed with dry in or air insulations causing frequent failures as flashovers and electrical discharges during operation. The failures are caused by dust or humidity to which the transformer was exposed.
[0005] Nowadays conventional state of the art traction transformers for electric railway propulsion vehicles are by the type of insulation and cooling oil-immersed transformers to meet the requirements. Oil being a very good heat transfer medium and a good electrically insulating material compared to air, when a high power density is needed. The windings and the core of oil-immersed transformers are completely encased in a tank which is filled with the transformer oil. The tank has therefore appropriate means on its outer side for mounting it to the propulsion vehicle. Such means for mounting are beams, plates etc. which are welded to the tank (housing) of the traction transformer and must take the full weight of tank, transformer and transformer oil. Consequently the tank must have a substantial wall thickness and must be made of heavy weight material as steel to provide the mechanical stability.
[0006] Document GB874730 discloses an oil-immersed transformer device for railway propulsion vehicle including the main transformer disposed in transformer tank. The transformer which delivers the required voltage levels for the propulsion is mounted in the transformer tank. The transformer tank is filled with oil. The tank is mounted under the floor of the railway vehicle.
[0007] WO2014086948 A2 discloses a transformer for traction applications with windings immersed in an oil filled enclosure. The closed loop core extends through the inner of a central inner cylinder element which forms part of the enclosure and is therefore of contact with oil.
[0008] It is an object of the present invention to provide a compact traction transformer design which allows a reduced size and weight while maintaining the required power density.
SUMMARY OF THE INVENTION
[0009] This object has been achieved by traction transformer according to claim 1 and 2 .
[0010] Further embodiments of the present invention are indicated in the depending sub-claims.
[0011] According to a first aspect, a traction transformer for railbound vehicles is provided, comprising:
an insulating liquid filled enclosure, at least two windings contained in the enclosure, a transformer core, mounting means for mounting the transformer to the railbound vehicle, wherein the transformer core is arranged outside the enclosure, and wherein the mounting means are attached to the transformer core.
[0016] One idea of the above traction transformer is that the windings are housed in the enclosure and the transformer core can pass through the enclosure without being in contact with the insulating liquid and therewith allowing to attach the mounting means directly to the transformer core for mounting the transformer to the railbound vehicle. With other words, the mounting means and the transformer core are directly connected and are in direct physical contact. Forces acting on the railbound vehicle are transmitted directly to the transformer core via the mounting means. On the other hand forces acting on the transformer are transmitted directly from the transformer core to the railbound vehicle via the mounting means. The transformer allows reducing the quantity of insulting liquid filled in the enclosure and simplifying the mechanical structure of the enclosure. Hence, the above traction transformer has reduced size and weight.
[0017] Furthermore, the enclosure of the traction transformer is attached to the transformer core by at least two support elements.
[0018] It may be provided that the mounting means are solely fixed to the transformer core ( 40 ) of the traction transformer. In this way other parts of the transformer, in particular the enclosure of the transformer is not used for fixation of the mounting means. Thereby less quantity of material and more lightweight material can be used for all parts do not contribute to the fixation of the mounting means. Such reduces the total weight of the traction transformer.
[0019] Furthermore, the enclosure may be formed by at least one cylindrical inner housing and by a cylindrical outer housing partially surrounding the at least one cylindrical inner housing, wherein an enclosed volume of the enclosure between the at least one cylindrical inner housing and the cylindrical outer housing is filled with the insulating liquid and wherein portions of the transformer core extend through the at least one cylindrical inner housing. The windings enclose the inner cylindrical housing and are supported by the outside surface of the inner cylindrical housing.
[0020] It may be provided that a first cover and a second covers are arranged at axial ends of the enclosure. The enclosure is clamp ed between the at least two support elements pressing at the axial ends onto the first and onto the second cover.
[0021] The first cover and the second cover are liquid-tight sealed to the axial ends of the enclosure. Both covers have at least one opening which matches to a diameter of the at least one cylindrical inner housing, in this way a hollow cylinder is formed which contains the insulating liquid. Typically the limbs as part of the transformer core extend through the passage of the hollow cylinder. The liquid-tight sealing may be formed by a glued joint, a gasket or by welding.
[0022] Furthermore, the, traction transformer is of core-type which means two yokes and two limbs form the core loop. To each of the limbs at least one winding is attached. The yokes extend outside at both axial ends of the enclosure to which the mounting means are fixed.
[0023] As the main function of the enclosure is to servers a tank for the insulating liquid and does not serve as fixation of the mounting means, it may be made of a lightweight material. Preferred enclosure materials may be types of glass fiber, epoxy based composite or aluminum.
[0024] In may be provided that the mounting means is a mounting frame having sidebars which run in parallel. The sidebars are fixed to the yokes and run parallel to the yoke direction.
[0025] Furthermore, stiffening elements may be comprised to absorb forces along the yoke direction and therewith along the moving direction of the railway vehicle. The stiffening elements are attached to the side bars of the frame and to the portion of the transformer which extends through the cylindrical inner housing.
[0026] It may be provided the at least two support elements are adapted to the shape of the first cover and the second cover. Those shaped support elements prevent escaping of magnetic stray fields in an axial direction of the windings and the core limbs. Parasitic effects of the stray field to neighboring ferromagnetic parts of the railway vehicle and to the rail causing eddy currents and other losses are reduced.
[0027] It may be provided that the enclosure has an eight-shaped cross section perpendicular to the axial direction of the windings. This cross section advantageously improves the mechanical stability of the cylindrical outer housing and therewith of the full enclosure and at the same time reduces the enclosed volume and therewith the quantity of the insulating liquid needed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Embodiments will be described in more detail in conjunction with the accompanying drawings, in which:
[0029] FIG. 1 shows a railbound vehicle with a traction transformer attached underneath the floor of the vehicle casing;
[0030] FIG. 2 a shows a perspective view of a traction transformer for horizontal mounting;
[0031] FIG. 2 b shows a side view of the traction transformer;
[0032] FIG. 2 c shows another side view of the traction transformer;
[0033] FIG. 2 d shows-a section view of the traction transformer according to the invention;
[0034] FIG. 3 shows perspective view of a traction transformer for vertical mounting.
DESCRIPTION OF EMBODIMENTS
[0035] Reference will now be made in detail to the embodiments, one or more examples of which are illustrated in the figures. Each examples provided by way of explanation, and is not meant as a limitation of the invention. Within the following description of the figures, the same reference numbers refer to the same components. Generally, only the differences with respect to individual embodiments are described.
[0036] FIG. 1 schematically shows a railbound vehicle 1 equipped with traction transformer 10 attached underneath the floor of the vehicle casing. In other configurations the transformer may be attached on the roof top of the vehicle or maybe attached in the machine room inside the vehicle casing.
[0037] In the following a first embodiment of the traction transformer is described in conjunction with the views according to FIGS. 2 a to 2 d. The traction transformer 10 comprises an enclosure 20 filled with insulating liquid 205 . The insulating liquid typically comprises mineral oil, silicon oil, synthetic or vegetable oil and serves for electrical isolation of the windings and for pooling of the windings.
[0038] The enclosure 20 is formed by two cylindrical inner housings 201 , 202 and by a cylindrical outer housing 203 surrounding the two cylindrical inner housings 201 , 202 . Each of the cylindrical inner housings 201 , 202 has an annular cross section and has a cylinder axis which is substantially parallel to the cylinder axis of the outer housing 203 , which is the axial direction Y as indicted in FIG. 2 d. The axial direction Y is also the axial direction of the windings 30 , 31 . The cylindrical inner housings 200 , 201 may also be shaped with different cross-sections (across the axial direction Y thereof).
[0039] Each of both axial ends of the enclosure 20 is closed by a first and a second cover 206 , 207 respectively. The first and the second cover 206 , 207 , the two cylindrical inner housing 201 , 202 , and the cylindrical outer housing 203 form an enclosed volume which is filled with the insulating liquid 205 in particular with transformer oil. The windings 30 , 31 which are accommodated in the enclosure are completely immersed in the transformer oil. Therefore the first and the second cover 206 , 207 are liquid-tight sealed to the cylindrical outer housing 203 and to the two cylindrical inner housings 201 , 202 . The sealing can be made by a glued joint. Alternatively, the sealing may be made by a gasket or by a type of welding,
[0040] FIG. 2 d is a section view of FIG. 2 b taken along the A-A line of the traction transformer 10 according to the first embodiment and shows two circular openings 208 , 209 in the first and the second cover 207 , 208 respectively which openings 208 , 209 match to the inner diameter of the cylindrical inner housing 201 . Two further openings are provided and matching to the inner diameter of the cylindrical inner housing 202 .
[0041] The two limbs 403 , 404 of transformer core 40 extend through the two cylindrical inner housings 201 , 201 and therewith through the two windings 30 , 31 . The limbs 403 , 404 are bridged by the two transformer yokes 401 , 402 at the axial ends of the enclosure 20 . In this way a core-type transformer is realized with the windings 30 , 31 solely immersed in the transformer oil. The transformer core 40 is outside the enclosure and therefore not in contact with transformer oil and may be called by air.
[0042] The windings 30 , 31 are wound around the respective cylindrical inner housing 201 , 202 . The conductors of the winding 30 , 31 can be wire-like, such as a coil of metal wire, e. g. copper wire, or plate-like, coated with an electrical insulation layer, and are spirally wound around the cylindrical inner housings 201 , 202 . The winding 30 may act as a primary winding and the winding 31 may act as a secondary winding of the traction transformer 10 or vice versa.
[0043] To avoid a short circuit, the two cylindrical inner housings 201 , 202 must not act as a turn of a parasitic secondary coil. Hence, both inner housings 201 , 202 are made of electric insulating material for example an epoxy based composite.
[0044] For the horizontal mounting of the traction transformer 10 to the railbound vehicle 1 the plane spanned by the X-Y directions is substantially parallel to the roof or to the underfloor of the railbound vehicle 1 .
[0045] As can be seen from the FIGS. 2 a to 2 d , the transformer core 410 is fixed to the mounting means 50 which are embodied as mounting frame. The frame allows a mounting of the transformer 10 onto the roof top or underneath the floor of the train and has two parallel side bars 501 , 502 which are welded together by two transverse bars. The side bars 501 , 502 are aligned along the train and along the moving direction of the train which is indicted as X-direction. By fixation of the transformer core 40 directly to the frame and therewith to the railbound vehicle the heaviest part beside the windings of the transformer is used for fixation and advantageously acceleration forces or vibrations from train vehicle can be transmitted directly to the transformer core. Such simplifies the mechanical construction of the traction transformer 10 and in particular the construction of its enclosure 20 .
[0046] The traction transformer 10 is fixed to the frame solely by means of the transformer core 40 which rests on the side bars 501 , 502 of the frame. In particular the transformer yokes 401 , 402 and the ends of the transformer limbs 403 , 404 which protrude beyond the axial ends of the enclosure 20 rest on top of the side bars 501 , 502 . In other embodiments it may be provided that the frame rest on top of the transformer core 40 .
[0047] The fixation between the transformer core 40 and the side bars 601 , 502 is made by screw joints. To provide a high rigidity and stability between the core 40 and the frame, the transformer core 40 is of stack-lap type in which one or several layers of the limbs 403 , 403 overlap with one or several layers of the yokes 401 , 402 as it is indicated in FIG. 2 d. 8 through-holes are provided in the transformer core 40 , of which four are made at the four corners of the transformer core 40 in the overlapping region of limbs 403 , 404 and the yokes 401 , 402 . When the transformer core 40 is mounted to the frame by screws then also the limbs are screwed together with the yokes 401 , 402 . The yokes 401 , 402 are oriented parallel to the side bars 501 , 502 and therewith along the X-direction.
[0048] The frame is mounted by four curved legs to the railbound vehicle 1 which are welded to the ends of the side bars 501 , 502 .
[0049] As can be seen from the FIGS. 2 a to 2 d, the enclosure 20 is fixed to the transformer core 40 by four support elements 60 , 61 , 62 , 63 which are angled and in which two of them 60 , 62 are arranged on the top of the transformer core 40 at the axial ends of the enclosure 20 and wherein the two other angled support elements 61 , 63 are arranged at the bottom side of the transformer core 40 at the axial ends of the enclosure 20 .
[0050] Each of the angled support elements 60 , 61 , 62 , 63 is screwed by one of its two legs directly to the transformer core 40 , whereas the enclosure 20 is clamped between the other legs. Latter ones press at the axial ends onto the first and second cover 206 , 207 . The support element 60 on the top of transformer core 40 and the support element 61 on the bottom side of the transformer core 40 have adjusting screws to set the contact force for damping the enclosure 20 . The adjusting screws are fixed on the leg of the support element 60 , 6 l which presses against first 206 or the second cover 207 .
[0051] Each of the yokes 401 , 402 of the traction transformer 10 is screwed together with the respective side bar 501 , 502 of the frame, with the respective support element 60 , 61 , 62 , 63 on the top of the transformer core and with the respective support element on the bottom side of the transformer 10 . The screw joint is arranged perpendicular to the axial direction Y of the windings.
[0052] The support elements 60 , 61 62 , 63 may be adapted partially or full to the shape of cover first 206 or the second cover 207 (not shown) so as to prevent escaping of the magnetic flux in axial direction Y of the windings. In this way shaped support elements 60 , 61 , 62 , 63 act as shielding and prevent a distraction of the unwanted magnetic stray field to the environment, in particular to the railbound vehicle or the rails.
[0053] The traction transformer 10 may be provided with stiffening dements 70 , 71 , 72 , 73 to absorb acceleration forces along the moving direction of the railbound vehicle 1 . The stiffening elements 70 , 71 , 72 , 73 are attached to top of the side bars 501 , 502 and along the X-direction. The fixation may be made by a screw joint as shown for stiffing element 70 in FIG. 2 b or may be welded to the side bars, 501 , 502 as it is exemplarily indicated for the stiffing element 71 in FIG. 2 b. The'stiffening elements 70 , 71 , 72 , 73 are positioned before and after the parts of the transformer core 40 which extend beyond the axial ends of the housing 20 , which are the yokes 401 , 402 .
[0054] Additional stiffening element may also be attached to the support elements 60 , 61 , 62 , 63 to absorb acceleration forces and are welded thereto. These additional stiffening elements are positioned also before and after the yokes 401 , 402 , may be screwed to the transformer core 40 and prevent an unwanted movement of the transformer core 40 along the X-direction.
[0055] FIG. 3 shows a further embodiment of a traction transformer 11 for vertical mounting to the railbound vehicle, suitable to be mounted for example in the machine-room of the vehicle.
[0056] The transformer core 40 is fixed to the mounting means 50 which are also embodied as a mounting frame. In difference to the embodiment according to the FIGS. 2 a to 2 d the transformer 11 and the mounting means 50 are turned by 90° in a upright position. With other words, the plane spanned by the X-Y directions is substantially perpendicular oriented to the floor of the railbound vehicle and therefore the axis of the windings are oriented vertically. The side bars 501 , 502 are welded together with two H-bars which run traverse between the side bars 501 , 502 and form the frame.
[0057] The cylindrical outer housing 203 has an eight-shaped cross section which provides a higher mechanical stability to the enclosure 20 as compared to a normal cylindrical shaped housing. Thus, a more lightweight material like aluminum instead of steel can be used as material for the cylindrical outer housing 203 . The cylindrical outer housing 203 can be made of aluminum which further shows a good heat conductivity compared to steel and improves the heat dissipation from the traction transformer 11 to its environment. It may be also provided to use lightweight material which is electric insulating as for example an epoxy composite, if the heat dissipation over the cylindrical outer housing 203 is not of importance for the design of the traction transformer 11 .
[0058] The traction transformer 11 has two legs which are welded to the ends of the side bars 501 , 502 at the same axial end of the enclosure 20 to mount the transformer in a vertical position to the railbound vehicle 1 .
REFERENCE LIST
[0000]
1 railbound vehicle
10 , 11 traction transformer
20 enclosure
30 , 31 windings
40 transformer core
50 mounting means
60 , 61 , 62 , 63 support elements
70 , 71 , 72 , 73 stiffening elements
201 , 202 cylindrical inner housing
203 cylindrical outer housing
205 insulating liquid
206 , 207 first and second covers
208 , 209 openings in the first and second cover
401 , 402 transformer yokes
403 , 404 transformer limbs
501 , 502 sidebars
600 adjustment screw
X axial direction of the yoke, direction of the side bars
Y axial direction of the windings and of the cylindrical inner housings
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The invention relates to a traction transformer for railbound vehicles comprising: an insulating liquid filled enclosure, at least two windings contained in the enclosure, a transformer core, mounting means for mounting the transformer to the railbound vehicle, wherein the transformer core is arranged outside the enclosure, and wherein the mounting means are attached to the transformer core.
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FIELD OF THE INVENTION
The present invention relates to a method and an apparatus for separating gas from a gaseous material preferably in a closed process. The method in accordance with the present invention is especially suitable for chemical processes in the wood processing industry so as to minimize the environmental disadvantages thereof. The apparatus in accordance with the present invention is applicable, for example, for the separation of residual gases of bleaching processes from fiber suspensions of wood processing industry. While the apparatus in accordance with a preferred embodiment of the invention is mainly designed for the discharge of gas, it may also be used for the discharge of fiber suspension bleach towers. The arrangement in accordance with another embodiment of the present invention is preferably applied in the discharge of gas from low consistency pulps, whereby the consistency of the pulp may be even below 5%.
PRIOR ART
There is a number of known gas discharge apparatuses, which have been used for removal of residual gases of a bleaching stage from fiber suspensions. U.S. Pat. No. 4,209,359 discloses a process for separating residual oxygen from pulp which has been bleached with oxygen. The separation apparatus in accordance with said patent is a relatively large vessel, to which the bleached pulp is discharged from a bleaching stage and in which the pulp is treated at a consistency of about 3%. The pulp is supplied to the vessel tangentially, whereby said pulp is subjected to a centrifugal force, which facilitates the separation of gas in a known manner so that a portion of the gas may be discharged directly from this stage. Thereafter the pulp is allowed to flow to the bottom of the vessel, where pulp is mixed for about 30 seconds to 5 minutes with two mixers of different types, of which the upper is used for pumping the pulp axially downwards and the lower is used for pumping the pulp radially outwards, whereby the pulp is brought into a circulating movement, by means of which residual gas is separated from the pulp.
Disadvantages of the disclosed apparatus are, for example, that it is necessary to dilute the pulp to a low consistency merely for the gas discharge and that the process pressure is not utilized in the form of dynamic pressure whereby, when the vessel and the inlet channel are relatively large, the centrifugal force remains small and the gas separation capacity low. As known, bleaching is carried out preferably at a consistency of about 10 to 12%, whereafter the bleached pulp is led to a washing stage either directly or through a gas separator. If residual gas is not separated from the pulp prior to washing, said gas in the pulp complicates the washing and weakens the washing result considerably. A number of washer types are known in the industry, to which pulp may be supplied at a so called MC consistency (medium consistency), whereby also gas should be removed from the pulp at the MC consistency. Washers operating at the MC range are, for example, diffusers, belt washers and so called DD washers. If it is necessary to dilute the pulp prior to the washing for removal of gas, larger amounts of liquid must be pumped to the washing than if the consistency is maintained original. For example, when the consistency is 3%, there is about 30 kg water in the pulp for each fiber kilogram. When the consistency is about 12% the amount of water has decreased to about 5 kg per a kilogram of fibers. Thus, when the consistency quadruples the amount of the water decreases to one sixth of that of the low consistency. In other words, the dilution of pulp results in that, if MC washers are used, the pulp must be thickened again or alternatively low consistency washers must be used, for example, a suction drum filter, whereby the amount of water--in a way eccessive--to be pumped to the washer is sixfold. Moreover, the arrangement in accordance with the disclosed publication has several portions of the apparatus exposed to the atmosphere, whereby the treatment of pulp does not take place in a hydraulically closed pressurized system. FIG. 6 discloses the process of said patent specification illustrating a bleaching tower 36, a gas separator 10 and a filter 46 which are all open unpressurized apparatuses. They allow the contact between the pulp and the air and thus result in foaming and odor problems.
U.S. No. Pat. 4,362,536 discloses an apparatus, by means of which gas may be removed from the pulp flowing in a channel prior to its free fall to a pulp vessel or the like member. The separation of gas is carried out in such a way that the gaseous pulp tangentially enters the separation apparatus, in which a rotatable rotor accelerates the rotational speed of the pulp and the gas is separated due to a centrifugal force to the center of the apparatus, from where it is removed. Gas is prevented from entraining the pulp by using baffle plates. The rotor is not designed to increase the pressure of the pulp, since it is not necessary when the pulp is allowed to fall freely to the vessel below. The apparatus is not applicable in a closed process, which requires a controlled gas discharge allowing fluctuation in pressure and a pressurized pulp discharge. Also the correct pressure difference between the entering pulp, the pulp to be discharged and the exiting gas must be maintained. It is also preferable to be able to increase the pressure of the exiting pulp in the gas separator, which is possible with the apparatus in accordance with the present invention, by means of which it is possible to decrease the pressure level of the reaction vessel and thus decrease the investment costs, unless it is necessary to further transfer the pulp with a pump.
It has been possible to eliminate the disadvantages of both the apparatuses and the methods of the above mentioned prior art references with an apparatus in accordance with international patent application WO90/13344 of A. Ahlstrom Corporation, which apparatus is located in the outlet of a pressurized pulp treatment reactor or the like or in the flow channel extending therefrom. The rotor of said apparatus is preferably formed of a rotationally symmetric casing, which is concentrically attached to a flange located substantially perpendicular to the axis of the rotor, and on the flange end thereof there are openings for the discharge of the gas-free suspension towards the discharge opening. Said arrangement is described more in detail in FIG. 1 and in the description thereof. It is typical of the method and apparatus in accordance with said patent application that gas may be separated from medium consistency pulp by disposing the apparatus in accordance with the application in the outlet of a closed reactor and the apparatus itself carries out the discharge of the reactor, the gas separation allowing the fluctuation in pressure and feeds the pulp further at an increased pressure. Due to its construction and control said apparatus can discharge gases without any pulp fibers entrained in them even if the pressure in the reaction vessel varies. The operation of the apparatus includes therefore both the gas separation and the purification of gas. The fibrous material separated in the purification of gas is recirculated through a gas separation apparatus to the pulp flow. A preferred embodiment of the gas separation apparatus carries the specific feature that it can increase the pressure of the exiting pulp.
Said prior art apparatus may still be developed to enable the utilization of pressure in said pulp vessel for the gas separation.
DISCLOSURE OF THE INVENTION
The object of the present invention is to eliminate or minimize the problems occuring in the apparatus in accordance with U.S. Pat. No. 4,209,359. The aim of the process and apparatus in accordance with our invention is to treat the pulp in an as air-free space as possible. In other words by pressurizing the apparatus gas is prevented from mixing with the pulp and by removing gas from the pulp, the disadvantages of the gas in the process are minimized.
Thus it is characteristic of the invention that an apparatus is provided in the discharge/flow channel for pulp, the purpose of which is to convert the process pressure to dynamic pressure and to pass the pressurized pulp suspension being discharged from the vessel to circulate along the inner surface of the flow channel at as high speed as possible, whereby due to a strong centrifugal force gas is separated from the pulp very efficiently and it may be discharged from the apparatus in a manner known from the prior art apparatus. Further it is characteristic of the invention that pulp is discharged under pressure from the apparatus so that the pulp may be directly supplied to the next treatment apparatus with the pressure of the gas separator.
The method in accordance with the present invention is characterized in that
the pressure difference between the inlet channel and the gas discharge is converted to kinetic energy by turning the direction of flow of material to a spiral rotational movement in the inlet channel;
gas is separated from the material to the center of the separation apparatus by means of the created strong centrifugal force;
gas is discharged to a separate further treatment; and
the kinetic energy of the circulating flow of material is converted back to pressure energy.
It is characteristic of the apparatus in accordance with the present invention that in the inlet channel for the material or communicating with such there are means for converting the pressure difference between the inlet channel and the gas discharge to kinetic energy of material, in other words to a circulating movement of the material.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described below, by way of example, with reference to the accompanying drawings, in which
FIG. 1 illustrates a preferred embodiment of an apparatus as described in the international patent application PCT/FI90/00085 of A. Ahlstrom Corporation;
FIG. 2 illustrates another apparatus in accordance with the prior art, as it is in said patent application of A. Ahlstrom Corporation;
FIG. 3 illustrates an apparatus in accordance with a preferred embodiment of the present invention;
FIG. 4 illustrates an apparatus in accordance with a second embodiment of the present invention;
FIG. 5 illustrates an apparatus in accordance with a third embodiment of the present invention;
FIG. 6 illustrates an apparatus in accordance with a fourth embodiment of the present invention;
FIG. 7 illustrates a preferred process embodiment of the method in accordance with the present invention; and
FIG. 8 illustrates another process embodiment of the method in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
According to FIG. 1 a gas separation apparatus 2 in accordance with the prior art comprises three main portions: a rotor 10, a casing 50 of the rotor and a body 70 of the separation apparatus. Rotor 10 again comprises a first sleeve 16 and a second sleeve 18 mounted on a shaft 12. A flange 20 extends substantially radially from sleeve 16, said flange being provided on one side, the so-called rear side, with a number of rear blades 22 rotating in a so-called second separation chamber. The front side of flange 20 is provided with a number of blades 24, which are supported by rings 26 and 28. In other words, blades 24 form an axially or radially changing, rotationally symmetric shell 118. It is characteristic of the shell 118 that it is completely open from the center excluding the hub of the rotor (cf. screw 14) and that on the flange end the rotor is provided with openings 112 between the blades, through which openings 112 the pulp flows out of the rotor 10 and the ribs at the inlet channel prevent the pulp from blocking between the inlet channel and the blade.
There are a number of blades 30 extending from said second sleeve 18 of the rotor 10, the front surfaces of which blades are perpendicular to the shaft 12 and are provided with a disc 32 and the front side of said disc 32 is provided with a second series of substantially radial blades 34, which are, however, dimensionally remarkably smaller than the blades 30. The blades 30 and 34 and the disc 32 have been arranged to rotate in a separate chamber 36, in a so-called third separation chamber, which is divided by said disc 32 into two subchambers 38 and 40 said chamber 36 being separated from the rest of the rotor space by a partition wall, which is a part of the body of the separation apparatus. Thus the blades 30 rotate in the chamber 38 and the blades 34 in the chamber 40.
A casing 50 of the rotor 10 comprises an axial inlet opening 52, which extends as an inlet channel 54 following the shape of the rotor 10 towards a preferably spiral chamber 56, which is provided with a discharge opening 58. The inlet opening 54 and spiral chamber 56 form a so-called first separation chamber. The clearance between the inner wall of the inlet channel 54 and the blades 24 of the rotor is within the range of 5-50 mm depending to a large extent on the other dimensions of the gas separation apparatus. The outer side of the wall 60 of the inlet channel 54 is provided with a flange 62, by means of which it is possible to attach the gas separation apparatus either to a pipe line, a bleaching tower or some other applicable place.
The body 70 of the gas separation apparatus 2 comprises a rear plate 72 mounted to the annular flange 64 of the casing, said rear plate 72 being provided with sealing and bearings (not shown) for the shaft 12 of the rotor 10. Additionally, the rear plate 72 forms the rear wall 74 of the chamber 36 of the blade-disc-blade combination extending from the second sleeve of the rotor 10. A machined annular disc 80 forms a ring 76 and a front wall 78 of the chamber 36, the inner side of the annular disc 80 being further provided with a ring 82 in a location radially inwards from the blades 34 but, however, at a distance from the second sleeve 18, the ring 82 extending inside the chamber 36 close to the surface of the disc 32. The purpose of the ring 82 is to prevent the discharge of the medium from the chamber 40 to the space between the disc 32 and the sleeve 18.
The rear wall 74 of the chamber 36 is provided with a gas discharge opening 84, which may be an annular opening between the rear plate 72 and the second sleeve 18. Respectively an opening 86 is provided radially outside the ring 82 on the front wall 78 of the chamber 36, the opening 86 leading to a space 42, a so-called second separation chamber, defined by the rear blades 22 of the rotor and the front wall 78 of the chamber 36. Further, a flow channel 44 is arranged in the flange 20 of rotor 10 or in the first sleeve 16 to lead the gas separated by the rotor to the space 42. It is preferable that the flow channel 44 is located closer to the shaft than the channel 86.
The apparatus in accordance with the prior art described above is used by mounting the apparatus in the discharge opening of a reaction vessel in such a way that the extended blades of the rotor extend into the vessel to some extent to mix the pulp in the vessel, which pulp in some cases may be even very thick, whereby the pulp flows at the pressure of the vessel through the inlet opening 52 of the apparatus to the inlet channel, in which the pulp is exposed to the rotational effect of the rotor 10. Since the rotor at least partially fluidizes the pulp and is able to accelerate the rotational speed of the pulp close to its own rotational speed, the pulp is able to be pressed more freely due to the centrifugal force against the rotor and the wall of the inlet channel to form an annular layer, whereby the gas separating from the pulp has ideal conditions to accumulate as bubbles and to drift towards the lower pressure in the center of the rotor. At the same time the rotational energy caused by the rotor in the pulp and the centrifugal force generating therefrom enables the increase of the pressure of the pulp at the outlet opening 58 compared with the inlet opening 52. Since the pressure is at its lowest close to the flange 20 around the sleeve 16 gas accumulates there and is discharged therefrom through the flow channel 44 to the space 42 behind the flange 20. Some pulp is also discharged with the gas to the space 42, whereby the purpose of rear blades 22 in said space 42 is to pump the pulp possibly entrained in the space 42 back to the spiral chamber 56. The gas flows from the space 42 either due to pressure in the space or due to suction connected to the gas separation system through a gap between the annular disc 80 and the second sleeve 18 to the effective range of the blades 30, from where it flows further through a gas discharge opening arranged close to the sleeve 18 either directly to the atmosphere or, if further gas treatment is desired, to a treatment apparatus or a recovery system. The purpose of the blades 30 is to ensure that even if fibers still entrain with the gas flow through the gap between the annular disc 80 and the second sleeve 18 to the chamber 36, the blades 30 pump the pulp through the subchamber 38 around the outer edge of the disc 32 to the subchamber 40 and further through the opening 86 to the space 42, wherefrom the rear blades 22 pass the pulp further to the spiral chamber 56. Blades 30 in the subchamber 38 develop a greater pressure than the pressure prevailing at the opening 86 in the chamber 42, whereby the blades 30 in fact return the pulp through the chamber 40 to the chamber 42. The purpose of the blades 34 is merely to prevent the pulp in the subchamber 40 from densifying and forming lumps in the subchamber 40 by generating a sufficient turbulence in the pulp in the subchamber 40. Further, the purpose of the blades 30 and 34 is to make the gas separation apparatus as insensitive as possible to pressure fluctuations in the spiral chamber or in the inlet channel, in other words to ensure that the gas discharge channel from the separation apparatus is always open without any fibers in any case entering the gas discharge opening 84 in the rear plate 72.
FIG. 2 illustrates a second gas separation apparatus 2 in accordance with the prior art, which apparatus is in principle similar to the apparatus in FIG. 1 excluding the flange 20. In the apparatus of FIG. 2, the front surface of the flange, i.e. the side by the blades 24, is provided with a few blades 46. The construction and operational principle of the blades 46 correspond to the construction and operational principle of the blades of a centrifugal pump. Their purpose is to feed the pulp from inside the shell formed by the blades 24 towards the spiral chamber 56 and further towards the discharge opening 58. Another purpose of the blades is connected with the location of the gas discharge openings and the gas removal process. Said gas discharge openings are preferably located in a dead space gathering air to the rear side of the blades. Said blades may also extend as far as to the inside of the spiral chamber 56. By increasing the number of said blades or the length thereof it is possible to improve the pressure increasing effect of the separation apparatus, which comes into question, when using the apparatus as a discharge apparatus of a bleaching tower for feeding the bleached pulp directly to the washer.
The embodiments of the apparatus in accordance with the invention with their variations illustrated in FIGS. 3-6 are up to the flange 20 identical with prior art apparatus considering the drive side of the apparatus (cf. the apparatus illustrated in FIGS. 1 and 2). FIG. 3 illustrates an apparatus in accordance with a preferred embodiment of the invention, which substantially differs from the apparatus in accordance with the prior art described above in the portion below the flange 20, i.e. by the inlet channel 54. The apparatus communicates by means of said inlet channel with the fiber suspension inlet channel, the discharge opening of a reaction vessel, or the like member. Said apparatus is designed for the treatment of a low consistency pulp or the like, in other words pulp, which does not tend to form a fiber matting clogging the flow channel when flowing, but flows almost like water. It is typical of the apparatus that the inlet channel 54 thereof is formed of at least one spiral flow channel 120 (the drawing illustrates two threads one within the other and thus two spiral flow channels), by means of which the pressure energy of the pulp being discharged to the apparatus due to the pressure difference, is converted to kinetic energy, which further due to the round shape of the cross-section of the inlet channel 54, results in a flow almost parallel to the rim and in generation of a strong centrifugal force by means of which the gas in the pulp is separated efficiently to the center of circulating flow. One method of arranging the spiral flow channel 120 is to mount one or more overlapping spiral strips 122 to the wall of the cylindrical inlet channel 54, the strips being restricted on the side of the shaft 124 of the apparatus to a stationary, relatively small cylindrical surface 126, whereby the cross-section of the flow channel(s) 120 is shaped rectangular. The inlet channel 54 of the apparatus is connected to a larger spiral casing 128 already known from, for example, a centrifugal pump, the front wall 130 of which having a number of guiding blades 132, the purpose of which is to slow down the speed of the pulp flow circulating along the thread and to increase the pressure for the discharge of pulp in a pressurized state from the apparatus. As in all other embodiments, the pulp is allowed to be discharged from the apparatus axially to the inlet channel where there is a surface (thread strips) inclined relative to the discharge direction, by means of which surface the axial movement of the pulp is turned to a circulating flow parallel to said surface. The operation of the apparatus may be illustrated as follows:
pressure energy→kinetic energy→pressure energy,
in other words pressurized fiber suspension is supplied to the apparatus, the pressure is converted to kinetic energy, in other words circulating movement, which again at the end of the separation process is converted back to pressure energy, whereby the suspension exiting from the apparatus has a certain pressure.
The gas separated to the center around the shaft 124 of the apparatus, or the cylindrical surface 126 corresponding to the shaft, is discharged through openings 44 in the flange 20 to the space behind said flange, the openings 44 being located relatively close to the shaft 124 of the flange 20 of the rotor 10 disposed in the spiral 128. The following separation process of gases and fibers corresponds to what is described in our above described WO patent application. It is appreciated from the described apparatus that its construction is the simplest in the product family, and in said apparatus only the flange 20 of the rotor and the portion behind it are used for the separation of fiber suspension flowing through the gas discharge openings 44 to the rear side of the flange 20 from the gas being discharged.
FIG. 4 illustrates an apparatus of the next technical development, in which the frontside of the flange 20 of the rotor 10 is provided with pumping blades 46, which replace the guiding blades 132 disclosed in FIG. 3 and by which the pressure of the pulp exiting from the apparatus is raised, if the discharge pressure reached with the embodiment of FIG. 3 is not high enough. Further, FIG. 4 illustrates with broken lines auxiliary blades 134 on the front side of the rotor 10 of the apparatus for accelerating the rotational speed of the pulp. A precondition for the use of the auxiliary blades 134 is that the circumferential speed of the auxiliary blades 134 is higher than the rotational speed of the pulp rotating in the inlet channel 54. Moreover, said auxiliary blades 134 may, of course, be replaced by axial extensions 136 of the blades 46 of the flange 20 of the rotor 10 (also shown with broken lines), whereby blades 46, 136 are thus continuous, or both the axial extensions 136 and the auxiliary blades 134 may be used. The operation of the apparatus may be illustrated as follows:
pressure energy→kinetic energy+additional energy→pressure energy,
in other words by introducing additional energy the separation of gas from pulp is facilitated and on the other hand the discharge pressure is raised. By adjusting the feed of the additional energy, for example, by dimensioning of auxiliary blades 134 or by changing the rotational speed, it is possible to adjust the amount of gas being separated in the apparatus and the energy consumption of the auxiliary blades reasonable.
FIG. 5 illustrates an apparatus in accordance with a more complicated embodiment, which is already designed for treating pulps which may form a fiber matting liable to clog the flow channel. In other words the consistency of the pulp may vary between 8 and 18 percent or sometimes even exceed it. Then the basic principle is that at least one of the walls of said flow channel is movable thus preventing the accumulation of fibers to a fiber matting. In an embodiment in accordance with the drawing the center of the flow channel 54 is provided with an extension 138 of the rotor 10, which may be a pipe or a closed space with a substantially smooth surface but it is possible to provide the surface with small protrusions, which more efficiently keep the pulp in a turbulent movement close to the surface and prevent the clogging of the flow channel. The end of the extension 138 of the rotor is preferably provided with blade-like members as shown in FIG. 5, which preferably extend to the inside of the pulp vessel in order to fluidize the pulp. At least one spiral strip 140, extending radially from the extension 138 of the rotor 10 to the wall of the inlet channel 54, is attached to the wall of the flow channel 54. Said construction ensures that the pressure difference between the spiral housing 128 of the apparatus and the inlet channel (not shown) is not able to level down at least along the wall of inlet channel 54, but only between the extension 138 of the rotor 10 and the spiral strip 140, because, of course, a reasonable clearance must be maintained between the extension 138 and spiral the strip 140 in order to avoid mechanical contact. Also it must be noted that although the drawing shows only the blades 46 of the flange 20 of the rotor 10, they may either continue axially inside the inlet channel 54, or the inlet channel 54 may be provided with auxiliary blades, as already shown in FIG. 4.
FIG. 6 illustrates yet another, the most complicated, embodiment in accordance with the present invention, in which a thread 150 is mounted on an extension 152 of the rotor 10 in such a way that the clearance between the wall thread 150 and the wall of the inlet channel 54 is adjusted as small as possible, at least at the end of the thread 150 by the flange 20 of the rotor 10. The thread 150 may be made equally "sealed" throughout the distance, in other words with equally small clearance, if the pressure difference between the inlet channel (not shown) and the spiral housing 128 is not very large, but it may also be designed to equalize the pressure differences to some extent, for example, in such a way that the pressure is allowed to evenly decrease within one or two pitches of the thread 150. In other words the thread is allowed to leak to some extent in order to allow a gradual decrease of pressure. The extensions 136 of the blades 46 are added in FIG. 6, which extensions are disclosed as alternatives to auxiliary blades 134 shown in FIG. 4. However, the same precondition concerns the extended blades 136 as the auxiliary blades 134, i.e. the circumferential speed of the blades 136 must be higher than the rotational speed of the pulp. It may still be appreciated from FIG. 6 that the rotational direction of the rotor 10 illustrated with an arrow with unbroken line is not the same as the rotational direction of the pulp in the spiral flow channel 154 of the inlet channel 54. In the situation described with an arrow with broken line the rotational direction of pulp is the same as the rotational direction of the rotor. However, it must be emphasized that the apparatus operates in both cases. In the drawing in the case shown with an arrow with unbroken line the circumferential speed of the pulp is less than in the case when the pulp circulates in the rotational direction of rotor 10 (the arrow with broken line). Thus it is clear that by changing the rotational direction of the rotor or preferably by making the threads either right-handed or left-handed respectively it is possible to increase or decrease the circumferential speed of the pulp. At high pressure differences it is preferable to slow down the rotational speed of the pulp in this manner. When considering the operation of the apparatuses it must be born in mind that the right- or left-handedness always determines the rotational direction of the pulp also when the pulp is discharged, regardless of what the rotational direction of the rotor is. The embodiment in FIG. 6 is provided with an extension 156 which is at least nearly axial and extends to the inlet channel of the thread 150 or possibly to the pulp vessel and its purpose is to generate turbulence in the inlet channel or in the pulp vessel to facilitate, similarly to the blade-like members shown in FIG. 5, the flow of the pulp to the inlet channel 54 and to readily lead the flow of the pulp from axial to spiral. Finally it may also be stated of the embodiment of FIG. 6 that it is not always necessary to have a thread operated by the extension of the rotor, but, of course, also a separately operated thread is possible.
It is characteristic of all the embodiments described above that the angle of the thread, the so-called flow angle, i.e. the angle between the thread and the level cutting the inlet channel perpendicularly is less than 30 degrees, preferably less than 15 degrees and most preferably less than 10 degrees.
The apparatus in accordance with the present invention operates as described above in connection with the different embodiments. How the gas separated to the center of the apparatus is discharged, is already described above in the WO patent application of A. Ahlstrom Corporation mentioned as prior art.
Example 1, gas separation apparatus.
When a pressure of about 5 bar prevails in the pulp vessel, it is possible to convert it to a rotational movement, the speed of which is about 22 m/s. Respectively, it may be considered that the rotational speed of the rotor of the gas separator, which is required for preventing the clogging of the pulp being discharged from the mass tower, is about 1500 rpm, resulting in that the circumferential speed of the rotor having a diameter of 150 mm is about 11.8 m/s. It is appreciated that if the rotational direction of the pulp determined by the rotor is the same as the rotational direction of the rotor, the circumferential speed of the pulp is about 34 m/s and if the rotational direction of the rotor is against the rotational direction of the pulp, the circumferential speed is about 10 m/s.
FIG. 7 illustrates a preferred application of an apparatus in accordance with the present invention. The schematic illustration describes the flow of the pulp from a cellulose pulp vessel 90 pumped by an MC pump 92 through a feed mixer 94 for bleaching chemical (e.g. O 2 , O 3 , Cl, ClO 2 ) to a bleaching tower 96, the discharge end of which is provided with a gas separation apparatus 2 in accordance with the present invention. In the preferred embodiment of FIG. 7 the discharge of pulp from the tower 96 is preferably carried out by said separation apparatus 2 in such a way that the extension, or extensions if two threads set one within the other are used, of the thread of the rotor 10 extending to the discharge opening of the tower fluidize(s) the pulp and enable(s) the discharge thereof to the separation apparatus, the blades 46 of which again raise the pressure of the bleached suspension in such a way that it may be supplied directly without any separate feed means to a washer 98, which may be either a pressure diffuser or a so-called MC drum washer.
The method in accordance with the present invention is described more in detail with reference to FIG. 7, in which pulp is pumped by a pump 92 to a chemical mixer 94, a reactor 96, a gas separator 2 and a washer 98. The whole process is carried out in a closed space without any contact between the air and the pulp. All means are pressurized and closed. Gas separation apparatus 2 operates partially as a pump, whereby the pressure of the pulp is raised prior to the washer. The washer is pressurized and closed. It is preferable to carry out the whole treatment at the same consistency, most preferably at the range of 8 to 20%.
In order to realize the method some of the apparatus required already exist and other necessary equipment are being developed. The high consistency pump 92 necessary in the process, a so-called MC pump, is disclosed, for example, in U.S. Pat. No. 4,780,053. Japanese patent 1617019 discloses a chemical mixer. A pressurized washer is disclosed in U.S. Pat. No. 4952314. A gas separation apparatus essential in the method is illustrated above with reference to FIGS. 3-6.
FIG. 8 illustrates another application of the apparatus in accordance with the present invention, in which pulp is pumped from a temporary pulp vessel 90 by an MC pump 92 through a feed mixer 94 of bleaching chemical (e.g. O 2 , O 3 , Cl, ClO 2 ) to a bleaching tower 100, the discharge of which is carried out by means 102 known per se to a drop leg 104, which is preferably provided with a gas separation apparatus 2 in accordance with the embodiment of FIG. 6. Also in this case the separation apparatus feeds the pulp directly to the washer. The apparatus in accordance with the present invention may be used in pressurized, but also in open unpressurized processes, which, of course, results in the use of a high rotational speed in order to obtain a sufficient circumferential speed and centrifugal force. It must also be noted that although bleaching chemicals are mentioned above, also other substances and organisms used, and to be used in the future, in the treatment of fiber suspension, such as enzymes or fungi, are also covered. Thus the term "chemical" in the above description must be understood in a broader sense than what is conventionally understood by said term "chemical".
It must also be noted that the spiral rotational movement of pulp may be brought about also by constructions other than a thread. It may be considered that, for example, a number of nozzles (shown schematically at 93 in FIG. 3) are mounted partly tangentially, partly pulp is discharged through the nozzles into said space converting the pressure energy to kinetic energy. It is, of course, possible to arrange into said member the thread illustrated in the previous embodiments if so desired, or a rotatable rotor, if it is considered necessary. Said member with its flange means again may be connected to a spiral housing described in connection with the previous embodiments.
As is appreciated from the above disclosed embodiments, a new gas separator type has been developed, which generally speaking and regardless of the above description of the applications concentrated on wood processing industry, is applicable in all apparatus in which gas must be separated from a material behaving like a liquid. The apparatus is very suitable for the wood processing industry, for example, because it is able to treat very solid and weakly flowing materials and additionally, beside the primary object, is able to discharge the bleaching tower very efficiently and in an energy saving way, if so desired, and to feed the pulp directly to the washer. However, it must be noted that the method and apparatus in accordance with the present invention may may be applied also in apparatus where it is not necessary to utilize its discharge or pumping ability. Thus the above described embodiments must not be seen as restricting the scope and protection of the invention, but merely exemplifying a number of most preferred construction alternatives and applications. Thus all details illustrated in connection with different embodiments such as auxiliary blades, extensions of blades, extensions of shafts, clearances, etc. may be used, where applicable, in all embodiments where they are not explicitly mentioned. It is also not characteristic of the present invention that, although the term "spiral housing" is used throughout the whole patent application, said portion is specifically spiral, but also other forms applicable in the particular use or purpose may come into question. The scope of protection of the present invention is disclosed and determined by the enclosed claims, alone.
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Gas is separated from fluent material, particularly a liquid or a cellulose fiber suspension having a consistency of about 8-18%, utilizing a closed separation apparatus having a spiral housing with a central axis, a fluent material inlet channel, a fluent material outlet, and a gas outlet. A pressure differential is maintained between the inlet channel and the spiral housing, and the pressure differential is converted to kinetic energy of the fluent material by causing the fluent material to flow through one or more spiral flow paths through the inlet channel toward the spiral housing. In the spiral housing a rotor is rotated to impart a strong centrifugal force to the fluent material to cause gas to separate and collect adjacent the central axis of the spiral housing, from which the gas is removed. The strong centrifugal force caused by the rotating rotor discharges the fluent material through the outlet. The spiral flow paths may be stationary or may rotate with the rotor in the spiral housing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to an optical assembly for a luminaire, and more specifically, this invention relates to a system of reflector components to provide the desired light distribution and lighting efficiency for an outdoor floodlight.
2. Description of the Prior Art
In utilizing an outdoor floodlight, it is necessary to utilize some type of light collection and focusing system to obtain the desired lighting efficiency and light distribution. Such light control or optical systems conventionally utilize metallic reflectors, the best known of which, perhaps, is the parabolic reflector in its various sizes and shapes. Such reflectors are made of relatively heavy material and must be preformed in the desired shape. The use of such relatively heavy stock and the preforming operations make the costs of such reflector systems relatively high. Further, as a result of the working required to get the desired shape, it is frequently necessary to establish the reflecting surface of the metal after it has been preformed. This adds still another increment to the overall cost of the optical system.
In addition, the necessity of the preforming operations means that the manufacture and assembly of the optical system is relatively complex, as is the replacement of the optical system.
While some attempts have been made to utilize a multiplicity of reflector elements to produce the desired light control, these systems have generally been complex, unwieldy and financially impractical.
SUMMARY OF THE INVENTION
By means of the present invention, the light distribution and lighting efficiency of a luminaire, such as pole-mounted outdoor floodlight, can be achieved by using thin gauge prefinished reflector stock, which greatly diminishes the costs of the system. In addition, the system is not complex or difficult to master and may be easily assembled. Further, the replacement of any damaged or defective reflector components can be easily accomplished.
These desirable results are achieved by utilizing a maximum of only five reflective components, all of which may be made of thin gauge prefinished reflector stock without any complicated preforming. The three basic or main reflector items include a back reflective component and a pair of side reflective components. The top and bottom reflective components are added to improve the optical efficiency of the system, as well as providing a more finished appearance. In addition, the top and bottom reflective components serve to separate the optical chamber from the other portions of the luminaire housing, which has an aperture at the front from which light emanates. All of these reflective components are made from thin gauge prefinished reflector stock.
None of the reflective components must be preformed, and the back reflective component is the only one that is preformed, this preforming providing an arcuate shape with a simple bend about a single axis of curvature, so that the prefinished reflector stock can be utilized without disrupting the reflecting surface. The side reflective components are merely straight sections which are given the desired arcuate shape or form by being inserted between appropriate positioning and holding members, such as a bracket at the back and a retaining flange at the front. As in the case of the back reflective component, the side reflective components are bent about a single axis of curvature, which lies in a vertical plane, so that the reflective finish is not disrupted. Each of the side reflective components are mounted by being placed against the mounting bracket at the back and then bent until the front edge fits in the retaining flange at the front. The retaining flange has an appropriate central cut-out to permit grasping the front edge of the side reflective component to remove it from the luminaire. The side reflective components have reflecting surfaces facing one another. After insertion of the side reflective component, the back reflective component is mounted by appropriate fastening means to cover the back edges of the side reflective components, with the reflecting surface of the back reflective component facing the aperture at the front of the luminaire housing. The fastening means may be any appropriate type of device, such as screws.
The top and bottom reflective components are essentially flat plates of the same thin gauge prefinished reflector stock as the other reflective components. The bottom reflective component is mounted on a mounting rim and fastened in any appropriate fashion to close the bottom of the optical compartment and separate it from a lower compartment that contains the electrical components for energizing the lamp of the luminaire. An opening is formed in this bottom reflective component to permit the base of the lamp to be inserted into a socket that is mounted in the electrical component compartment.
At the top of the optical assembly, the top reflective component is held on top of the side and back reflective components by a suitable biasing arrangement, such as tabs formed from the top reflective component or, as shown herein, a pair of spiral springs exerting a downward force. These springs permit the top reflective component to be pushed upwardly when inserting or removing the lamp from the luminaire, if additional room is needed for such actions.
With the invention disclosed herein, an optical or reflective system for a luminaire is provided which is efficient, inexpensive, easily assembled and easily dismantled for repair or replacement. In addition, the optical assembly disclosed herein provides a luminaire having a nice appearance and one in which the optical chamber is separated from other areas of the luminaire by the reflective components, while at the same time permitting insertion and removal of the lamp of the luminaire through an opening in the bottom reflective component by lifting the top reflective component against the spring bias.
These and other objects, advantages and features of this invention will hereinafter appear, and for purposes of illustration, but not of limitation, an exemplary embodiment of the subject invention is shown in the appended drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a left front perspective view of a luminaire incorporating the optical assembly of this invention.
FIG. 2 is a left front perspective view, partially broken away and partially exploded, illustrating the optical assembly in the housing of the luminaire of FIG. 1.
FIG. 3 is a cross-sectional view of the luminaire of FIG. 1, partially broken away.
FIG. 4 is a cross-sectional view taken along lines 4--4 of FIG. 3.
FIG. 5 is an exploded view of the housing of the luminaire of FIG. 1 illustrating the optical assembly of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawing, a luminaire 11, such as a pole-mounted outdoor floodlight, is illustrated. Luminaire 11 has a housing 13, which is enclosed by a door 15. Door 15 has a bottom opaque portion adjacent a compartment in which the electrical components for energizing a lamp 19 are located. A transparent portion, such as a lens or window 21, is located adjacent the compartment in which the lamp 19 is positioned to produce the desired light, hence providing an aperture from which light emanates. The optical assembly of the present invention is located in the chamber with the lamp 19 to provide the desired light distribution pattern and lighting efficiency. Luminaire 11 is mounted on a pole or tenon 23, by means of a mounting arrangement or fitter 25.
In FIG. 2, the door 15 has been pivoted to an open position about hinges 27 and 29. With the door in this position, and the top of housing 13 partially broken away as shown, the optical assembly 30 may be seen more easily. Optical assembly or system 30 has a main reflector portion that includes a back reflective component 31 and side reflective components 33 and 35. In addition, the optical system 30 includes a top reflective component 37 and a bottom reflective component 39.
Back reflective component 31 is a rectangular piece of thin gauge prefinished reflector stock, which is formed with a desired amount of curvature about a single axis, such axis of curvature lying in a horizontal plane when component 31 is placed in housing 13. Back reflective component 31 could be formed with the desired curvature by forcibly inserting component 31 between appropriate stays. However, in this preferred embodiment, the back reflective component 31 is preformed with the desired curvature. As this curvature is about a single axis, it does not adversely effect the reflective surface of the prefinished stock, which is positioned to face the aperture of lens 21.
The back reflective component 31 is secured in place by an appropriate fastening means, such as screws 41 and 43. Screws 41 and 43 are inserted into a mounting assembly, such as mounting brackets 45 and 47, respectively, as may be better seen in FIGS. 3 and 5. Side reflector components 33 and 35 are flat rectangular sections of thin gauge prefinished reflector stock. The desired curvature of these side reflective components, as illustrated in FIGS. 2 and 5, is achieved by forcibly inserting them in a desired location, where they are retained by an appropriate holding structure. The back edge (i.e., the edge at the back of the open housing 13) of each of the side reflective components 33 and 35 abuts against a respective mounting bracket 45 or 47. The front edges of the side reflective components 33 and 35 are engaged by the retaining flanges 49 and 51, respectively, when the side components are forced into position between the mounting bracket 47 and retaining flange 49, in the case of reflective side component 33, and between mounting bracket 45 and retaining flange 51, in the case of reflective side component 35. The tension of side components 33 and 35 when placed between the respective mounting bracket and retaining flange is sufficient to forcibly retain it in position without further fastening.
Retaining flanges 49 and 51 are located on extending mounting plates 53 and 55, respectively, of the optical system. Extending mounting plates 53 and 55 are firmly secured in housing 13 by appropriate bolts or screws 57. The extending plates 53 and 55, and the retaining flanges 49 and 51, contain cut-away portions 59 and 61. These cut-away portions are for the purpose of permitting a person to grasp in the front edges of the reflective side components for removal from the optical system.
Bottom reflective component 39 is generally planar and shaped to roughly conform to the horizontal cross section of housing 13. A depending flange 39 is located on the front edge thereof, and an opening 67 is provided in the central portion thereof. Opening 67 permits passing of the base 69 of lamp 19 therethrough and is so positioned that the threaded base 69 of the lamp will be inserted into a socket 71 stationed in the compartment below the reflective component 39. Bottom reflective component 39 separates the lighting compartment in which the otpical system is located from this lower compartment, in which the energizing components for the lamp 19 are located.
Bottom reflective component 39 is supported by a mounting rim or ridge 73 located on the inner surface of housing 13. This rim 73 may be cast as an integral portion of the housing. Bottom reflective component 39 is then maintained in position on mounting rim 73 by an appropriate fastening arrangement, such as screws threaded into the projecting mounting plates 53 and 55.
Top reflective component 37 has essentially the same shape as bottom reflective component 39, but with an upwardly extending flange 75. Top reflective component 37 rests on top of the side reflective components 33 and 35 and the back reflective component 31. Component 37 is biased downwardly against the back and side reflective components 31, 33 and 35 by a pair of tension springs 77. Each of the springs 77 extends between an appropriate opening 79 formed on top of reflective component 37 and another opening 81 formed in the projecting mounting plates 53 and 55, the ends of the springs 77 being fastened in the appropriate openings 79 and 81. The biasing of springs 77 holds the top reflective component 37 in place, and yet permits it to be urged upwardly when inserting or removing a lamp 19. Projections 83 at the top back of housing 13, which may be integrally cast with the housing, limit the upward movement of the back end of upper reflective component 37.
With reference to FIG. 5, the assembly of the optical system may be readily observed. Side reflective component 33 is inserted into housing 13 with the reflective surface thereof facing toward the center of the housing. The back end 85 of component 33 is placed against the mounting flange 47, and component 33 is then forcibly urged toward the side wall until the front end 87 thereof fits behind retaining flange 49. When so positioned, side reflective component 33 will have the curvature illustrated in FIG. 5, about an axis of curvature in a vertical plane. Side reflective component 35 is similarly inserted by placing the back end 89 thereof against the mounting flange 45 and bending until the front end 91 will fit behind retaining flange 51, thus, side reflective components 33 and 35 will then have the curvature illustrated in FIG. 5, with the reflecting surfaces 34 and 36 facing one another. The back reflective component 31, which could be arranged to be formed when inserted into the housing 13 as in the case of the side components 33 and 35, is, in this preferred embodiment, preformed to have the curvature illustrated. This back reflective component 31 is then mounted by the screws 41 and 43 inserted into the mounting flanges 45 and 47, so that the back reflective component 31 covers a portion of the back ends of the side reflective components 33 and 35. Bottom reflective component 39 will then be inserted on top of the rim 73 and appropriately fastened in place. Similarly, the top reflective component 37 may be inserted under the protruding stops 83 and then fastened in place by hooking the springs 77 into openings 79 and 81.
With the invention shown and described herein, an optical assembly for a luminaire is provided of a relatively few number of reflective components, each of which is formed from a thin gauge prefinished reflective stock and only one of which is preformed in this preferred embodiment. The reflective components may be easily assembled and easily removed, if repair or replacement is required. Accordingly, a highly efficient and yet relatively inexpensive optical system is produced.
It should be understood that various modifications, changes and variations may be made in the arrangements, operations and details of construction of the elements disclosed herein without departing from the spirit and scope of this invention.
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An optical system for a luminaire, such as an outdoor floodlight, is provided by an assembly of reflectors. The main reflector assembly has a simply curved preformed back component and a pair of side components that are formed in the desired shape by forcing them into place between appropriate holding members in the luminaire housing. Top and bottom reflector components may be added to provide improved optical efficiency, improved appearance and separation thermally, mechanically and electrically between the optical chamber and other portions of the luminaire. All reflector components may be made of thin gauge prefinished reflector stock.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a device for the measurement of magnetic properties of surfaces of bodies, in particular ferromagnetic substances, magnetic alloys, catalysts and spin glasses.
2. Discussion of Related Art
For the measurement of magnetic properties, in most cases a magnetic field externally applied to the body is required to align the magnetic domains in a definite preferred direction, i.e., the direction of the external magnetic field. With the detector of the present invention, magnetic properties of surfaces, for example, may be detected in a very simple manner without the use of an external magnetic field.
The methods considered efficient at the present time for the investigation of magnetic properties, for example, of surfaces, employ:
(a) the emission of polarized electrons by magnetic surfaces (by field emission, photoemission) and the detection of polarized electrons accelerated to approximately 100 KeV by Mott scattering (see: H. C. Siegmann in Phys. Rep. Phys. Lett. C (Netherlands), Vol. 17c, No. 2, pp. 37-76 (April, 1975)); and
(b) the capture of polarized electrons in ionic reflection and ion neutralization on surfaces and subsequent transfer of the electron spin polarization (ESP) by means of hyperfine interaction to produce core spin polarization, which may be used as a measurable value for the ESP (see: C. Rau in Comments on Solid State Physics, Vol. 9, No. 5 (1980)).
All of the methods have in common that a preferred direction in space by means of the application of an external magnetizing field is required for the alignment of the domains.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and apparatus for measuring magnetic properties which eliminate the need for an externally applied field and thereby also eliminate stray fields.
A further object of the present invention is to substantially simplify the existing technology for measuring magnetic properties and to provide a method for the measurement of microscopic magnetic properties on macroscopic bodies.
The above and other objects of the present invention are attained by examining the square of a magnetic value, of magnetic polarization or the ESP in the microscopic range (mm - μm), wherein ferromagnets always exhibit ferromagnetic behavior. The scattering particle beams with the exchange of two electrons, for example, by capture in the particles, is used. The lateral interaction length of the particles with the surface of a body amounts to only a few hundred atomic distances; it is always less than the lateral extension of magnetic domains. Using, e.g. small scattering angles, the particles are specularly reflected and do not penetrate into the surface of the body, a fact revealing the extreme surface sensitivity of this method. This opens a way to detect the magnetic properties of the top most surface layer of a body. This fact is highly useful to the understanding of surfaces of alloys, catalysts, spinglasses etc. The method of the invention is carried out by generating a beam of particles, which particles undergo a change of charge state by exchange of two electrons having preoriented magnetic spin moments. The beam is focused on body such that it is reflected from the surface of the body. Then the number of the particles charge state changes which occured, in the reflected beam is measured. The generation of the beam is carried out by forming the beam from H, D, He or heavier particles. The measurement may be carried out by detecting singulet and triplet states of the particles. Further, the measuring step may comprise electrostatically separating different charged components of the beam and simultaneously detecting the separated beam components and taking current measurements in the beam. Furthermore, the method may include the step of calibrating the measured number of charge state changes through the measurements of the temperature dependence of the magnetic value.
The apparatus for carrying out the present invention comprises means for generating a beam of particles, which particles undergo a known charge state change in response to an exchange of two electrons having preoriented magnetic moments; means for focusing the beam on a body such that the beam is reflected from the surface of the body; and means for measuring the number of particle charge state changes which occurred in said reflected beam.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and advantages will become more readily apparent as the invention becomes more completely explained in the Detailed Description, reference being had to the accompanying drawings in which like numerals represent like parts throughout and in which:
FIG. 1 is a schematic drawing of one embodiment of an apparatus for carrying out the present invention; and
FIG. 2 is a schematic drawing of a second embodiment of an apparatus for carrying out the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In dielectronic exchange in the atomic shell of a particle in scattering there are two boundary cases:
In the interchange of two electrons with magnetic moments antiparallel to each other, at a body to be examined, a singulet state would be produced in the particle (for example H + +2 e=H - (1s 2 )). In the other case of the transition of two electrons with magnetic moments parallel to each other, a triplet state would be generated (H + +2 e=H - (1s2s)).
A very simple path to a solution results from the use of hydrogen particle beams. It is known that H - (1s 2 ) exists in the singulet state, but not in the triplet state (H - (1s2s)). References: C. L. Pekeris, Phys. Rev., Vol. 126, pp. 1470-1476 (Jan., 1962) and R. Hill, Phys. Rev. Lett., Vol. 38, pp. 643-646 (Sept., 1976). This signifies in the present case that the measurement of the magnetic value may be reduced to a simple measurement of the state of charge, i.e., to current measurements. This may be effected, following the electrostatic separation of the charges (H + component and H - component of the current) by means of Faraday cups or electrostatic energy and angle analyzers.
A high ESP value (numerous parallel moments of electrons) thus signifies the formation of few H - . A low ESP (numerous antiparallel moments available for interchange) then means the formation of more H - than with a high ESP value.
Example: A paramagnet such as Copper has zero ESP; the H - /H + ratio is then larger than in the scattering of particles on a surface of a ferromagnetic body such as Ni.
The use of hydrogen particles, since only the singulet state exists, is extremely simple for the execution of the measurement. A further possibility naturally consists using heavier particles, such as He, etc. The effective cross section for the neutralization, exchange and capture rates of electrons always depends on the size of the particles. The latter differs for example for singulet and triplet helium (Pauli exclusion principle). Obviously, this provides in principle a sensitivity for the measurement of a magnetic value. Example: the neutralization of He ++ to He O by means of dielectronic capture on the surface of the magnetic body. The He O /He ++ neutralization rate naturally depends on the magnetic properties of the body.
In an investigation of excited particles and in measurements of light emission, these values may also be measured.
The advantages to be attained by the invention include the fact that in place of a complex apparatus with magnetic fields applied to the specimens, it is now possible to effect investigations without the application of fields, simply and inexpensively, using nonprofessional personnel. The testing of a body to determine whether it is magnetic or not (specifically its uppermost atomic layer) may now be effected by means of simple current measurements.
With reference to FIGS. 1 and 2, the apparatus to be used will now be set forth. A HF ion source 1 with a Wien filter 3 (ortec Model 320 and a velocity filter according to L. Wahlin, Nuclear Instr. Meth., Vol. 27, pp. 55-60 (Sept., 1963)) produces energetic ions (D + ) in an energy range of up to 10 KeV (high rate of H - or D - formation in this energy range) with a high intensity through a small solid angle (approximately 0.5°). A magnetic body 5 with a smooth surface produces the small angle scattering of approximately 5 KeV D + ions at an angle of approximately 1° against the surface. Measurement of the reflected particles is made by a Faraday cup 6 with bias voltages for the separate measurements of the D - and D + components in the beam reflected at an angle around 1° by the surface. The measurements are effected in a vacuum.
EXPLANATION OF FIG. 1
A beam generator 1 generates a beam of particles which is passed through electrostatical lenses 2 and subsequently through a Wien filter 3 to allow only single charged positive ions or if wanted doubly charged positive ions to leave and to reach apertures 4 (diaphragms, beam collimators) to strike a surface of a body 5. After reflection at the surface of the body the beam passes apertures 4 and then hits a Faraday cup 6 which is biased to detect either positive or negative particles. The ion current is measured with a current meter 7.
The beam generator 1 is a commercial ion source of type Model 320 RF Ion source from Ortec Inc. or Ionex. Inc. or is a Colutron Ion source from Colutron. These beam generators provide particle beam accelerated to 500 Volts up to 30,000 Volts.
The lenses 2 are standard electrostatical focussing devices and consist of stainless steel tubes at high voltage.
The Wien filter 3 is a velocity filter for particle beams and consists of crossed electric and magnetic fields to separate and to disperse parts of a beam in such a way that only one velocity selected part of the beam is striking pairs of diaphragms used for collimating the beam.
The beam diaphragms 4 consist of stainless steel plates with a hole for beam passage and collimation.
The magnetic body 5 is mounted on a target holder and consists of any magnetic material to be investigated. In case of calibration, this magnetic body can be replaced by a nonmagnetic body by lateral movement of the target holder.
After reflection, the beam passes pairs of diaphragms 4 for defining a fixed solid angle in space.
A Faraday cup 6 is a standard equipment to measure current. Dependent on the bias voltage positive or negative current can be collected.
The electrical current itself is measured using a standard Ampere meter 7.
Calibration of the charge states in the reflected beam is performed by monitoring the beam current at the magnetic body 5.
EXPLANATION OF FIG. 2
Deuterium gas is ionized in a RFion source and accelerated to 5 KeV by a voltage. After the focusing and selecting the D + -part of the beam by using the Wien filter a 5 KeV D + beam strikes a magnetic body. Before reflection, the beam is collimated using stainless steel apertures which generate a beam of divergence of less than 0.1 degree.
During the reflection at the magnetic body part of the beam effects electron exchange with the magnetic body.
After reflection, the beam passes apertures (diaphragms) and then passes an electrostatical condensor to separate charged and neutral parts of the beam. 6 are detectors for positive or negative charged beams, e.g., Faraday cups. 7 is a detectors for neutral particles, e.g., there the neutral particles are again ionized and the electrical currents are measured.
The above description is set forth for purposes of illustration only, it being understood that numerous changes, modifications and additions may be made to the present invention without departing from the scope thereof as set forth in the appended claims.
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A beam of particles which undergoes a known charge state change in response to an exchange of two electrons having preoriented moments is generated. The beam is focused on a body, the magnetic properties of which are to be determined, in such a manner that the beam is reflected from the surface of the body. The number of particle charge state changes which occurred are measured in the reflected beam and provide an indication of the square of the magnetic value of the body and shows the magnetic state of the surface of the body.
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CROSS REFERENCE TO RELATED APPLICATIONS
This claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Ser. No. 60/263,935, entitled “Cementing Tool,” filed Jan. 24, 2001. This is also a continuation-in-part of U.S. Ser. No. 09/518,365, filed Mar. 3, 2000 now U.S. Pat No. 6,349,769, which is a continuation of Ser. No. 08/898,700 filed Jul. 24, 1997 now U.S. Pat. No. 6,056,059, which is a continuation-in-part of Ser. No. 08/798,591 filed Feb. 11, 1997 now U.S. Pat. No. 5,944,107, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Nos. 60/013,227, filed Mar. 11, 1996, 60/025,033, filed Aug. 27, 1996, and 60/022,781, filed Jul. 30, 1996, all hereby incorporated by reference.
TECHNICAL FIELD
The invention relates generally to cementing operations for wellbores. More specifically, the invention relates to a method and apparatus for cementing casing in a wellbore.
BACKGROUND
In the petroleum industry, wells are drilled in selected formations in an effort to produce hydrocarbons in commercially feasible quantities. During drilling operations for a typical oil or gas well, various earth formations are penetrated. To complete the well, casing is installed into the drilled wellbore.
Referring to FIG. 1, an example casing assembly 20 used in some oil and gas wells is shown. The casing assembly 20 for a given well is typically selected with an outer diameter that is small enough to go into the hole and still leave room for a cement layer 22 around the casing assembly 20 , and an inner diameter that is large enough for the passage of downhole tools. Typically, as joints of the casing assembly 20 are connected to form a conventional casing string, the casing string is gradually moved downhole into the well. Once the desired length of a casing assembly 20 is connected, the casing assembly 20 is suspended or “hung” in the well, either from the surface or from the end of a previously cemented casing.
A casing assembly 20 may include a guide shoe (not shown) at the bottom of the casing assembly 20 to guide the casing assembly 20 as it is lowered into the well. A guide shoe prevents the casing assembly 20 from snagging on the wall of the wellbore 14 as it is lowered into the well. A fluid passage is typically formed through the center of the guide shoe to allow drilling fluid to flow up into the guide shoe as the casing assembly 20 is lowered into the wellbore 14 . The fluid passage also allows cement pumped down the casing assembly 20 to flow downhole and out of the casing assembly 20 during cementing operations.
Cementing of the casing assembly 20 in the well is typically done by pumping a volume of cement into the casing assembly 20 sufficient to fill the annulus between the casing assembly 20 and the wellbore 14 , followed by pumping displacement fluid on top of the cement to displace the cement down the casing assembly 20 and up the annulus between the casing assembly 20 and wellbore 14 . The volume of cement required to fill the annulus between the casing assembly 20 and the wellbore 14 can be calculated from the geometry of the wellbore 14 and the geometry of the casing assembly 20 inserted in the wellbore 14 .
Cementing techniques are well developed for single-bore wells. However, multilateral wells are becoming increasingly more desirable to improve production. A bore leading from the surface is referred to as a primary or main wellbore. Each of directional wellbores extending from the primary wellbore is referred to as a lateral wellbore. The junction between a primary wellbore and one or more lateral wellbores is referred to as a wellbore junction.
Casing and cementing in a multilateral well presents a greater challenge than for uni-bore wells, especially in providing support and pressure integrity at the wellbore junction between the primary wellbore and a lateral wellbore. Existing cementing technology for multilateral wells makes use of hardware components, such as cement retainers, packers, and diverters, which are permanently set in the casing assembly during cementing operations that must be milled to clear the path for subsequent drilling operations. At a wellbore junction, the milling of the hardware components and cement in the internal volume of the wellbore may cause damage at the wellbore junction. This milling operation can also be time consuming and costly because of the number of downhole trips required.
SUMMARY
In general, an improved cementing tool for cementing a casing assembly at a junction of plural wellbores is provided. For example, the cementing tool includes a body, an anchoring mechanism adapted to anchor the body within the casing assembly, and a flow conduit adapted to channel cement flow to an annular region outside the casing assembly. The anchoring mechanism is adapted to be released to enable retrieval of the cementing tool from the casing assembly.
Other or alternative features will be apparent from the following description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of conventional casing cemented in a wellbore.
FIG. 2 illustrates a multilateral well in which a cementing tool according to some embodiments can be installed.
FIG. 3 illustrates one embodiment of the cementing tool used to cement a casing assembly at a lateral junction.
FIG. 4 is an isolated view of the cementing tool of FIG. 3 .
FIG. 5 is an isolated view of the casing assembly of FIG. 3 .
FIG. 6 is an isolated view of another embodiment of a cementing tool configured to cement the casing assembly of FIG. 5 .
FIG. 7 illustrates the cementing tool of FIG. 6 being used to cement the casing assembly of FIG. 5 .
FIG. 8 illustrates one example of bypass tubes useable with the cementing tool of FIG. 4 or 6 , the bypass tubes configured to break at selected locations.
FIGS. 9A-B are sectional views of one example of a securing mechanism used in the cementing tool of FIG. 4 or 6 .
FIGS. 10A-10J illustrate a cementing tool according to another embodiment in different positions.
FIGS. 11A-11D are a longitudinal sectional view of the cementing tool of FIGS. 10A-10J.
FIGS. 12A-12D are a side view of the cementing tool of FIGS. 11A-11D.
FIGS. 13A-13B illustrate the detachment of the cementing tool from a hardened block of cement.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
As used here, the terms “up” and “down”; “upper” and “lower”; “upwardly” and downwardly”; “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the invention. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
As shown in FIG. 2, a cementing tool according to some embodiments is positionable at various well junctions 21 in a multilateral well 15 . In the example embodiment shown, a platform 11 is provided at the surface of the well 15 , which is a subsea well. However, in other embodiments, the well 15 can be a land well.
The well 15 includes a primary wellbore 17 and several lateral wellbores 19 . As used here, the term “wellbore” or “bore” can refer to either the primary wellbore or a lateral wellbore. The multilateral well 15 is completed with a casing assembly, including junction assemblies at respective well junctions 21 . The cementing tool according to some embodiments is designed to cement the casing assembly at the well junctions 21 . The term “casing” is intended to cover both casings and liners, or any other structure designed to line the wall of a wellbore.
FIG. 3 shows one embodiment of a cementing tool 110 being used to cement a casing assembly 200 . The casing assembly 200 includes a casing junction assembly 100 that may be installed at each well junction 21 in the well 15 . In the embodiment of FIG. 3, the cementing tool 110 is configured to be retrieved and to prevent the accumulation of cement in an internal volume 100 a of the casing junction 100 so that the clean up required in the internal volume 100 a of the junction 100 is minimized. An isolated view of the cementing tool 110 is shown in FIG. 4 . An isolated view of the casing junction assembly 100 is shown in FIG. 5 .
Referring now to FIGS. 3 and 5, the casing assembly 200 includes the casing junction assembly 100 coupled to the end of a casing string (not shown) by a coupling section 102 . The casing junction assembly 100 is used to provide support and pressure integrity for the lateral junction 21 defined between the primary wellbore 17 and one or more lateral wellbores 19 to be drilled. According to the guidelines established by the Technological Advancement of Multilaterals (TAML) consortium, this type of multilateral support structure may be classified as a Level 6 TAML Multilateral System. However, other types of casing junction assemblies can be used in other embodiments.
The casing junction assembly 100 illustrated in FIG. 5 is a deformable casing junction assembly 100 , such as one disclosed in U.S. Pat. No. 5,944,107, which is hereby incorporated by reference. To install the casing junction assembly 100 in a wellbore, the casing junction assembly 100 in its deformed position (not shown) is suspended into a wellbore which has been back-reamed to produce a lower wellbore section with a larger diameter than the wellbore section above it (as shown in FIG. 3 ). An expansion tool (not shown) is then run into the casing junction assembly 100 and used to expand the casing junction assembly 100 from its deformed position to its reformed (fully opened) position, shown in FIGS. 3 and 5. Once in its opened position, the junction assembly 100 may be cemented in the wellbore and the lateral wells drilled through branches 100 b defined by the casing junction assembly 100 .
In this example, the end of the casing assembly 200 includes a guide shoe 108 attached to the bottom of the multilateral casing junction assembly 100 to guide the casing assembly 200 as it descends into the wellbore. The guide shoe 108 includes a fluid channel 109 that allows fluid to pass through the guide shoe 108 and up the annular space between the casing 200 and the wellbore. The fluid channel 109 in the guide shoe 108 includes one or more fluid inlets 109 a at the upper side of the guide shoe 108 and one or more fluid outlets 109 b at the lower side of the guide shoe 108 .
The coupling section 102 has an internal landing profile 102 b and a casing joint 104 . The coupling section 102 may also include an orienting profile 301 , such as a “muleshoe,” to orient the cementing tool 110 . The casing joint 104 is positioned in the casing to provide a desired spacing between the junction assembly 100 and the landing profile 102 b . The casing assembly 200 shown in FIG. 5 is only one example of a casing assembly for which a cementing tool may be configured for use in, as other types of casing assemblies can be used in other embodiments.
FIGS. 3 and 4 show one embodiment of the cementing tool 110 . FIGS. 6 and 7 show another embodiment of the cementing tool. Referring to FIGS. 3 and 4, the cementing tool 110 is adapted to attach to the end of a work string 112 . The work string 112 includes a string of hollow pipe used to lower the cementing tool 110 into the casing assembly 200 . The work string 112 may also be adapted to channel cement and displacement fluid pumped from the surface down to the cementing tool 110 when positioned in the wellbore.
The cementing tool 110 includes a generally cylindrical body 111 . The body 111 includes a first member 111 a slidably coupled with respect to a second member 111 b . One end of the first member 111 a is adapted to couple to the work string 112 . The other end of the first member 111 a operatively couples to the second member 111 b and is adapted to slide axially to a limited extent with respect to the second member 111 b . An internal bore 113 extends axially through the first member 111 a and the second member 111 b to permit fluid flow through the body 111 of the cementing tool 110 .
Another embodiment of a cementing tool 110 configured for use in the casing assembly 200 of FIG. 5 is shown in FIG. 6 . The body 111 of the cementing tool in this embodiment also includes a first member 111 a and a second member 111 b slidably coupled in a manner similar to the embodiment described above. However, in other embodiments, the body 111 may be configured differently than generally cylindrical and may include one member or a plurality of connected members with a fluid passage defined therein, without departing from the spirit of the invention.
Referring to FIGS. 3 and 7, the cementing tool 110 further includes at least one bypass device 120 for channeling cement from the body 111 of the cementing tool 110 to a desired location to prevent the accumulation of cement in an intermediate volume of the casing junction assembly 100 . The distal end of each bypass device 120 is configured to seat in the fluid channel 109 of the guide shoe 108 . In one embodiment, the bypass device 120 may form a seal with the fluid channel 109 of the guide shoe 108 to prevent cement exiting the bypass device 120 from flowing into the internal volume 100 a of the casing junction 100 . In the embodiments shown, the at least one bypass device 120 includes a plurality of bypass tubes (or another type of conduit) that extend from the second member 111 b of the body 111 and are adapted to engage in fluid communication with a corresponding fluid channel 109 in the guide shoe 108 .
In another embodiment of the invention, the cementing tool 110 does not include a bypass device 120 , and the guide shoe 108 does not include the fluid channel 109 . Instead, the second member 111 b of the body 111 includes outlets enabling the flow of cement from the interior to the exterior of the cementing tool 110 .
The cementing tool 110 further includes an anchoring mechanism 114 configured to anchor the cementing tool 110 into place within the casing assembly 200 . In the embodiments shown, the anchoring mechanism 114 includes a plurality of keys 114 a azimuthally disposed about the body of the cementing tool 110 and configured to engage into a landing profile 102 b in the casing assembly 200 . In the embodiment shown in FIG. 3, the anchoring keys 114 a are radially extendable, attached to the second member 111 b , and slidably coupled about an outer surface of the first member 111 a of the body 111 .
FIG. 3 shows the anchoring keys 114 a in the activated (or expanded) position, and FIG. 4 shows the anchoring keys 114 a in a deactivated (or retracted) position. In another embodiment, the anchoring mechanism may include a single key, such as a retractable ring-shaped key radially disposed about the body of the cementing tool.
As shown in FIG. 3, the anchoring mechanism 114 is configured to engage in the landing profile 102 b provided in the coupling section 102 located above the casing junction assembly 100 . The anchoring keys 114 a are radially biased outwardly to engage in the annular recess 102 a of the landing profile 102 b as the cementing tool 110 descends into position in the casing junction assembly 100 . Alternatively, the anchoring keys 114 a may be spring loaded to automatically extend outwardly when brought into axial alignment with the landing profile 102 b , as in the embodiment of FIG. 7 .
Once the anchoring keys 114 a land in the landing profile 102 b , the lower body 111 b and the at least one bypass device 120 will be restricted from further axial movement in the casing assembly 200 . Subsequent increase of the axial force on the cementing tool 110 results in the axial downward movement of the first member 111 a with respect to the second member 111 b and the anchoring mechanism 114 . With downward movement of the first member 111 a , an enlarged portion 111 c of the first member 111 a slides down to engage and lock the keys 114 a in the landing profile 102 b.
In one embodiment, the keys 114 a are configured to withstand axial forces, which may be exerted on the cementing tool 110 , such as forces due to the weight of the tool 110 and work string 112 or buoyancy forces exerted by the cement 124 on the tool 110 during the cementing operation. Those skilled in the art will appreciate that the invention is not limited to an anchoring mechanism 114 with keys 114 a as described above. Rather, any type of anchoring mechanism suitable for downhole tools may be used in other embodiments without departing from the spirit of the invention.
The cementing tool 110 may also include at least one orienting key (not shown) attached to the body 111 . In one embodiment, the orienting key may be one of the anchoring keys 114 a that is specially adapted and located to mate with orienting profile 301 in the casing assembly 200 . The orienting key cooperates with the orienting profile 301 of the coupling section 102 to orient the cementing tool 110 so that each bypass device 120 lands in an inlet 109 a of the fluid channel 109 of the guide shoe 108 . It is noted that the orienting key and orienting profile 301 are not required in those embodiments of cementing tool 110 that do not include a bypass device 120 .
As shown in FIGS. 4 and 6, the body 111 of the cementing tool 110 also includes at least one shear pin 111 e connecting the first member 111 a and the second member 111 b of the body 111 to prevent axial movement of the first member 111 a with respect to the second member 111 b until a sufficient shearing force is applied on the pin 111 e . Once the cementing tool 110 lands and is anchored into the casing assembly 200 , as shown in FIGS. 3 and 7, the shear pin 111 e connecting the first member 111 a to the second member 111 b may be sheared by applying an increased downward force on the tool 110 . Once the pin 111 e is sheared, the first member 111 a is permitted to move axially with respect to the second member 111 b to lock the anchoring keys 114 a of the tool 110 into the landing profile 102 b of the casing assembly 200 .
Once the first member 111 a of body 111 has concluded its sliding motion, a securing mechanism, such as a ratchet mechanism 450 (see FIGS. 3, 7 , 9 ), is activated to secure the first member 111 a to the second member 111 b of the body 11 . FIGS. 3 and 7 show the general location of the ratchet mechanism 450 , while FIGS. 9A-B shows the ratchet mechanism 450 in more detail. FIG. 9A shows the ratchet mechanism 450 prior to the sliding motion of first body member 111 a . FIG. 9B shows the ratchet mechanism 450 subsequent to the sliding motion of first body member 111 a . The ratchet mechanism 450 comprises teeth 452 on second body member 111 b that mate with teeth 458 on first body member 111 a when the first body member 111 a has concluded its sliding motion (as shown in FIG. 9 B). Prior to this, the first body member teeth 458 are located above the second body member teeth 452 . When mated, the teeth 452 , 458 are configured to prevent upward movement but allow downward movement of first body member 111 a relative to the second body member 111 b . First body member teeth 458 are, in one embodiment, located on a ratchet key 456 that is attached by a shear pin 460 within a recess 454 of first body member 111 a . In another embodiment (not shown), it is the second body member teeth 452 that are located on a similar ratchet key attached by a shear pin within a recess of second body member 111 b.
The cementing tool 110 further includes at least one sealing element 116 disposed about the exterior of the cementing tool 110 to affect a fluid seal between the cementing tool 110 and the casing assembly 200 . Once the cementing tool 110 is in position in the multilateral casing junction assembly 100 , the sealing element 116 may be hydraulically set to seal the volume in the annulus between the work string 112 and the casing string above the sealing element 116 from the volume in the annulus between the multilateral casing junction assembly 100 and the cementing tool 110 below the sealing element 116 . The sealing element 116 may be disposed within a recess in the exterior surface of the second member 111 b of the body 111 . Those skilled in the art will appreciate that the invention is not limited to using a sealing element or the sealing element described above. Rather any sealing device, including hydraulically, electrically, and mechanically set sealing devices, may be used without departing from the spirit of the invention. Further, it should be understood that the sealing element 116 can be attached to some other component.
The cementing tool 110 may further include a flow control device 118 disposed within the body 111 of the cementing tool 110 to selectively permit the flow of cement through the cementing tool 110 . In the embodiment shown in FIG. 3, the flow control device 118 is a check valve 119 that permits the downward flow of cement through the cementing tool 110 but prevents the upward flow of cement back up the cementing tool 110 and into the work string 112 .
In the embodiment shown in FIGS. 6 and 7, a flow control device 118 a according to another embodiment is a sliding sleeve 121 remotely controlled from the surface. The sliding sleeve 121 includes a cylindrical body having one or more orifices 121 a through which fluid, such as cement slurry, may flow. The sliding sleeve 121 is integral with the first member 111 a of the body 111 and thus moves with the first member 111 a as it is moved from its upper position (FIG. 6 ), to its lower position (FIG. 7) with respect to the second member 111 b . The orifice(s) 121 a are positioned within the sliding sleeve 121 such that when the first member 111 a is in its upper position (FIG. 6) the orifice(s) 121 a are blocked by the second member 111 b to prevent fluid flow through the orifice(s) 121 a . However, when the first member 111 a is in its lower position (FIG. 7 ), orifice(s) 121 a are unobstructed to permit fluid to flow through them. In other embodiments, the flow control device 118 may include any other device that can be used to selectively permit flow through the cementing tool 110 . Further, the location of the flow control device 118 can be varied.
To permit retrieval of the cementing tool 110 from the casing assembly 200 after the cementing operation, the anchoring mechanism 114 of the cementing tool 110 is configured to be set and released on demand from the surface. In one embodiment, the anchoring mechanism 114 may be released from the surface by pulling up on the first member 111 a of the body 111 . The pulling motion may be performed by the work string 112 , which may be left downhole throughout the cementing operation, or by a retrieval tool (not shown) attached to the end of another (or the same) work string that is adapted to attach to the first member 111 a . The resulting upward force on the first member 111 a results in the shearing of the ratchet shear pins 460 (FIGS. 9A-9B) and thus the disablement of the ratchet mechanism 450 . Once the ratchet mechanism 450 is disabled, the resulting upward movement of the first member 111 a relative to the second member 111 b results in the position shown in FIGS. 4 and 6, wherein the first member 111 a no longer prohibits the inward motion of the keys 114 a (the protruding portion 111 c of the first member 111 a is no longer wedged against the keys 114 a ). Continued upward movement eventually results in the first member 111 a picking up on the second member 111 b (at shoulder 115 of the first member 111 a ) and the second member 111 b being pulled upwardly together with the first member 111 a.
Continued upward movement causes the keys 114 a to be released from (forced out of) the landing profile 102 b . This release is facilitated by the angled portions 300 of the keys 114 a and the landing profile 102 b that interact with each other and due to the fact that the keys 114 a are no longer locked in place by the first member 114 a and are now free to retract radially inward. After the keys 114 a are released from the annular recess 102 a , the cementing tool 110 can be removed from the casing assembly 200 upon completion of the cementing operation, as further described below.
In the FIG. 7 embodiment, the cementing tool 110 may further include a barrier 126 disposed about a periphery of at least one bypass device 120 to prevent cement 124 from back filling into the internal volume 100 a of the junction 100 . In one embodiment, the barrier 126 includes a deformable rubber retainer. The barrier 126 may include an opening therein for receiving a bypass device 120 . When the cementing tool 110 is inserted into the casing assembly 200 , the barrier 126 may deform into a retracted position to fit down the primary borehole of the casing assembly 200 and then may expand in the casing junction assembly 100 between a bypass device 120 and the inside of the lateral branches 100 b of the casing junction assembly 100 . The barrier 126 may also be configured, such as with sloped edges capable of scaling the wall of the junction, to retract as the tool is moved up the casing junction assembly 100 and primary bore of the casing assembly 200 for removal after the cementing operation. Alternatively, the barrier 126 may be designed to break away from the portion of the tool 110 removed from the wellbore 128 and remain downhole after the cementing operation. In such case, the barrier 126 will have to be milled or drilled out before resuming drilling operations. In other embodiments, the barrier may include any device or material capable of preventing the back flow of cement into the junction 100 without departing from the spirit of the invention. In one embodiment, the barrier 126 prevents cement back flow without forming a pressure seal to allow for pressure equalization across the walls of the junction 100 during the cementing operation.
Alternatively, in the FIG. 3 embodiment, the cement is prevented from back filling into the internal volume 100 a of the casing junction assembly 100 (at 127 ) by the drilling fluid trapped in the internal volume 100 a of the casing junction 100 . In this embodiment, drilling fluid in the internal volume 100 a of the casing junction 100 prior to cementing is trapped in the internal volume 100 a between the seals 116 of the cementing tool 110 and cement exiting the guide shoe 108 and flowing up the annulus between the casing assembly 200 and the wellbore 128 .
To perform a cementing operation with the example tools shown, the cementing tool 110 is attached to the end of the work string 112 , which is then lowered into a casing assembly 200 in the wellbore 128 . In the embodiment including the bypass device 120 , the orienting profile 301 of the coupling section 102 acts to orient the cementing tool 110 so that each bypass device 120 lands in an inlet 109 a of the fluid channel 109 of the guide shoe 108 . The at least one bypass device 120 at the lower end of the cementing tool 110 lands in the corresponding inlet 109 a of the fluid channel 109 of the guide shoe 108 . The bypass device 120 and the inlet 109 a in the guide shoe 108 may be configured with sloped mating surfaces to guide the bypass device 120 into position in the guide shoe 108 . Downward axial force on the cementing tool 110 may further force the mating surfaces of the bypass device 120 and guide shoe 108 together which may help them form a fluid seal.
As the bypass device 120 lands in the guide shoe 108 , the anchoring mechanism 114 enters the landing profile 102 b above the casing junction assembly 100 . The keys 114 a are biased to extend radially outwardly when brought into substantial axial alignment with the landing profile 102 b to engage in the landing profile 102 b . This anchors the cementing tool 110 in place. As a result, an increased downward axial force on the cementing tool 110 shears the shear pin ( 111 e in FIGS. 4 and 6) between the first member 111 a and the second member 111 b of the body 111 . The first member 111 a then slides axially downwardly with respect to the second member 111 b and anchoring mechanism 114 to lock the keys 114 a into the landing profile 102 b in the casing assembly 200 . The first member 111 a comes to rest against shoulder 111 d of the second member 111 b of the body 111 and further downward movement of the cementing tool 110 ceases. As the first member 111 a concludes its sliding motion, the ratchet mechanism 450 engages (the teeth 452 , 458 mate) thereby securing the first member 111 a to the second member 111 b.
At the surface, proper landing and locking of the cementing tool 110 into the casing assembly 200 may be determined based on the “hung weight” at the top of the work string 112 at the surface. Thus, the cementing tool 110 , advantageously, can provide positive feedback on the positioning of the cementing tool 110 in the casing assembly 200 based on hung weight reductions corresponding to the landing of the anchoring mechanism 114 , the shearing of the shear pin 111 e , and the locking of the tool 110 into the casing assembly 200 .
In another embodiment, instead of or in addition to the anchoring mechanism 114 , the casing junction 100 includes a shoulder (not shown) in its interior. The cementing tool 110 sits on the shoulder, which shoulder absorbs all or a portion of the weight.
Once the cementing tool 110 is locked into place, the sealing element 116 is hydraulically set. Prior to pumping cement, the cementing tool 110 and work string 112 will be surrounded by drilling fluid or the like. Thus, prior to pumping cement down the work string 112 , the internal volume 100 a of the casing junction 100 will be filled with drilling fluid.
Cement is then pumped down the work string 112 to the cementing tool 110 . A fluid separator, such as a rubber plug ( 129 in FIG. 7 ), may precede the flow of cement in the work string 112 to separate the cement from drilling fluid in the work string 112 and the cementing tool 110 prior to the pumping of cement. Cement is then pumped on top of the plug 129 to displace drilling fluid down the work string 112 and out of the cementing tool 110 . The plug 129 eventually comes to rest proximal the flow control device 118 in the body 111 of the cementing tool 110 .
In the embodiment of FIG. 3, the rubber plug (not shown), if used, may seat above the check valve 119 at the internal lip shown at 130 . The plug may include a membrane that ruptures due to continued pumping of the cement on top of the plug once it seats to cause a membrane in the plug to rupture, opening a passage in the plug that permits the flow of cement through the cementing tool 110 and into the guide shoe 108 .
In the embodiment of FIG. 7, rubber plug 129 seats in the sleeve 121 below the orifice(s) 121 a such that the flow of cement behind the plug is permitted to exit the sleeve 121 of the tool and flow through the at least one bypass device 120 to the guide shoe 108 .
In the embodiments including the bypass device 120 , the connection between the at least one bypass device 120 and guide shoe 108 and fluid trapped in the internal volume 100 a of the casing junction 100 may prevent the cement from back flowing into the internal volume 100 a of the multilateral casing junction assembly 100 . However, as noted above the barrier 126 in FIG. 7 may be provided on the tool 110 to extend between the bypass device 120 and the corresponding branch 100 b of the casing junction assembly 100 to prevent the back flow of cement 124 into the internal volume 100 a of the junction assembly 100 , while permitting pressure equalization across the walls of the junction assembly 100 .
At the surface, once the predetermined amount of cement has been pumped down the work string 112 , displacement fluid is pumped down the work string 112 to force the last of the cement down the work string 112 and out of the cementing tool 110 . A second fluid separator, or rubber plug 131 (in FIG. 7 ), may be placed in the work string 112 to separate the cement from the displacement fluid as the displacement fluid is pumped down the work string 112 .
As illustrated in FIG. 7, the pumping of displacement fluid continues until the second rubber plug 131 displaces the last of the cement through the body of the cementing tool 110 . The second rubber plug 131 comes to rest against the first plug 129 seated in the cementing tool 110 and prevents further flow of displacement fluid through the cementing tool 110 .
In the embodiment of FIG. 3, the second plug 131 may seat in the first plug (described above) to block the fluid passage in the first plug. In the embodiment of FIG. 7, the second plug 131 seats on the first plug 129 , as shown, and blocks the orifice(s) 121 a in the sliding sleeve 121 . The seating of the second plug 131 in the cementing tool 110 is indicated at the surface by a pressure increase, at which time pumping of displacement fluid ceases.
In the embodiment including the bypass device 120 , the cement pumped through the cementing tool 110 passes through the at least one bypass device 120 , into the fluid channel 109 , and out of the fluid channel 109 through outlet 109 b . Once out of the outlet 109 b , the cement is forced upward to the annular area between the casing junction assembly 100 and the wellbore to cement the casing assembly 200 in place. The displacement fluid pumped on top of the second plug 131 ensures that the necessary volume of cement is forced into such annular area. As the displacement fluid is pumped, the cement is forced upwardly in the annular area. The cement will typically surround at least the entire casing junction assembly 100 , but may also surround a substantial portion of the remainder of the casing assembly 200 .
In the embodiment not including the bypass device 120 , cement flows through the bottom (outlets) of the cementing tool 110 and through the outlets of the casing junction assembly 100 . The cement is then forced upward to the annular area between the casing assembly 200 /casing junction assembly 100 and the wellbore to form the cement layer 124 .
Once the cement pumping phase is complete, the cementing tool 110 (in part or in whole) will remain in place until the cement 124 in the wellbore has hardened. The work string 112 may be detached from the cementing tool 110 and returned to the surface during this time. Once the cement has cured, the anchoring mechanism 114 , being isolated from the cement operation, may be unlocked and disengaged from the casing so that the cementing tool 110 can be retrieved from the wellbore 128 .
Depending on the type of anchoring mechanism used, retrieval of the cementing tool 110 from the wellbore may require a retrieving tool to unlock the anchoring mechanism 114 from the landing profile 102 b of the casing assembly 200 . However, in the embodiments shown in FIGS. 3 and 7, the cementing tools are configured such the work string 112 attached to the first member 111 a of the cementing tool 110 may be used to provide a sufficient upward axial force to pull the first member 111 a into its upward position to disengage the ratchet mechanism 450 (by shearing the shear pins 460 ) and unlock the anchoring mechanism 114 from the landing profile 102 b . Once unlocked, an additional upward force can be applied to the tool 110 to force the anchoring keys 114 a to retract as they are forced up the landing profile 102 b . In an alternative embodiment, the anchoring keys 114 a may be, at this point, biased radially inward, in which case the keys 114 a will automatically disengage once unlocked from the landing profile 102 b . Other devices and techniques for locking and retrieving downhole tools may be used in other embodiments.
In one embodiment, once the cementing tool 110 is unlocked from the casing assembly 200 , the only connection retaining the cementing tool 110 in the wellbore 128 is the column of hardened cement 124 in the at least one bypass device 120 leading into the guide shoe 108 . The connection between the cementing tool 110 and the guide shoe 108 may be severed simply by applying a rotational torque and/or an upward axial force to the cementing tool 110 to break the cement column between the at least one bypass device 120 and the guide shoe 108 . In this manner, the cementing tool 110 in its entirety is retrieved, including the bypass device 120 as a whole. In such case, no clean up or drill-out in the internal volume 100 a of the junction 100 is typically required. This, advantageously, allows normal drilling operations to be resumed quickly and safely down the selected lateral branch 100 b of the junction assembly 100 without harm to the mechanical integrity of the junction assembly 100 .
In other embodiments, once the cementing tool 110 is unlocked from the casing assembly 200 , a simple upward force on the cementing tool 110 is not sufficient to break the connection between the cementing tool 110 and the cement 124 . In some applications, this connection may be broken by providing at least one bypass device 120 of the cementing tool 110 that is frangible such that in response to a sufficient upward force, the connection between the at least one bypass device 120 and the second member 111 b of the body 111 is broken. This results in the at least one bypass device 120 being left in the casing junction 100 and the body 111 and other portions of the cementing tool 110 being released from the wellbore 128 and pulled to the surface.
Alternatively, the cementing tool 110 may be designed to have one or more selected weak points, such that a sufficient upward force or torque on the tool will result in the breaking off of a portion of the tool 100 below the weak point. For example, the at least one bypass device 120 may be bypass tubes configured to have a weak point, such as a narrowed section or neck ( 140 in FIG. 8 ), configured to break in response to a sufficient upward or twisting force applied to the cementing tool 110 . Thus, if cement is allowed to backfill to a limited degree into the casing assembly 200 around the end of the bypass device 120 , as shown in FIG. 3, rotation of or an upward force on the cementing tool 110 may result in the shearing of the at least one bypass device 120 at or above the portion of the bypass device 120 embedded in the cement 124 .
Alternatively, the lower part of the body 111 may include a subsection designed to break off, such as at 133 in FIG. 3 where the at least one bypass device 120 inserts into the body. The location of the weak point or breakaway point may be located at various points along each bypass device 120 . However, in some embodiments, a substantial portion of the cementing tool 110 is retrievable from the wellbore 128 so that milling or drill out operations originate in the branches 100 b of the junction 100 rather than above the junction divider 106 to minimize the likelihood of damage to the junction 100 during milling.
If a portion of the at least one bypass device 120 is left in place in the cement 124 , then that portion, along with the cement 124 and a portion of the guide shoe 108 below the internal volume 110 a of the junction 100 will need to be milled before the lateral wells can be drilled. Therefore, the at least one bypass device 120 and the guide shoe 108 may be formed of a material that is easily milled, such as a plastic, rubber, thin-walled aluminum, or other frangible or drillable material, so that milling can be easily done without producing large resultant forces on the milling tool that could cause the mill to forcibly knock against and damage the divider 106 and branches 100 a of the casing junction 100 .
FIGS. 10A-10J are schematic diagrams of a different embodiment of a cementing tool 500 adapted to be installed in the casing assembly 200 . A longitudinal sectional view of the cementing tool 500 is shown in FIGS. 11A-11D. FIGS. 12A-12D are a side view of the cementing tool corresponding to the view of FIGS. 11A-11D. Reference is made to FIGS. 10A-10J, 11 A- 11 D, and 12 A- 12 D in the following description. The cementing tool 500 includes locking keys 502 for engagement in landing profiles 102 b of the casing assembly. Upper ends of the locking keys 502 are engaged by leaf springs 506 (FIG. 11B) to an upper housing 504 of the cementing tool 500 , while the lower ends of the locking keys 502 are engaged by leaf springs 506 to another body portion 520 .
The cementing tool 500 also includes a retrieving mandrel 508 that has a retrieving profile 510 to which a retrieving tool can be engaged to lift the cementing tool 500 for retrieval from the well. The cementing tool 500 also includes a control mandrel 512 . A lower end of the control mandrel 512 is attached to a sleeve 514 by a shearing mechanism 516 (see FIG. 11 A). In one embodiment, the shearing mechanism 516 includes one or more shear screws.
The lower end of the retrieving mandrel 508 is attached to an anchoring mandrel 509 , which has enlarged portions 518 a and 518 b that protrude outwardly from an outer surface of the anchoring mandrel 509 . The outer portions of the enlarged portions 518 a and 518 b are adapted to engaged corresponding portions of the locking keys 502 when the anchoring mandrel 509 is pushed downwardly (as shown in FIG. 10 B). In the position shown in FIG. 10A, which is the landing position, the enlarged portions 518 a and 518 b are disengaged from the locking keys 502 .
The anchoring mandrel 509 also extends a substantial length of the cementing tool 500 . As shown in FIG. 11C, the outer surface of the anchoring mandrel 509 has a pair of grooves 562 and 556 that are adapted to be engaged by stop rings 560 and 558 , respectively, when the anchoring mandrel 509 moves downwardly by a predetermined distance. Also, the stop rings 560 and 558 are engaged to unsetting members 572 and 574 , respectively, to enable the unsetting of the sealing elements 532 and 534 .
The sleeve 514 defines an inner bore 522 in the cementing tool 500 through which fluid can pass. Examples of such fluid include cement slurry as well as displacement fluid to push the cement slurry during cementing operations. The lower end of the sleeve 514 is attached to a valve member 524 (FIGS. 10 A and 11 D). The sleeve 514 is movable longitudinally (with movement of the control mandrel 512 ) in the cementing tool 500 to move the valve member 524 up and down to open or close radial ports 526 . In the position of FIG. 10A and 11D, the radial ports 526 are open to enable fluid flow between the inner bore 522 and an annular passageway 549 that leads to a chamber 550 in the cementing tool. Fluid in the chamber 550 flows out of the cementing tool 500 through one or more outlet ports 551 into the casing assembly 200 .
The cementing tool 500 includes two sealing elements 532 and 534 (as compared to the one sealing element in the embodiments of FIGS. 3 and 7 ). The sealing elements 532 and 534 are expandable to engage an inner wall of the casing assembly 200 . The sealing elements 532 and 534 are set by a downward force applied by respective setting pistons 528 and 530 , which are moveable downwardly by an increased pressure communicated down the work string and through the inner bore 522 of the cementing tool 500 . Chambers 536 and 538 are provided above respective setting pistons 528 and 530 that cooperate with reference chambers 540 and 542 (which can be filled with air, for example) to create a differential pressure for moving the setting pistons 528 and 530 downwardly. The setting pistons 528 and 530 are initially attached to the body of the cementing tool 500 by shearing mechanisms 580 (FIG. 11B) and 582 (FIG. 11 C), respectively.
Pressure in the bore 522 of the cementing tool 500 is communicated through radial ports 544 of the sleeve 514 and the anchoring mandrel 509 to the chamber 536 when the sleeve 514 and anchoring mandrel 509 are lowered into axial alignment with an inlet of the chamber 536 (as shown in FIG. 10 B). Similarly, radial ports 546 formed in the sleeve 514 and the anchoring mandrel 509 communicate fluid pressure from the inner bore 522 of the cementing tool 500 into the chamber 538 when the ports 546 are axially aligned with inlets of the chamber 538 . In addition, the chamber 538 has an outlet 548 . A nozzle (not shown) is provided at the outlet 548 that provides pressure buildup in the chamber 538 in response to pressure flow through the nozzle.
An outer sleeve 590 is formed around an outer portion of the cementing tool 500 below the sealing element 534 . The outer sleeve 590 is formed of a stretchable material, such as rubber or other stretchable material, to facilitate the retrieval of the cementing tool 500 after the cement layer around the cementing tool 500 hardens.
In operation, the cementing tool 500 is attached to a work string, with the cementing tool 500 lowered to a position such that the locking keys 502 are aligned with the landing profiles 102 b of the casing assembly 200 , as shown in FIG. 10 A. Next, as shown in FIG. 10B, the cementing tool 500 is actuated to its anchoring position, where the control mandrel 512 is moved downwardly a predetermined distance to push the sleeve 514 and the anchoring mandrel 509 downwardly by the same distance. This causes the enlarged portions 518 a and 518 b of the anchoring mandrel 509 to engage the locking keys 502 so that the locking keys are locked against the landing profiles 102 b of the casing assembly 200 . Also, downward movement of the sleeve 514 and the anchoring mandrel 509 causes the radial ports 544 and 546 to be aligned with inlets of the chambers 536 and 538 , respectively. The downward movement of the sleeve 514 also causes the valve member 524 to move downwardly, closing the ports 526 to prevent communication of fluid between the inner bore 522 and the annular region 549 .
The downward movement of the anchoring mandrel 509 is stopped when a stop ring 558 (biased radially inwardly) engages a groove 556 in the outer surface of the anchoring mandrel 509 (FIG. 11 C), and when a stop ring 560 engages a groove 562 in the outer surface of the anchoring mandrel 509 . Note that the distance between the initial positions of the groove 556 and stop ring 558 and between the initial positions of the groove 562 and stop ring 560 are the same.
Next, fluid is pumped down the work string and into the inner bore 522 of the cementing tool 500 to communicate fluid to chambers 536 and 538 . This causes pressure to build up in the chambers 536 and 538 , which in turn causes creation of a differential pressure between the chambers 536 and 540 and between chambers 538 and 542 , which shears the shearing mechanisms 580 and 582 and pushes respective setting pistons 528 and 530 downwardly to set the sealing elements 532 and 534 , respectively.
Setting of the sealing elements 532 and 534 are shown in FIG. 10 C. Once the sealing elements 532 and 534 are set against the inner wall of the casing assembly 200 , the annular region above the sealing element 532 is isolated from the annular region below the lower sealing element 534 .
After being set, the sealing elements are tested to ensure that there are no leaks. By using two sealing elements 532 , 534 , fluid under pressure communicated through the workstring and into the inner bore of the cementing tool 500 is communicated to an annular space outside the cementing tool 500 between the sealing elements 532 , 534 (now set as shown in FIG. 10 C). The fluid under pressure is communicated through the ports 546 , into the chamber 538 , and out of the chamber 538 into the annular space between the sealing elements 532 , 534 . Any leaks around the sealing elements 532 , 534 can be detected at the well surface.
Next, as shown in FIG. 10D, the cementing tool 500 is actuated to its cementing position. This is performed by pulling the control mandrel 512 upwardly. Note that the control mandrel 512 can be moved upwardly without causing a corresponding movement of the anchoring mandrel 509 . However, since the control mandrel 512 is connected to the sleeve 514 , upward movement of the control mandrel 512 causes a corresponding movement of the sleeve 514 by the same distance. The upward movement of the sleeve 514 causes the valve member 524 to move to its open position so that radial ports 526 are allowed to communicate fluid between the inner bore 522 of the cementing tool 500 and the annular region 549 . Thus, cement slurry pumped down the work string and into the inner bore 522 is communicated through the radial ports 526 to the annular region 549 and chamber 550 , which in turn is communicated out of the port 551 of the cementing tool 500 into the lateral legs of the casing junction assembly 100 .
As shown in FIG. 10E, in accordance with one embodiment, a plug 554 (in the form of a dart) is provided ahead of cement slurry 556 . The dart 554 has an inner bore 558 through which fluid can communicate. Initially, a rupture disk 560 is provided in the bore 558 of the dart 554 . Once the dart 554 lands in a profile provided by the valve member 524 , the pressure generated by the cement slurry 556 causes the rupture disk 560 to rupture, thereby allowing the cement slurry to flow through the dart 554 and out through radial ports 526 . As shown in FIG. 10F, a second plug 562 is run behind the predetermined volume of the cement slurry, with displacement fluid provided behind the second dart 562 . Once the second dart 562 lands on the first dart 554 , further movement of the cement slurry is stopped. Although not shown, the cement actually flows to the annular space outside the junction assembly to cement the casing assembly to the wellbore.
The valve member 524 is then moved upwardly to close the radial ports 526 , as shown in FIG. 10 G. This is performed by lifting the control mandrel 512 a predetermined distance. By applying a sufficiently large upward force, the shear screws 516 (FIG. 11A) are sheared to allow the control mandrel 512 to be disconnected from the cementing tool 500 , as shown in FIG. 10 H. Next, a retrieving tool is lowered into the wellbore, with a retrieving element 570 provided at the lower end of the retrieving tool, as shown in FIG. 10 I. The retrieving element 570 engages the retrieving profile 510 of the retrieving mandrel 508 .
Once the cement has cured after a predetermined time period, a block 592 of cement hardens around the outer surface of a lower portion of the cementing tool 500 below the sealing element 534 . The retrieving tool is then lifted to unset the sealing elements 532 and 534 . As the retrieving tool is lifted, the retrieving mandrel 508 and anchoring mandrel 509 are moved upwardly so that the anchoring mandrel 509 is disengaged from the locking keys 502 . Also note that the stop rings 558 and 560 (FIG. 11C) are engaged in corresponding grooves 556 and 562 of the anchoring mandrel 509 at this time. As a result, upward movement of the anchoring mandrel 509 causes a corresponding upward movement of unsetting members 572 and 574 . The unsetting members 572 and 574 have respective shoulders 566 and 570 (FIG. 11C) that are configured to engage protruding portions 564 and 568 , respectively, of setting pistons 528 and 530 . Thus, upward movement of the unsetting members 572 and 574 causes a corresponding upward movement of the setting pistons 528 and 530 . This allows the sealing elements 532 and 534 to unset.
After disengagement of the locking keys 502 and unsetting of the sealing elements 532 and 534 , further upward movement causes the cementing tool 500 to be filled. This unlocks the locking keys 502 . The outer sleeve 590 is stretched to detach or unbond the sleeve 590 from the cement block 592 . This enables easier lifting of the cementing tool 500 out of the cement block 582 . The stretching of the sleeve 590 is illustrated in FIGS. 13A-13B.
Some embodiments of the invention may provide one or more of the following advantages over the prior art. A retrievable cementing tool, in some embodiments, can be used to selectively cement around objects or volumes in a casing assembly to avoid the accumulation of cement around the object or in the volume during cementing operations. A casing assembly including a casing junction assembly can be cemented in a wellbore such that clean up at the junction assembly is minimized. A cementing tool is configured to match closely with the internal geometry of a casing junction assembly, which includes one or more bypass devices to convey cement through the internal volume of the junction assembly, thereby preventing cement from filling the junction assembly during the cementing process. Some embodiments of the invention may also be used to reduce the number of downhole trips required for clean up of the junction after cementing operations and to preserve the integrity of the casing junction assembly.
Advantageously, some embodiments of the invention also include an anchoring mechanism, which can be mechanically set and/or released from the surface. This allows for anchoring the cementing tool in the casing during cementing operations and then releasing it from the casing after cementing operations are completed without the need for a subsequent milling operation. Further, because the volume around the anchoring mechanism and body of the cementing tool are protected from cement invasion, the operation of the anchoring mechanism is not altered by the cementing operation and the cementing tool, in whole or in part, can be retrieved from the wellbore. It should be understood that the advantages noted above are merely examples of possible advantages associated with one or more embodiments, and are not intended as limitations on the invention.
While the invention has been described with respect to exemplary embodiments, those skilled in the art will appreciate that numerous modifications and variations can be made therefrom without departing from the spirit of the invention.
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An apparatus and method includes releasably engaging a cementing tool in a casing assembly at a junction of plural wellbores. Cementing slurry is pumped through the cementing tool to fill an annular region around the casing assembly. The cementing tool is retrievable without first milling components at the junction. The cementing tool has an anchoring mechanism adapted to engage a landing profile of the casing assembly. Further, the cementing tool has an external seal adapted to seal inside the casing assembly.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a divisional of, and claims priority to co-pending U.S. patent application Ser. No. 13/422,518, filed Mar. 16, 2012, which is a divisional of U.S. patent application Ser. No. 13/109,202, filed May 17, 2011, which is a divisional of U.S. patent application Ser. No. 12/959,655, filed Dec. 3, 2010, which was a divisional of U.S. patent application Ser. No. 11/132,771, filed May 19, 2005, which claimed priority to U.S. Provisional Application Ser. No. 60/572,365, filed May 19, 2004, all of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of managing digital information and more particularly to the field of creating, importing, exporting, and accessing the digital information via networked multimedia systems.
BACKGROUND OF THE INVENTION
[0003] The possibility of downloading a quality movie via the internet, or some other data network, also called video on demand (VoD), using current broadband connections such as cable or DSL, has been simplified by the recent introduction of the H.264 (also known as MPEG-4 AVC) and Microsoft Windows Media Video 9 (WMV9) codecs. However, the issue of content protection (for the content being downloaded from the content provider) has been a major obstacle to allowing consumers to rent or purchase digital video disk (DVD) quality video via the internet, or some other data network. Thus, a system is needed which will provide protection for the content downloaded while, at the same time, will allow ease of use and convenience for the consumer.
[0004] One of the issues looming on the horizon is the potential use of a “broadcast flag” to protect broadcast digital TV content from being freely distributed to unauthorized parties. However, the “fair use” doctrine allows the consumer to record and reuse content which they own or receive. Using this criterion, a system could allow a user to transfer authorized content anywhere within the system network, including via a secure connection on the internet, for usage at the user's convenience.
[0005] Another important development has been the ability to record an incoming video stream in digitized form onto a mass storage device such as a hard disk drive, and playback that recorded video as desired by the user. This functionality has become known as a digital video recorder (DVR) or personal video recorder (PVR) and is viewed as a superior alternative to conventional video tape recorders for capture and subsequent playback of programming content. The DVR is located within the consumer's premises, and it typically may be used by two or more users.
[0006] Televisions have become so prevalent in the United States, that the typical household may have two or more television sets. Each television set requires its own DVR, if the consumer wishes to have access to the enhanced functionality. However, because DVRs can be expensive, users may be hesitant to purchase additional DVRs. These DVRs are typically configured as standalone units with limited ability to network or interconnect with other DVRs at the consumer's premises. In the cases where networking is available, the setup can be cumbersome and require considerable technical expertise and time to accomplish.
[0007] The current multimedia networking options are rather sparse and, for the most part, are PC centric and/or limited in the scope of options which they offer the user. Many multimedia products typically provide limited access to multimedia services and do not easily integrate with products providing different multimedia services or from different vendors. Some potential multimedia products such as digital cameras, video games, telephony and internet browsing have had limited adoption into multimedia systems. The ideal multimedia system would be based upon a distributed architecture and would appear as transparent as possible to the consumer.
[0008] The conversion to wireless communication will simplify the operation of and vastly increase the flexibility of multimedia networks. Upcoming wireless protocols such as IEEE 802.16, IEEE 802.11n, ultra broadband, and ultra wideband will advance this initiative tremendously. With these changes, the possibility of receiving and enjoying the maximum multimedia experience, even in a mobile environment, becomes much more attainable.
[0009] Therefore, a need exists for systems and methods that easily download quality video/audio and other content via the internet, or other data network, that have reliable and flexible content protection, that incorporate DVRs and that ease the use of multimedia networks. Specifically, there exists a need for systems and methods which allow multiple users operating discrete DVRs, or multimedia components, within a premise or vehicle to have access to quality video/audio content via the internet, or some other data network, received by and/or stored in another DVR or storage device. There also exists a need to provide a scaled down access client which can access all system content but at the same time be relatively inexpensive. A system is also needed which allows the content provider to have an interactive relationship with the user network to determine the license status of all content provided by that provider located on the network. An additional need is the ability to easily move content to a portable multimedia device or to a valid system device via the Internet, or other data network, for remote usage at the convenience of the consumer.
SUMMARY OF THE INVENTION
[0010] The invention provides a multimedia networking system. The invention utilizes various multimedia components networked together using either wired or wireless networking methods and protocols. This network also connects to the internet for retrieval and sharing of content. The system allows for parts of individual components to be shared with other components throughout the system to optimize the utilization of various components. The invention allows for the importation of content from an external content provider via the internet. This provides the opportunity for the user to download high quality movies, music, video games or other content for rental and purchase, through an easy and convenient process. This method also allows considerable flexibility for the content provider in the way the content is distributed and managed. The entire process is automated and very easy for the user to accomplish from any component in the system.
[0011] The invention allows the system to optimize the handling of content and more easily recover from the failure of system components. The system chooses the most efficient location and handling method for incoming and internally created content depending upon several factors including, but not limited to, processor utilization rate, processor speed, hard drive memory space available, fragmentation of data on hard drive, speed of hard drive data access, scheduled recording, quality of network connection and user preferences. Another important capability is being able to move content to different locations, so it is still available to users, when a component is being removed from the system. Another example of the system flexibility is the ability of the system to use any available tuner to view or record a program. This allows an opportunity to record more programs simultaneously and also allows more efficient use of available TV tuners.
[0012] The invention allows the access to the multimedia network to become virtually transparent to the user, whether within the confines where the main network resides or at a remote location connected via the internet, or some other data network. The user can freely import, create, and share content within the network.
[0013] The invention accepts various types of multimedia content such as analog video, analog audio, digital video and analog video. Some of these arrive in the form of TV input and may come in several varieties such as the analog NTSC or PAL broadcasts. Analog TV streams are converted to a H.264, WMV9, or MPEG2 formatted data stream, for efficient digital signal handling.
[0014] The system also accepts, digital TV forms such as Digital Satellite System (DSS), Digital Broadcast Services (DBS), or Advanced Television Standards Committee (ATSC). Another source is the playback of a DVD from a valid system device or streamed from an external DVD player.
[0015] The invention allows a digital camera to be connected to the system and then have the digital video from that digital camera stored within the system or streamed to any point in the system. The invention allows VoIP telephony using packet switching technology. The system can accept VoIP phone calls, accept messages, and give voice mail. The invention allows the importation and usage of video games. The games can be played by the use of emulation software or a hardware interface. The invention allows the user to connect the output from a radio tuner into the system which then allows the audio from that radio tuner to be streamed throughout the network. The radio tuner can also be adjusted remotely from anywhere in the system if it is type designed as system component.
[0016] The invention allows the use of an RFID tag to be used to automatically log the user into system via the use of an infrared (“IR”) or radio frequency (“RF”) remote control. The RFID tag referenced by the system for the user can be updated by the user if the user changes the RFID tag he or she is using. This change may be useful for security or if the original tag is lost or damaged.
[0017] The invention allows the user to control functions of the system from any component linked to the network and properly designated to access the network. These control functions may include importation of content, access to content, and handling of content. Among the handling options are the typical options available when viewing a digital video disk (DVD) such as fast forward, rewind, play, pause, fast/slow forward play and fast/slow reverse play.
[0018] It should be emphasized that the embodiments of the invention described above are merely possible examples, among others, of the implementations, setting forth a clear understanding of the principles of the invention. Other details and advantages of the invention will become apparent from the following detailed description in combination with the accompanying figures illustrating the principles and operation of the invention.
[0019] Many variations and modifications may be made to the above described embodiments of the invention without departing substantially from the principles of the invention. All such modifications and variations are intended to be included herein within the scope of the disclosure and invention and protected. In addition, the scope of the invention includes embodying the functionality of the preferred embodiments of the invention in logic embodied in hardware and/or software configured mediums.
ADVANTAGES OF THE PRESENT INVENTION
[0020] 1. The system comprises at least one multimedia server or multimedia storage server.
2. The system may have multiple multimedia servers.
3. The system may have multiple local multimedia clients.
4. The system may have multiple remote multimedia clients.
5. The system may have multiple multimedia storage servers.
6. The system may have multiple DVD/CD player/recorders.
7. The system may have multiple radio players.
8. The system may have multiple digital cameras.
9. The system may have multiple video game players.
10. The system may have multiple telephony transceivers.
11. Content may be generated within the system or received from an external source.
12. The system content may contain, but is not limited to, video data, audio data, digital images, video game software, and system data.
13. The system may accept content from non-system sources such as, but not limited to, digital camcorder, analog camcorder, digital camera, VCR, MP3 player, PDA, and/or a computer.
14. The system may accept local data input using protocols such as, but not limited to, Universal Serial Bus (USB) and Firewire.
15. The system may record programs from a television (TV) signal input for viewing at some future time.
16. The system may have a programming program guide to allow for easy selection of programs to be recorded.
17. All system components may share a single program guide via the system network.
18. The system may allow the recording schedule to be updated via the internet or other data network.
19. The system may allow viewing of Internet pages and access to internet page content.
20. The system may allow the use of an e-mail client for access to e-mail via the Internet or some other data network.
21. The system may have a virus protection program installed or available.
22. The system may provide voice over internet protocol (VoIP) or a similar type of telephony.
23. The system may automatically notify a user when a telephone call is received via the system.
24. The user may use the VoIP capabilities without the loss of access to any of other system functionality.
25. The system may automatically answer a phone call, received via the system, and accept voice mail.
26. The system may contain a system clock and a display clock.
27. The system clock may be automatically adjusted via the internet, or some other data network.
28. The system may allow user to adjust the display clock.
29. The display clock may be synchronized with the system clock at the command of the system or when display clock synchronization is done via the internet or some other data network.
30. The system may block usage of protected content if the system clock has been reset, by events such as system failure or programmatic adjustment, without connection to the internet, or some other data network, for time resynchronization of the system clock.
31. External content may be received via various transmission sources such as, but not limited to, RF sources like IEEE 802.16, ultra broadband, satellite, 3G, GPRS or TV antenna and terrestrial sources like cable or DSL (digital subscriber line).
32. The system may interact with a protected content provider Internet web server, or a comparable device, to test the connection speed and report to the user the estimated download time for the requested content, before the user has to choose to begin the download process.
33. The system may interact with the protected content provider Internet web server, or a comparable device, to automatically download content.
34. The system may interact with the protected content provider internet web server, or a comparable device, to automatically resume download when an interruption occurs.
35. The system may interact with the protected content provider Internet web server, or a comparable device, to adjust the time period for which the content license was originally granted.
36. The system may interact with the protected content provider internet web server, or a comparable device, to determine the license status of content previously supplied by that content provider.
37. The system may interact with the protected content provider internet web server, or a comparable device, to verify that the system device receiving content is a valid device type.
38. The system may interact with the protected content provider internet web server, or a comparable device, to update data within the software or hardware of the system, which may be used in a security algorithm for access to the content of that content provider.
39. The system may interact with the protected content provider internet web server, or a comparable device, to a renew content license without downloading the content again.
40. The system may interact with the protected content provider internet web server, or a comparable device, to limit the number of times protected content can be viewed.
41. The system may require both a valid device type and a valid content license to grant access to content for usage.
42. Content may be encrypted and/or locked and may allow decryption and/or unlocking, for use, when a correct security algorithm is used.
43. A security algorithm and/or data used to decrypt and/or unlock protected content may be embedded in the hardware of the system.
44. The system may use security protocols such as, but not limited to, VPN (virtual private network), WPA (WiFi Protected Access) and/or PKI (public key infrastructure).
45. When new system components are added, the system may automatically configure the new components in a fashion similar to “plug-and-play” and may require the user to login via the prompt on the new device display or to accept the new device via the prompt on the primary multimedia server display or the designated display for the multimedia storage server.
46. The system components communicate via wired protocols such as, but not limited to, ethernet and/or wireless protocols such as, but not limited to, IEEE 802.11, Bluetooth, or ultra wideband.
47. The system may comprise multiple multimedia servers, wherein one server is designated as the primary multimedia server.
48. The system may comprise additional multimedia servers, which can be considered secondary multimedia servers.
49. All secondary multimedia servers and multimedia storage servers may contain some data, which is duplicated from the primary multimedia server periodically, to allow the secondary multimedia server, or multimedia storage server, to be automatically reassigned as the system controller, if the original primary multimedia server is unexpectedly removed from the system.
50. If the primary multimedia server is removed from the system unexpectedly, the system may automatically reassign a secondary multimedia server as the new primary multimedia server, if a secondary multimedia server is available. The multimedia storage server can take system control, if a secondary multimedia server is not available.
51. The user may request removal of a multimedia server or a multimedia storage server from the system.
52. When requesting removal of a multimedia server or a multimedia storage server from the system, the system may allow transfer of content before removal from the system.
53. When requesting removal of the primary multimedia server, the system may verify the availability of and then assign system control to a new primary multimedia server or multimedia storage server.
54. The system may allow transfer of content within the system at any time, by the system user which owns content.
55. Remote multimedia clients may be different types and may contain video/audio, and/or audio and/or other data.
56. Remote multimedia clients may be detached from system for remote use of content.
57. Detached remote multimedia clients may allow unlimited use of unprotected content and usage of protected content for the time specified by and according to the guidelines specified by the content provider.
58. The remote multimedia client may prohibit access to protected content if the system clock is reset by events such as system failure or programmatic adjustment.
59. When it is reconnected to the system, the remote multimedia client may update the license status of all protected content which it contains, based upon information about the license status of the same protected content located in permanent storage locations within the system.
60. The system may communicate with and service requests from non-system devices, but those devices may have limited access to protected content.
61. The system may allow multiple user accounts to be created.
62. All content may be assigned to a user created account or may be assigned to the system default account.
63. All video content assigned to a system user may be viewed as a single consolidated list, viewed as content per server, sorted chronologically, or sorted using other user determined criteria.
64. The system may store preferences for each user such as, but not limited to, content view, language, or background theme.
[0021] 65. When a request to store content is given, the system may select the most efficient location within the system to store that content based upon various criteria such as, but not limited to, processor utilization rate, processor speed, hard drive memory space available, fragmentation of data on hard drive, speed of hard drive data access, scheduled recording, quality of network connection, and user preferences.
[0000] 66. The system may monitor the fragmentation of hard drive, or other mass storage device, and may prompt the user to conduct data defragmentation when it is determined to be advantageous.
67. The system may automatically schedule defragmentation, with user approval, based upon information such as, but not limited to, upcoming recording sessions, local time of day, typical usage patterns, and memory space available.
68. When scheduling more simultaneous recordings than the number of tuners which exist in the system, the system may prompt the user to approve the action.
69. The system may be able to receive both analog and digital television broadcasts from various sources such as, but not limited to, cable, satellite, and other RF sources.
70. The system may convert all analog television information to a digital format.
71. The system may recognize incoming digital video formats to avoid unnecessary conversion processes.
72. The system may encode and decode video information, as needed, to or from various digital video formats such as, but not limited to, MPEG2 (Motion Picture Experts Group-2), H.264 (also known as MPEG-4 AVC), and Microsoft Windows Media Video 9 (WMV9) depending upon user requests and system needs.
73. The system may store digital information on the hard drive, or appropriate mass storage device, located on a multimedia server, multimedia storage server, or other valid storage device.
74. The system components which receive an external television signal may convert that signal to an appropriate digital format and store the information on a storage media located somewhere within the system.
75. The system components which do not receive an external television signal may receive digital television information from another system device which has a television tuner available.
76. The local multimedia client preferably does not include mass storage space for content. If the local multimedia client does not have mass storage space for content, then the local multimedia client can be connected to the system to gain access to full system capabilities.
77. The local multimedia clients may or may not have a connection to receive a television signal from outside the system.
78. The digital video information, from a system component, which was previously stored, may then be sent to that system component, specified by the system, at the rate specified by the component receiving the information.
79. The multimedia server, the local multimedia client, the remote multimedia client, or the radio player may have multiple tuners.
80. The system may record multiple programs simultaneously by utilizing tuners which are not being utilized for recording at the current time.
81. Picture-in-picture capabilities may be provided by use of a second tuner in a single component or by the use of a tuner in another system component which is not being utilized at the current time.
82. The system may reconfigure protected content into a format which can be copied to permanent media such as, but not limited to, a DVD-R or CD-R, via a valid system device type.
83. The system may allow copying of protected content onto permanent media, such as a DVD-R or CD-R, within the parameters specified by the protected content provider.
84. The system may reconfigure content, for more efficient storage, on a remote multimedia client or may reconfigure unprotected content, for more efficient storage, on a non-system device which is external to the system.
85. Some content exchanged via system communications may be encrypted or modified to protect content.
86. The system may display various television standards such as, but not limited to, National Television Standards Committee (NTSC), PAL, and high definition (HD).
87. The system may display video as either interlaced scanned frames, progressive scanned frames, or other protocols, as desired.
88. The system may handle various audio formats such as, but not limited to, MP3, WAV, and AC3.
89. The system components may be controlled using an IR or RF remote control device.
90. The system may allow the user to use an RFID tag, or a similar device, to identify the user to the system, via the remote control, and automatically log the user into the system, if the user so chooses.
91. The system may allow the user to change the RFID tag, or similar device, at the request of the user.
92. A keyboard, keypad, or other input device may be used for inputting system functions and configurations.
93. The system may use a video game emulator front-end to allow access to video games.
94. Video camera input may be allowed from a system or a non-system device and may contain both audio information and video information.
95. The system may be configured to stream or transfer stored or live content, such as TV, radio, or digital video over the internet, or other data networks.
96. The system may be configured to stream or transfer protected content over the internet, or other data networks, to a valid system device using a secure connection protocol such as, but not limited to, VPN.
97. Recording schedules may be adjusted via the internet, or some other data network, or via a WAP enabled, or with comparable protocol, wireless phone.
98. The system may automatically create a copy of a content file if requests for access are determined to be causing a sufficient conflict in accessing the original content file.
99. The system may monitor status of connection to internet, or other external network, and may notify the user when a download process is interrupted and/or connection has been lost.
100. The system may allow the user, within the system, to reassign ownership of content to another user, within system, with the approval of the new owner.
101. The system may encode information into content which may then be used by system for security algorithms and/or license status information.
102. The system may allow user to exclude a system component from being automatically considered for usage as a tuner and/or data storage location.
103. The system may allow an administrative user account to be created.
104. The system may allow the administrative user to have access to all content, to move content, to make changes to individual user accounts, and/or have the ability to change system wide settings.
105. The system may authenticate the valid system device receiving content via the internet, or other data network, as part of the original system network sending the content.
106. Each system component contains its own hardware and/or software functionality but overall control of the system can be maintained by the primary multimedia server or multimedia storage server.
107. The system may interact with protected content provider internet web server, or a comparable device, to set the time period for which the content license is granted.
108. The system may allow instant messaging on system components with output display device.
109. The system component may allow for the display of two or more sources of video information on an output device.
110. The system may allow control of various system functions and/or content via the internet, or other data network, using a valid system device.
111. The system may monitor and record the number of times content is accessed.
112. The system may interact with protected content provider Internet web server, or a comparable device, to determine the number of times content has been accessed.
113. When requesting removal of the primary multimedia server, the system may allow the user to specify which secondary multimedia server to assign as the new primary multimedia server or may allow user to specify a multimedia storages server as the system controller.
114. The system may use a graphical user interface (GUI) for the components which have a visual media output device.
115. The system components which display video output or receive video, in a form requiring digitization, may have a video coder and/or decoder.
116. The system components which serve as storage devices, such as the multimedia servers and multimedia storage servers may have router capabilities.
117. The system may contain a web server to provide access to send data to and receive data from the Internet.
118. The system may allow data stream to flow from incoming input/output (I/O) to outgoing I/O when user is viewing video or listening to audio in real time.
119. The system may allow usage of different port numbers for input and output of data to and from system devices.
120. In one exemplary embodiment, the multimedia storage server does not comprise a tuner.
121. The system may allow user to query and display the status of protected content.
122. The current status of protected content on the system may be stored in an extensible markup language (XML) file, or a similar format file.
123. Local multimedia clients may have mass storage space sufficient to run the operating system and related software.
124. The DVD/CD player/recorder may be in same enclosure as a multimedia server or multimedia storage server.
125. The content key may contain information which is stored in an XML file, or a similar format file.
126. The system may allow a multimedia storage server as the system controller, even when a multimedia server is available within the system.
127. The system may allow for the periodic generation of a new private key within a system device for purposes of enhanced security.
128. The system may allow for the generation of new private key within a system device using a seed from a random number generator or some other source.
129. The system may allow compilation and storage of content usage history in a file called content usage history file.
130. The system may allow multiple content usage history files to be created by the use of specific criteria, such as usage for daily intervals or weekly intervals or usage for individual system users.
131. The system may allow deletion of selected content usage history from the content usage history file when the appropriate content provider has retrieved that information and given permission for the deletion of the data.
132. The system may allow compilation and storage of the license status of content in a file called content license status file.
133. The system may allow the conversion of all encrypted content keys, content usage history files and content license status files contained within a system device, from an old public key to new public key, when a new private key is generated within that system device.
134. The system may include an additional level of validation for a valid system device logging into system via the internet, or some other data network.
135. The system may allow encryption of live content if needed.
136. The system may incorporate the point-to-multipoint (PMP) wireless protocol to enhance the data distribution within the system.
137. The system may allow streaming content from an external provider to be stored on a storage device for a short period of time during the streaming process to improve the quality of the streaming content.
138. The system may have an interactive program guide, which can search for content from various sources and display the content available in a consolidated format to simplify the choice of programming to view, record, and/or import.
139. The system may allow information to be compiled and stored in the content license status file, relating to the network identification, user identification, and device identification to which each piece of content is assigned.
140. The system may include a web server which can be used to provide secure access to the system, from a valid system device or non-system device, via the internet.
141. The system may include the use of an additional means of user identification, such hardware containing a security certificate, for a user accessing the system via the internet, or other data network.
142. Each system device may include an operating system but overall system control is given to a designated primary multimedia server or multimedia storage server.
143. Each system device may include multiple processors to improve operating efficiency.
144. The system may allow flow of data within system to reduce contention and improve the efficiency of data exchange and data usage.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0022] FIG. 1 is a block diagram representation of a multimedia system according to an illustrative form of the present invention showing the content flow between components within the system.
[0023] FIG. 2 is a block diagram showing flow between components within the system of FIG. 1 and components external to the system.
[0024] FIG. 3 is a block diagram showing the handling of input/output functions within the system of FIG. 1 .
[0025] FIGS. 4A and 4B are block diagrams showing the flow of live and delayed content in the system of FIG. 1 .
[0026] FIG. 5 is a block diagram showing use of a RFID tag to verify user identification in accordance with an exemplary embodiment of the present invention.
[0027] FIG. 6 is a block diagram showing use dual data ports for sending and receiving data in accordance with an exemplary embodiment of the present invention.
[0028] FIG. 7 is a flow chart showing the process for a request for content access in accordance with an exemplary embodiment of the present invention.
[0029] FIG. 8 is a flow chart showing the process for a request for a record in accordance with an exemplary embodiment of the present invention.
[0030] FIG. 9 is a flow chart showing the process for a request to find a television tuner in accordance with an exemplary embodiment of the present invention.
[0031] FIGS. 10A and 10B is a flow chart showing the process for a request for server removal in accordance with an exemplary embodiment of the present invention.
[0032] FIG. 11 is a flow chart showing the process for a request for transfer of protected content from a provider.
[0033] FIG. 12 is a block diagram showing a request for transfer of protected content from a content provider in accordance with an exemplary embodiment of the present invention.
[0034] FIG. 13 is a flow chart showing the process of a transfer of protected content between system devices.
[0035] FIG. 14 is a block diagram showing a transfer of protected content between system devices in accordance with an exemplary embodiment of the present invention.
[0036] FIG. 15 is a flow chart showing the process for a request for a content license update from a provider in accordance with an exemplary embodiment of the present invention.
[0037] FIG. 16 is a block diagram showing a request for a content license update from a provider in accordance with an exemplary embodiment of the present invention.
[0038] FIGS. 17A and 17B are a flow chart showing the process for a request to create a hard copy of protected content in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Referring now to the drawing figures, in which like reference numbers refer to like parts throughout the several views, preferred forms of the present invention will now be described by way of example embodiments. It is to be understood that the embodiments described and depicted herein are only selected examples of the many and various forms that the present invention may take, and that these examples are not intended to be exhaustive or limiting of the claimed invention. Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.
[0040] As described herein, the term “content” is used to describe the data and/or files that are imported, exported, and/or managed within the system. Such content can include audio files, video files, and video game programs.
[0041] The present invention is embodied in a networked multimedia system which can import content via the internet, or other data network and create content within, from various sources, such as TV, radio and digital camera. The present invention allows for multiple user accounts, including an administrative account, to be created and allows content to be assigned to specific users. An administrative account can control all system preferences and move or reassign ownership of any content. For example, content assigned to a specific user is not visible to other users, but any user can reassign content ownership, with the approval of the recipient.
[0042] The present invention allows the content provider to access and update the status of content, located within the system, which the provider of the content has previously supplied.
[0043] The present invention allows for transmission of data between the various system devices and also with other non-system devices. Transmission media include coaxial cables, copper wire, and fiber optics. Transmission media can also take the form of acoustic or light waves, such as those generated during radio wave and infrared data communications.
[0044] FIG. 1 is a block diagram of a system 100 showing the pathways for sending and receiving content within the system 100 . The system 100 comprises a plurality of system components. Each system component preferably includes a processor unit and a software program to control that component, or other components as desired. All data within the system is preferably in digital form or converted into digital form. Data is exchanged in the form of data packets and/or frames, depending upon the communication protocol being used.
[0045] The system 100 includes a primary multimedia server 101 , a secondary multimedia server 103 , a multimedia storage server 102 , a remote multimedia client 104 , and a DVD/CD player/recorder 105 . Each of these devices preferably has some type of storage media such as, but not limited to, a hard disk drive, DVD-R/CD-R, or DVD-RAM. The system 100 also includes a local multimedia client 106 , which preferably does not have content storage media but can include memory for program usage.
[0046] Preferably, the remote multimedia client 104 is a portable device that can be detached from the system 100 . The detached remote multimedia client 104 allows access to all content stored on it, including protected content such as DVD quality movies, which have been imported via the internet from a remote location. Thus, content stored on the remote multimedia client 104 can then be accessed by the user at his or her convenience and at his or her preferred place of viewing and/or listening.
[0047] In an exemplary embodiment, the primary multimedia server 101 , the secondary multimedia server 103 , the remote multimedia client 104 , and the local multimedia client 106 each can have the ability to send and receive TV signals. The primary multimedia server 101 , the secondary multimedia server 103 , the remote multimedia client 104 , and the local multimedia client 106 can each include at least one encoder/decoder capable of working with at least one TV format (such as NTSC, PAL, and HD). Having multiple encoders is less important than having multiple decoders because a single encoder, which is efficient and compatible with the system 100 , can be used while achieving one of the goals of the present invention. Preferably, each decoder is operable to handle multiple codecs because content may come from different sources such as DVDs, movie downloads, or internally generated content. Codecs can be hardware or software based. Hardware based codecs, such as a dedicated digital signal processor (DSP) or field programmable gate arrays (FPGA), may be faster and require less processor intervention but may offer less flexibility on which codecs are available. The flexibility of the software based codecs are a high priority but must be balanced against the cost and complexity of the processor which may be desired. Alternatively, multiple decoders each can operate to handle a single codec, or a few codecs can be incorporated into each of the primary multimedia server 101 , the secondary multimedia server 103 , the remote multimedia client 104 , and the local multimedia client 106 .
[0048] Preferably, either the primary multimedia server 101 or the multimedia storage server 102 maintains primary control over the other system components. This control can be accomplished by running a software program on the primary multimedia server 101 (if the primary server is to maintain control) or on the multimedia storage server 102 (if the multimedia storage server 102 is to maintain control). The server in control can assign control to other system components for specific tasks, such as streaming data or moving data files. Preferably, the secondary multimedia server 103 is running a similar core program to the program running on the control server but the secondary multimedia server program relies upon the control server to direct which operations and functions for which the secondary multimedia server 103 is responsible. The secondary multimedia server 103 can also contain some data and files duplicated from the control server which allows the secondary multimedia server 103 to become the primary multimedia server 101 , if the primary multimedia server (if control server) or the multimedia storage server 102 (if control server) is unexpectedly removed from the system.
[0049] The system 100 can have various analog or digital devices connected to it. Such devices can include, but are not limited to, a digital camera 107 , a radio tuner 108 , a video game player 109 , and a telephony transceiver 110 .
[0050] The digital camera 107 can be connected to the system 100 and can send output (i.e., digital pictures or digital video) to the primary multimedia server 101 , the secondary multimedia server 103 , or the multimedia storage server 102 . The digital images from the camera 107 can then be stored in any of the server's storage media and sent to another system component or a non-system device, such as a web page accessed via the internet.
[0051] The radio tuner 108 can also be connected to the system 100 and can send output to the primary multimedia server 101 , the secondary multimedia server 103 , or the multimedia storage server 102 . The audio data can then be stored in any of the server's storage media and sent to another system component, for example to the media output device of a system component which could be a TV or a headphone output from a remote multimedia player. Then the audio data be stored and sent to yet another system component (such as remote multimedia player, multimedia server or multimedia storage server) or non-system device, such as to a web page accessed via the internet.
[0052] The video game player 109 can be connected to the system 100 and can access game software stored within the system 100 to allow the user to play video games using an emulation interface or a hardware interface. The video game player 109 can download the game software from the system 100 (i.e., a one-way communication) or use the game software which is still stored on another system device (i.e., a two-way communication), depending on the configuration which is most advantageous.
[0053] The telephony transceiver 110 can be connected to the system 100 and can receive VoIP phone calls via software running on the primary multimedia server 101 (if control server) or the multimedia storage server 102 (if control server). The VoIP uses packet switching to send and receive data, which is converted to or converted from an audio conversation. The system can automatically notify user of an incoming phone call and then allows the user to answer the call or accept voice mail from the caller. Preferably, the voice mail greeting is recorded in a digital format. The greeting is then sent in digital format, via the internet, to the caller where it is converted to an analog audio format for the caller to hear. The caller then provides a message in analog audio, which is converted to digital format and sent, via the internet, back to the system for storage. The system accepts and stores the caller's message in a digital form, which can later be accessed by the user.
[0054] FIG. 2 is a block diagram showing the pathways for content sent or received from components external to the system 100 . Typically, there can be two kinds of external components: valid system devices 201 , which can access protected content, and non-valid system devices 202 , which cannot access protected content. The valid system device 201 can be any system device capable of accessing the Internet, or other data network, which is recognized by the system as a valid system device. Exemplary valid system devices 201 include any system any system component shown in FIG. 1 that can provide proper validation credentials to the system. The system 100 can verify that the component is a valid system device 201 by using an algorithm which is located in the software and/or hardware of the component. Preferably the valid system device 201 is capable interacting with the system 100 to access system functionality such as sending content to system, receiving content from the system, and performing system administrative functions. The non-valid system device 202 is a device which can interact with the system to perform only certain functions. Preferably, a non-valid system device can access the internet, but it cannot provide proper validation credentials to the system. Thus, the non-valid system device cannot gain access to protected content. Exemplary non-valid system devices include a cellular phone which can modify the recording schedule, a MP3 player, which can store unprotected content from the system, and a computer, which can store and access unprotected content from the system.
[0055] An external content provider 203 can be connected to the system 100 and can send content to various system components. The external content provider 203 can interact directly with system components to determine and modify the status of content that the provider has supplied. The external content provider 203 can verify that the system component receiving content is a valid system device 201 which assures that the protected content is not available to unauthorized parties or devices. The external content provider 203 can also test the connection speed and report to the user the estimated download time for requested content, before the user chooses to begin the download process. Alternately, the external content provider 203 can automatically download content and automatically resume download when an interruption occurs. Additionally, the external content provider 203 can adjust the time period for which the content license was originally granted, can verify that system device receiving content is valid device type, can update data within the software or hardware of the system 100 , which may be used in a security algorithm for access to the content of that content provider, can renew the content license without downloading the content again, and can limit the number of times protected content can be viewed.
[0056] Preferably, the primary multimedia server 101 (if control server) or the multimedia storage server 102 (if control server) handles all content sent or received from external sources. Alternately, the secondary multimedia server 103 or the multimedia storage server 102 can handle all content sent or received from external sources. Preferably, the primary multimedia server 101 , or multimedia storage server 102 manages the transfer of content and can also transfer control for specific transfer tasks to the secondary multimedia server 103 .
[0057] FIG. 3 depicts a block diagram showing the handling of content which is generated or handled within the system 100 according to an exemplary embodiment. It should be noted that the input and output functionality examples used can be located within any system component. It should also be noted that even though FIG. 3 shows three inputs and four outputs, any number of devices can provide input, as well as any number of output devices can receive output from the system. It should be noted that the primary multimedia server 101 , the secondary multimedia server 103 and the multimedia storage server 102 can have storage devices for storing content generated within the system 100 for any input or output.
[0058] In this exemplary embodiment, the source of input 304 is an analog TV signal. When the primary multimedia server 101 (if control server) or the multimedia storage server 102 (if control server) gives I/O 305 a proper command, the I/O 305 begins sending the output from an encoder 306 to an I/O 307 (which supplies input to the primary multimedia server 101 ) or I/O 308 (which supplies input to the secondary multimedia server 103 ) or I/O 309 (which supplies input to the multimedia storage server 102 ) for storage. The choice of which device will receive the input for storage is determined by the program running on the primary multimedia server 101 or multimedia storage server 102 , based upon a predetermined algorithm.
[0059] The source of input 310 is a digital TV signal. When the primary multimedia server 101 (if control server) or the multimedia storage server 102 (if control server) gives I/O 311 a proper command, the I/O 311 begins sending the signal from input 310 to I/O 307 or I/O 308 or I/O 309 for storage. The choice of which device will receive the input for storage is determined by the program running on the primary multimedia server 101 or multimedia storage server 102 , based upon a predetermined algorithm.
[0060] The source of input 312 is an analog audio signal. When the primary multimedia server 101 (if control server) or the multimedia storage server 102 (if control server) gives I/O 313 a proper command, the I/O 313 begins sending the output from an encoder 314 to I/O 307 or I/O 308 or I/O 309 for storage. The choice of which device will receive the input for storage is determined by the program running on the primary multimedia server 101 or multimedia storage server 102 , based upon a predetermined algorithm.
[0061] The output from output 315 is an analog TV signal. When the primary multimedia server 101 (if control server) or the multimedia storage server 102 (if control server) gives I/O 316 or I/O 317 or I/O 318 the proper command, the I/O 316 or I/O 317 or I/O 318 begins sending the output to the I/O 319 which then forwards the data to the decoder 320 which then sends the decoded TV signal to the TV via output 315 . The choice of which device will be the source of the data is determined by the program running on the primary multimedia server 101 or multimedia storage server 102 , based upon a predetermined algorithm.
[0062] The output from output 321 is a digital TV signal. When the primary multimedia server 101 (if control server) or the multimedia storage server 102 (if control server) gives I/O 316 or I/O 317 or I/O 318 the proper command, the I/O 316 or I/O 317 or I/O 318 begins sending the output to the I/O 322 which then sends the signal to the digital TV via output 321 . The choice of which device will be the source of the data is determined by the program running on the primary multimedia server 101 or multimedia storage server 102 , based upon a predetermined algorithm.
[0063] The output from output 323 is a digital audio signal. When the primary multimedia server 101 (if control server) or the multimedia storage server 102 (if control server) gives I/O 316 or I/O 317 or I/O 318 the proper command, the I/O 316 or I/O 317 or I/O 318 begins sending the output to the I/O 324 , which then sends the signal to the device connected to output 323 . The choice of which device will be the source of the data is determined by the program running on the primary multimedia server 101 or multimedia storage server 102 , based upon a predetermined algorithm.
[0064] The output from output 325 is an analog audio signal. When the primary multimedia server 101 (if control server) or the multimedia storage server 102 (if control server) gives I/O 316 or I/O 317 or I/O 318 the proper command, the I/O 316 or I/O 317 or I/O 318 begins sending the output to the I/O 326 which then forwards the data to the decoder 327 which then sends the decoded audio signal to the device connected to output 325 . The choice of which device will be the source of the data is determined by the program running on the primary multimedia server 101 or multimedia storage server 102 , based upon a predetermined algorithm.
[0065] FIG. 4A depicts a block diagram showing the flow of live content. I/O 401 sends a data stream being generated by a system device (i.e., a valid or non-valid system device), such as a TV tuner, radio tuner or digital camera, to I/O 402 . The I/O 402 determines whether data stream from I/O 401 is live or delayed based upon information from the system software. The system software determines this status based upon whether the user is choosing to delay content or view it live. Preferably, if the content is viewed live, then an identical data stream is sent to storage device 403 , to be saved on a storage media, and to I/O 404 . The data is then sent directly from I/O 404 to I/O 405 . The data is then sent from I/O 405 to the appropriate output device, such as a TV or audio amplifier. Preferably, the I/O 402 and I/O 404 are both parts of the I/O of a system component but are separated in FIGS. 4A and 4B to clarify that the signal source going to I/O 404 can vary depending upon whether the content is being viewed live or delayed.
[0066] FIG. 4B depicts a block diagram showing the flow of delayed content. The flow of content differs from that displayed in FIG. 4A if the system software determines that the user chooses to view the content later in time. In this case, I/O 406 sends a data stream generated by a system device (i.e., a valid or non-valid system device), such as a TV tuner, radio tuner or digital camera, to I/O 407 . Since the content is being delayed, the data stream is sent to storage device 403 , to be saved on a storage media. The delayed content, which was previously stored from the data stream, is then sent to I/O 408 in the direction (forward or reverse) and frame rate specified by the user while the storage device continues to save the live content stream if there is still a live stream. The delayed content is then sent from I/O 408 to I/O 409 . The delayed data is then sent from I/O 409 to the appropriate output device, such as a TV or audio amplifier.
[0067] If the user chooses to return to the live content viewing option, then the data flow path will revert to the direct path from I/O 402 to I/O 404 , as described earlier in the live content flow method.
[0068] FIG. 5 depicts a block diagram representation of user authentication using an RFID tag 501 . Preferably, the RFID tag 501 automates a login via a remote control 502 . The RFID tag 501 emits a signal which is detected by the remote control 502 . The remote control 502 receives the login information, in the signal from the RFID tag 501 , and transmits that information to the system component 503 , which can be the remote control. The system component 503 then uses that information to authenticate the user and log the user into the system 100 or perform whatever predetermined functions are specified by the user. Alternatively, other forms of user authentication, including the use of user identification and a password, biometric login methods or any combination of these measures, can also be used.
[0069] FIG. 6 shows the use of multiple ports for handling of input/output. The I/O 601 sends data on IP1:Port1 (IP address 1:Port 1—an example could be 1111.1111.1111.0001:0001), receives data on IP1:Port2 and handles all system control communications on IP1:Port3. The I/O 602 is the I/O section of the system storage device 603 . The I/O 602 uses IP2:Port2 to receive data, IP2:Port1 to send data and handles all system control communications on IP2:Port3. The I/O 604 sends data on IP3:Port1, receives data on IP3:Port2 and handles all system control communications on IP3:Port3. Using this configuration throughout the system allows all devices to consider data on port 1 as outgoing data, data on port 2 as incoming data and all data on port 3 as system control. This can help simplify data handling and movement within the system.
[0070] FIG. 7 shows a flowchart representation of a process 700 for requesting access to content. Beginning at step 701 , the user requests access to content, such as via the remote control. At step 702 , the system 100 determines if the content requested is protected content. If the system 100 determines, at step 702 , that the content is not protected, then the system 100 allows access to the content by any valid system device or non-valid system device without restriction at step 703 , and the process 700 ends. If the system 100 determines, at step 702 , that the content is protected, then the system determines at step 704 , if the device type requested is a valid device type.
[0071] If the system 100 determines that device type is not a valid device type, then at step 705 , the system displays a message to the user that tells the user that device is not valid. Thus, access is denied at step 706 , and the process 700 ends. If the system 100 determines that the device is a valid device, then the process 700 proceeds to step 707 .
[0072] At step 707 , the system 100 determines whether the license for the content is valid. If at step 707 , the system 100 determines that the license is valid, then full access to the content is granted on the system device at step 708 . If, however, at step 707 , the system 100 determines that the license is not valid, then the process 700 proceeds to step 709 and displays a message to the user asking the user to choose whether to renew the license. The process 700 proceeds to step 710 , where it determines whether input has been received to update the status of the license. If input has been received to update the status of the license, then the system 100 updates the license at step 711 , and loops back to step 701 . If, however, the system 100 , at step 710 , determines that no input has been received to update the license (or if input has been received not to update the license), then the system 100 displays a message at step 713 to the user stating that the license is not valid and denies access to the content at step 714 . The process 700 then ends.
[0073] FIG. 8 shows a flowchart representation of logic 800 used in determining which tuner should be used for a recording process. Beginning at step 801 , a request to record is received from a system component. At step 802 , the system 100 determines whether the tuner of the system component requesting the recording is available. If the tuner is available (i.e., a tuner is available when it is not being used by the system for another purpose, such as viewing or recording) at that time, the tuner is selected to record at step 803 , and the recording of the content begins at step 804 . If, however, the system 100 determines that the tuner of the system component requesting the recording is not available, then the system determines whether an unused tuner is available elsewhere in the system at step 805 . If another tuner is available, then the system selects the available tuner for recording at step 806 . The recording of the content begins at step 807 .
[0074] If, however, the system 100 determines that an unused tuner is not available elsewhere in the system, the system then determines if the system component requesting the recording is in fact recording other content at step 808 . If the system component is not recording other content, then the system 100 selects the system component's tuner for recording at step 809 . The recording of the content then begins at step 810 . If the system component is in fact recording other content, the system then determines that step 811 whether there is any tuner in the system that is not in fact recording content. If no other tuner is available, the system records an error at step 812 , and the recording process 800 is aborted. If the system 100 determines that a tuner within the system is not recording, then the system selects that tuner for recording at step 813 . From there, the process 800 for recording begins at 814 .
[0075] FIG. 9 shows a flowchart representation of logic 900 used in determining which tuner should be used for content viewing. Beginning at step 901 , the system receives a request from the user for program viewing. As step 902 , the system 100 determines whether the system component requesting the viewing has its own tuner. If the system 100 determines that the system component does not have its own tuner, the system then determines, as step 903 , whether there is an unused tuner available within the system. If the system 100 determines that there is an unused tuner available, then the system selects the unused tuner for program viewing at step 904 , and the system begins using that tuner at step 905 . If at step 903 , the system determines that an unused tuner is not available, the system displays a message to the user telling the user that no tuner is available at step 906 . The system 100 will then wait for the user to input the next command at 907 , and the process 900 ends.
[0076] If at step 902 the system 100 determines that the requesting system component does have its own tuner, the system determines whether that specific tuner is currently recording content at 908 . If the tuner is not recording content, the system 100 selects the requesting component's tuner for program viewing at step 909 , and the system begins using the tuner at step 910 . If, however, that requesting component's tuner is currently recording other content, then the system 100 , at step 911 , determines whether there is an available tuner elsewhere in the system. If there is not an available tuner within the system, the system 100 displays a message to the user telling the user that no tuner is available at step 912 . The system will then wait for the user to input the next command at 913 , and the process 900 ends. If, however, there is an available tuner within the system, the system 100 selects the available tuner for program viewing at step 914 , and the system begins using the tuner at step 915 . The process 900 then ends.
[0077] FIGS. 10A and 10B show a flowchart representation of logic 1000 used to request removal of a multimedia server 101 or 103 . Beginning at step 1001 , a request is received to remove a multimedia server (i.e., 101 or 103 ). At step 1002 , the system 100 determines whether content will be removed from the server. If content is to be removed, the system at step 1003 determines whether there are other multimedia servers within the system. If another multimedia server is available, then the system 100 , at step 1004 , selects a new primary multimedia server from among the other multimedia servers within the system. The content on the original primary multimedia server is then moved (and/or copied) to the new primary multimedia server at step 1005 . The system 100 then displays a message telling the user that the original multimedia server can be removed at step 1006 . The logic 1000 then ends, and the user can physically remove the original multimedia server.
[0078] If, however, at step 1003 another multimedia server is not available, then the system determines whether a multimedia storage server is available at step 1007 . If no multimedia storage server is available, the system displays a message telling the user that no other server is available at step 1008 . The system will then wait for the user to input the next command, and the logic for requesting removal of the multimedia server ends.
[0079] If at step 1007 , the system determines that a multimedia storage server is available, then the system 100 , at step 1010 , selects the multimedia storage server as the system controller. Then, the content located on the original primary multimedia server is copied and/or moved to the multimedia storage server at step 1011 . The content can be moved or copied, as determined by the user. The system can also make a copy automatically if the original is being requested to the extent that it is causing degradation of the quality of content being delivered to the users. At step 1012 , the system 100 displays a message to the user telling the user that the multimedia system can be removed. The logic 1000 for requesting removal of the multimedia server ends.
[0080] If, referring back to step 1002 , the system determines that content is not to be removed from the multimedia server, then the system 100 proceeds to step 1020 (as depicted in FIG. 10B ). At step 1020 , the system determines whether the primary multimedia server is the server to be removed. If the system 100 determines that the server to be removed is not the primary multimedia server, then the system as step 1021 displays a message to the user telling the user that the server can be removed. The logic 1000 for removing a server then ends, and the user can then physically remove the server.
[0081] If, however, the system 100 determines the primary multimedia server is the server to be removed, then the system at step 1022 determines if there is another multimedia server within the system. If there is another multimedia server in the system, then the system 100 selects a new primary multimedia server from among the other multimedia servers in the system at step 1023 . Then, the system 100 displays a message to the user telling the user that the multimedia server can now be removed at step 1024 . The logic 1000 for removing the server then ends, and the user can physically remove the server.
[0082] If, on the other hand, another multimedia server is not within the system, then the system determines at step 1025 whether a multimedia storage server is available. If no multimedia storage server is available, then the system displays a message to the user telling the user that no other server is available at step 1026 . The system will then wait for the next command, and the logic 1000 for removing the server ends. If the system determines a multimedia storage server is available, the system selects the multimedia storage server as the system controller at step 1028 . Next, the system 100 displays a message to the user telling the user that the multimedia server can now be removed. Then, the logic 1000 for removing a server then ends, and the user can physically remove the server.
[0083] FIG. 11 shows a flowchart representation of a process 1100 of requesting protected content from the external content provider 203 . Beginning at step 1101 the system 100 requests protected content from the external content provider. Next, the system 100 receives a request from the content provider for verification of a valid device type at step 1102 . The system 100 , at step 1103 determines whether the device type is valid. If the device type is not valid, then the system 100 , at step 1104 , displays a message on the system to the user stating that the content cannot be transferred. Thus, the content is not transferred, and the process 1100 ends.
[0084] If, however, the system determines that the device type is valid, then the system receives a request from the external content provider for the status of other protected content sent to the system at step 1105 . The system 100 then sends status information to the content provider at step 1106 . At step 1107 , the system 100 receives instruction from the content provider. Based on the instruction received from the content provider, the system determines if it is eligible to receive additional content at step 1107 . If the system 100 is eligible to receive additional content, then the system receives a request from the content provider for the public key from the system device at step 1109 . Next at step 1110 , the system device sends its public key to the content provider so that the content key sent from the content provider can be encrypted with the system device's public key. At step 1111 , the system 100 receives the content key that is encrypted with the system device's public key and the content, which is encrypted using the content key. The process 1100 of requesting protected content from the content provider ends.
[0085] If, however, at step 1108 the system determines it is not eligible to receive additional content, then the system displays a message asking the user if he or she chooses to update the content license at step 1112 . The system then determines at step 1113 whether it has received an input to update the content license. If the system does receive an input to update the content license, the content license is updated at step 1114 , and the process 1100 can loop back to step 1101 , where the system, now with the updated content license, requests protected content from the content provider. If no input is received or if an input is received not to update the content license, then the process 1100 of requesting protected content from the content provider ends.
[0086] With this capability, the user and the content provider have an interactive relationship that allows considerable flexibility and ease of use for the user. An example of this process can occur when a user chooses to download a new movie to the system. The content provider can check the total quantity of movies that the user has in use by mail order rental, in-store rental, and downloaded rental. Thus, this embodiment is an improvement upon the prior art because it allows the content provider the capability to check the total quantity of movies, music, video games or other content which the user has in use by mail order rental, in-store rental, or downloaded rental as compared to just the status of the mail order items. This allows instant return of items by the system user which then allows checkout of additional content.
[0087] It is important to note here that the content key, referred to throughout this document is the key used to encrypt the protected content and is then used to decrypt the content for usage. Two additional files are also used by the system for storing relevant information for future use by the system or content provider. One such file is the content license status file, which includes various types of information relating to how the content may be used such as name of content provider, content description, license information, time restraints on usage, number of allowed usages, quantity of copies allowed, and the network where content stored. Another such file is the content usage history file, which contains data related to content usage history.
[0088] FIG. 12 depicts a block diagram representation of the relationship between the system 100 and the external content provider 203 when the system requests protected content from the content provider. The system 100 requests protected content from the content provider 203 at step 1202 . Once the content provider 203 receives this request, the content provider requests verification of a valid device type from the system 100 at step 1204 . Upon receiving this information, the system 100 sends verification of a valid device type to the content provider 203 at step 1205 . Once the content provider 203 verifies a valid device type, the content provider requests the status of previously sent content from the system 100 at step 1206 . Then at step 1207 , the system 100 sends the status of previously sent content to the content provider 203 . If the content provider 203 determines that the status information is acceptable, the content provider then requests the public key from the system 100 at step 1208 . Then the system 100 sends the public key to the content provider 203 at step 1209 . Once the public key is received, the content provider encrypts the content key and transfers the content key and content encrypted using the content key to the system 100 at step 1210 .
[0089] FIG. 13 depicts a flowchart representation of a process 1300 for moving content between two system devices. Beginning at step 1301 , the system 100 receives a request to transfer protected content from one system device to another system device. It should be noted that the request for transfer can be initiated by the sending device, receiving device, or by a third system device not currently involved in the transfer. For example, the user can network to the system, via the internet using a valid system device, and can instruct the system to move protected content from a multimedia server to a remote multimedia server, so that the remote multimedia server can later be detached from the system and used to view the protected content while traveling. Another example can occur when a user accessing a local multimedia client instructs the system to move protected content from a multimedia server in the home to a multimedia server in an automobile, which is located in the garage of the home, via a wireless connection, so the user can view the protected content in the automobile.
[0090] As step 1302 , the sending device verifies that the receiving device is a valid device type. For purposes of this discussion, the sending device is the device containing the content to the transferred, and the receiving device is the device that is to receive the content from the sending device. If the system 100 determines as step 1303 that the device type is not a valid device type, then at the step 1304 the system displays a message stating that the content cannot be transferred to the receiving device. Thus, the process 1300 ends.
[0091] If, however, the system 100 determines that the device type is valid, then the sending device requests the public key from the receiving device at step 1305 . At step 1306 , the receiving device sends its public key to the sending device. Upon receiving the public key, the sending device, at step 1307 , decrypts the content key with the private key and then encrypts the content with the receiving device's public key. At 1308 , the sending device transfers the content to the receiving device with the content key encrypted with the receiving device's public key. At this point, the process 1300 ends. It should be noted that the protected content can be streamed from the sending device to the receiving device, in an encrypted format, where it is decrypted by the receiving device, using the private key, and accessed for use.
[0092] FIG. 14 depicts a block diagram representation of the relationship between the sending device and the receiving device when the receiving device requests protected content from the sending device. The receiving device 1401 requests protected content from the sending device 1402 at step 1403 . Upon receipt of the request, the sending device 1402 requests verification of a valid device type from the receiving device 1401 at step 1404 . Then at step 1405 , the receiving device 1401 sends verification of a valid device type to the sending device 1402 . The sending device 1402 , in turn, requests the public key from receiving device 1401 at step 1406 . Upon receiving the request for its public key, the receiving device 1401 sends the public key to the sending device 1402 at step 1407 . Then, the sending device 1402 transfers the encrypted content to the receiving device 1401 at step 1408 .
[0093] FIG. 15 depicts a flowchart representation of a process 1500 a system device undergoes when requesting a license update for protected content from an external content provider. Beginning at step 1501 , the system device requests a content license update from the external content provider 203 . At step 1502 , the system 100 receives a request from the content provider 203 for verification of a valid device type. The system 100 , at step 1503 , determines if the device type is valid. If the device type is not valid, then the system 100 displays a message to the user stating that the content license cannot be updated at step 1504 . The process 1500 for requesting a license update for protected content ends.
[0094] If, however, the system determines that the device type is valid, then the system notifies the content provider of the same at step 1505 . At step 1506 , the system 100 receives a request from the content provider 203 for the public key from the system device. Next, the system device sends its public key to the content provider at step 1507 . Upon receiving the system device's public key, the content provider encrypts the updated content license status file with a system device public key and then transfers the updated content license status file that is encrypted with the system device public key at step 1508 . Next, the system device converts the old content license status file to the new content license status file by using its private key. At this point, the process 1500 ends.
[0095] This ability to check the status of content on the system 100 and update the content license instantly allows a considerable flexibility and ease of use for the user and a real-time inventory status update for the content provider. An example where this could be very advantageous for both would be when a user chooses to download a new movie to the user system. The content provider can check the total quantity of movies which the user has in use by mail order rental, in-store rental, and downloaded rental. If the content provider determines that the user has the maximum number of movies rented by mail order rental, in-store rental, and downloaded rental, then the content provider can allow the user can choose to instantly ‘return’ an online movie, by license revocation, and then download a new movie for rental while staying within the requirements specified by the content provider.
[0096] FIG. 16 depicts a block diagram representation of the relationship between the system device 1601 and the external content provider 203 when the system device 1601 requests a license update for protected content from the external content provider 203 . The system device 1601 requests a content license update from the content provider 203 at step 1602 . At step 1604 , the content provider 203 requests verification of a valid device type from the system device 1601 . The system device 1601 , in turn at step 1605 , sends verification of a valid device type to the content provider 203 . Upon receiving verification of a valid system device, the content provider 203 , at step 1606 , requests the public key from system device 1601 . The system device 1601 then sends its public key to content provider 203 at step 1607 . Upon receiving the system device's public key, the content provider 203 encrypts the content license status file and transfers the updated content license status file to system device 1601 at step 1608 .
[0097] FIGS. 17 and 17B depict a flow representation of a process 1700 of converting protected content to a hard copy. For this description, the sending device is the device sending the content and the receiving device is the device receiving and creating a copy of the content. Beginning at step 1701 , the user requests protected content be converted to a hard copy. At step 1702 , the system 100 determines whether the device type is valid. If the device type is not valid, the system 100 , at step 1703 , displays a message to the user stating that the content cannot be transferred. Then, the process 1700 ends. If, however, the device type is valid, then the system 100 , at step 1704 , determines whether the license allows a copy to be made. If the license does not allow a copy to be made, the system 100 displays a message to the user asking the user if he or she chooses to update the content license. The user can then choose to update the license or not at step 1706 . If the user does not update the license, the process 1700 ends. If the user does choose to update the content license, the content license is then updated at step 1707 , and the process 1700 can loop back to the determination box 1704 .
[0098] If the system 100 determines that the license allows a copy to be made at step 1704 , then the sending device requests the public key from the receiving device at step 1708 . The receiving device then sends its public key to the sending device at step 1709 . At the step 1710 , the sending device decrypts the content key with its private key and then encrypts the content key with the receiving device's public key. At step 1711 , the sending device transfers the content to the receiving device with the content key encrypted with the receiving device's public key. Next, the system 100 determines whether the content is in a format to make copy at step 1712 . If the content is in a proper format, the content is converted to a hardcopy at step 1713 . At this point, the process 1700 then ends. If, however, the content is not in a format to make a copy, then the receiving device decrypts the content key with its private key and then decrypts a content and step 1714 . Then at step 1715 , the receiving device encrypts the content and formats the content such that a copy can be made. The content is then converted to a hardcopy at step the 1716, and the process 1700 then ends.
[0099] It should be noted that in some cases the content may be download from the content provider in a format which can be converted directly to a hard copy. In this case, the content can still be moved to a valid system device such that the valid system device limits other uses of the content.
[0100] While the invention has been shown and described in preferred forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein. These and other changes can be made without departing from the spirit and scope of the invention as set forth in the following claims.
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This system provides wired and/or wireless access throughout a multimedia network built on a distributed architecture which can be transparent to the user. This multimedia network includes content which is imported or generated within the network. The system allows for the content provider to determine the license status of content and update the license status of content which was previously provided by that provider. The external content can be accessed in real time or downloaded and stored within the system for later access at the convenience of the user. The usage of some content is controlled by the use of encryption and other protection methods. The system allows for storage of live video by storing the digitized video and allowing the user to control how, when and where the content is viewed. The system makes available multiple multimedia services to all users in the network or connected via the internet.
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FIELD OF THE INVENTION
The present invention relates to an electric motor, more specifically a stepper motor. As a starting point the motor has quite general options for application, but it is particularly constructed with the intent to drive a vehicle without following a course via clutch, gearbox, countershaft (possibly a belt drive) and differential. This is achieved by building the stator part of the motor into the drive wheel itself, and by making the rotor part a main part of the wheel rim. In accordance with the desired vehicle power, one or several wheels of this type are mounted. When the motor is to be used for other purposes, the rotor part is appropriately designed on its outside for the application in question.
BACKGROUND OF THE INVENTION
There is previously known from U.S. Pat. No. 4,280,072 a motor with some features which exhibit similarity with the present invention. According to the embodiment shown in FIGS. 9 and 10 of said U.S. patent, an outer rotor part is used which comprises four inside-mounted magnets, each covering an angular range of 90° of the entire circumference. The inside stator part comprises four components which are similar to cog rims, however these components do not comprise circumferentially uniformly distributed flux conducting elements or "fingers". There are two so-called "poles" on each component, each respective pole being divided into three "teeth", and each such pole range covers about 90°. Three "teeth" extend in between three corresponding "teeth" on an oppositely facing component, and a corresponding set of two components are found right next to the first two components, with a 45° shift in relation to the first set.
A serious question must be asked regarding the ability of the above mentioned motor regarding achieving a successively and uniformly increasing rpm from standstill to the desired rotation speed, due to the small number of magnets in the rotor part and the correspondingly small number of "poles" on the stator part, i.e. with only two "pole ranges" on each cog rim-like component. However, it appears from said U.S. patent that the electric machine primarily is a sort of asyncronous generator, so that the motor aspect is a secondary consideration, at least regarding the ability to provide a high torque. In the motor function, said U.S. patent attaches most importance to a smooth and "ripple"-free running. Besides, a main feature of said U.S. patent is that the angle between the "step intervals" in the "poles" on the stator part should not be equal to the angle between the magnet pole centers on the rotor part. This is an unfortunate feature regarding achieving a high torque.
From British patent application, publication no. 2,211,030 is previously known a stepper motor based upon some of the same principles as the present invention, but which as a starting point has a reversed construction, i.e. with the rotor placed in center and the stator on the outside. Thus, the motor is not directly usable in the manner mentioned in the first section of this specification. Besides, the construction of the flux-conducting elements in the stator part is more similar to an abandoned development stage of the the present invention, with axially inward bent fingers from annular plates conducting flux from the stator coils.
SUMMARY OF THE INVENTION
The present invention has as its main object to provide a motor with a high torque.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall be illuminated further by first describing the above mentioned abandoned development stage, in order to provide a better understanding of the detailed embodiment example of the present invention, which embodiment example follows thereafter, and it will be referred to the appended drawings, where FIGS. 1-6 show the prior art and FIGS. 7-13 show the invention:
FIG. 1 shows an example of a motor wheel in accordance with the previous development stage, in a side view and partially in section,
FIG. 2 shows a cross section through the same motor wheel as appears in FIG. 1 along line A--A,
FIG. 3 shows part of the radially outward facing surface of the stator part, with four cog rims, the two cog rims in the middle being mounted together back-to-back,
FIG. 4 shows part of the same cross section as in FIG. 2, where one rotor magnet and the outer, bent cog rims right inside, appear in closer detail,
FIG. 5 shows a corresponding picture as FIG. 3, however, putting more emphasis on the presumably best geometrical embodiment of cogs/teeth and spacings, and
FIG. 6 is a scheme showing how field change or field reversal is controlled while the motor is operating.
Further, there is shown
in FIG. 7, with a corresponding sketch as in FIG. 1, a motor wheel in accordance with the simplest embodiment of the present invention, i.e. an embodiment with two coils in the stator,
in FIG. 8 a cross section through a part of the same motor wheel as in FIG. 7, in analogy with FIG. 2,
in FIGS. 9 and 10 the shape of the flat lamellae which in the present invention compose flux-conducting blocks having T- and Γ-shapes,
FIG. 11 shows the lamella blocks arranged in the topical geometry of the simplest embodiment of the invention, i.e. with two coils, in a view radially from the outside, in analogy with FIG. 3,
FIG. 12 shows the arrangement of single magnets in the rotor part in the same two-coil embodiment shown in FIGS. 7, 8 and 11, and
FIG. 13 shows a field reversal scheme which is analogous with the scheme shown in FIG. 6, for the two-coil embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The motor in accordance with the invention is provided with energy from a current source which via an electrical regulator supplies power to the motor coils, which power is variably controlled both regarding voltage level and frequency. The regulator constitutes per se no part of the present invention, which relates only to the motor itself. However, the motor comprises preferably sensor elements for feedback to the regulator regarding the instant motor condition (speed, rotation direction, position), so that the regulator may adapt the current feed in a correct manner.
In FIG. 1 is shown a motor wheel embodiment originally suggested during development toward the invention now present, said original motor wheel embodiment having a stator part comprising three cogged rings 1, 2, 3 (see also FIG. 2) connected to a hub 4 via spokes 5. The material in the rings 1, 2, 3 might be iron or some other magnetizable, sintered powder material designed for high frequencies. Between the cogged rings 1, 2, 3, see FIG. 2, windings 6 and 7 were mounted coaxially about an annular core 8 which was also coaxially arranged about the wheel hub 4. The rings 1, 2, 3 were mounted in tight engagement with or integrated with the core 8. The core 8 was preferentially made of the same material as the cogged rings 1, 2, 3. The spokes 5 formed a housing for bearing 9 for rotation of the rotor part axle 22. An axle neck 10 worked as an attachment means for the stator part. Bolts were used to keep the stator part together, e.g. in positions indicated by reference numerals 11.
The rotor part consisted in the development embodiment of a wheel rim 12 with inside permanent magnets 13 along the entire circumference. The circumferential width of these magnet areas, which either were constituted by separate permanent magnets or by an alternately magnetized ring, was approximately equal to the distance C between the cogs/teeth, see FIG. 3. A tire 23 was mounted on the rim 12.
Each magnet 13 had poles in a radial direction. The magnetic fields from the permanent magnets 13 were supposed to interact with the magnetic fields in the gaps existing between the cogged rings 1, 2, 3 on the stator part, i.e. gaps on the outside (in the radial sense) of the coils 6, 7. As it appears from FIG. 5, where the cogs/teeth 17, 18, 19, 20 are designed with a 90° bend as it appears from FIG. 4, the development embodiment was constructed so that the cogs were imparted a slanting shape, and in such a manner that opposite cog rims "entered a little into each other", with a small lateral gap. However, the cogs were shifted from one cog rim to another, in such a manner that from the outer left rim to the closest rim, cogs where shifted 1/2 cog period, while the back-to-back mounted cog rims in the middle had a respective cog shift of substantially 1/4 cog period. The shift between the two cog rims on the right was the same as on the left side, i.e. 1/2 cog period.
The rim 12 was fixed to the axle 22 via a rim plate 14 made of a strong material. The rim plate 14 had slots to let air circulate for cooling the coil winding. The heated air was collected by the end pipe 16, optionally to be used for compartment heating. The rotor part rotated coaxially about the stator, and was as previously mentioned, supported by a bearing via axle 22.
In order to obtain practical use of the construction, i.e. in an electrically powered car, it is necessary that the motor develops a high starting torque. This was achieved in the development embodiment by making the number of permanent magnet poles 13 as large as practically feasible, and by having the number of cogs on the outer rings 1 and 3 the same as the number of permanent magnet poles of polarity M (or S) cooperating with the stator part. In a practical test embodiment of the development embodiment, 48 permanent magnet areas in an alternately magnetized ring were used.
On the ring 2 which comprised two cog rims, the same number of cogs/teeth were present, as the number of permanent magnet poles of polarity N and S cooperating with the stator part. The mutual locations of cogs on the cog rims appear schematically in FIG. 3, which figure shows that the cog width B is about equal to the distance C between cogs, and that the shift between the two central cog rims are B/2. Further, the cogs of the two outer cog rims are arranged so as to point substantially toward cog intervals of the rims on the inside.
When a voltage was supplied to the two coils 6, 7 via supply conductors not shown, a magnetic flux was established through the inside situated core 8 and through rings 1, 2, 3 to cogs 17, 18, 19, 20. By alternating current directions in coils 6, 7 in accordance with a carefully regulated scheme, a force influence on the rotor part was obtained, in such a manner that it moved stepwise. A course of alternations to drive the rotor part forward in one direction, is shown in FIG. 6:
FIG. 6 indicates the polarity of each of the cog rims as determined by electrical current direction in the coil therebelow. A start situation is shown at the bottom, with the left rim having polarity N, the next one S, the next rim N and the rim on the right side having polarity S. At a time t 1 the current direction in coil 6 is changed, so that the polarity of the two cog rims on the left change. The two rims on the right remain as before.
At a time t 2 (which is determined by the regulator and which is not necessarily equal to 2t 1 ) the current direction in coil 7 is turned around, while coil 6 remains as before. Thus, the polarity is altered for the two cog rims on the right side, while the two rims on the left maintain their polarities.
At a new time t 3 the polarities of the two left side cog rims are alternated, while the two right side rim polarities are maintained, and this operation keeps on and on. The timings for alternations are adjusted for the regulator on the basis of measurements of the position, speed and rotation direction of the rotor part. The measurements were in the development embodiment made by Hall elements 21 which provided an indication of the instant positioning of the permanent magnets to the regulator control. Thereby it was possible to determine which polarity was desirable for a chosen rotation direction. Further, the Hall elements 21, together with further electronic circuitry would record the rpm. In a vehicle equipped with this type of drive in e.g. both rear wheels, a speed reduction for a wheel in a curve inside will cause a corresponding power supply/frequency increase to occur for the other wheel of the wheel pair, caused by an interplay between the Hall elements and the remaining electrical control means.
By controlling that the electrical current direction is changed in such a manner that the cog magnetization takes a course as explained above in connection with FIG. 6, the motor would advance one full step, i.e. the distance from one cog/tooth to next cog on the same cog rim, see the indication "1 step" in FIG. 5 and FIG. 6.
By repeating this course of alternations at a high rate (adapted to the current wheel rotation speed), the wheel would would have a soft start and a uniform travel due to the high number of cogs/teeth and permanent magnets. It will be appreciated that by making alternations in a different consecutive order, the motor would have the opposite rotation direction.
As mentioned above, it would be possible to construct a wider motor, having several intermediate cog rims. The cog shift would then follow a corresponding pattern as the pattern already explained, it being rather simple to visualize that a new cog rim to the right of what is shown in FIG. 5, is mounted bak-to-back to ring 3 and having 1/4 period shift, with cogs/teeth protruding to the right. Next one mounts on the outside to the right, a new outer right cog rim with teeth shifted furter 1/2 teeth period as a termination. Three, four or more coils (not shown) are then used, and coil energizing is then changed in accordance with an extended scheme in relation to the scheme shown in FIG. 6. Now, in FIGS. 7-13 is shown the further development of the motor which constitutes the present invention. In these figures, the same reference numerals as in previous FIGS. 1-6 are used, to the extent possible. However, the further development of the invention has resulted in some new elements which are shown by means of additional reference numerals.
It turned out during development of the present invention, that it was necessary to provide a different design in order to bring sufficient magnetism forward in "the fingers" or "cogs/teeth" of what has previously been called "cog rims". In the novel construction, the inventor realized that it would be favourable to construct these "fingers" from thin metal sheets having a thickness of preferably about 0,3 mm. Thin sheet metal profiles were stamped out using respectively T and Γ shapes in accordance with what is shown in FIGS. 9 and 10. By adding preferentially about 40-50 pieces of such thin metal sheets together as a package, a lamella block 30 of the type shown in FIG. 9 was obtained, respectively a lamella block 35 of the type shown in FIG. 10. Each T and Γ consists generally of an upright stem 24, respectively 26, and a top beam 25, respectively 27.
Instead of the cog rims which were used in the first development embodiment, having shifted cogs from one cog rim to the next, in the present case there are provided circularly arranged rows of radially standing T- and Γ-profiles, such as appears from FIG. 7. This figure shows the motor wheel in accordance with the invention in a side view, and in one "open" quadrant showing a section in a view along C--C in FIG. 8, one can see radially upright stems 24 of the T-profiles 30. On the radial outer end of these stems are located the top beams 25, and circumferentially between these top beams, the top beams 27 of the Γ -profiles 35 are located. (Strictly, these last mentioned top beams are not to be found in said section, since they do not reach all the way to the sectional plane, but they are drawn in the figure for the sake of lucidity. There is a gap 34 between the ends of the two Γ top beams which point towards each other.) Between top beams 25 and 27 there is a flux gap 36. The radially upright profile stems 24, 26 engage with their lower ends the annular cores 8.
In FIG. 8 appears a view of the motor wheel which is similar to the view presented in FIG. 2. Here one attempts to show, by means of different types of shading, that the rotor magnets 13 in the shown cross section has different pole directions. This appears clearly in FIG. 12, where it is possible to see that in the motor in accordance with the present invention one uses shifted magnet rows in the rotor, i.e. not the same magnet in the axial direction, such as in the first embodiment attempt. In the embodiment shown in FIG. 8, namely an embodiment having two coils 6, 7 lying on each respective core 8, there are in correspondence with the two coils provided two separate rings of magnets 13, where the magnets are shifted one-half width from one ring to the next, see FIG. 12. In FIG. 8 appears also that the T- and Γ-profiles 30, 35 are arranged with their top beams in an axially straight configuration, i.e. not any more with circumferentially shifted cogs/teeth from one cog rim to the next in the axial direction, such as in the first embodiment attempt, cp. FIG. 3. The configuration in accordance with the invention appears most clearly in FIG. 11, where the profile top beams can be viewed radially from the outside. The gap 34 between two Γ top beams 27 facing each other, appears in this figure, and also the important flux gap 36 between two top beams extending in parallel directions. It is the magnetic field in this flux gap which interact with the magnetic field from the single magnet 13 in the outside magnet rings in the rotor.
Further details in FIG. 8 which must be mentioned, are in addition to the profiles or lamella blocks 30 and 35, side plates 28 which keep the stator together, which side plates include bearing housing 29 having rotating bearings 9, and which are held together by screws/bolts 11. The motor is attached by means of fixing screws 31.
As an alternative to the Hall-elements mentioned previously in the specification in connection with FIGS. 3 and 4, which elements can also be used in connection with the invention as now present, in FIG. 8 is shown an index disk 32 which in cooperation with an opto-coupler 33 is adapted to provide measurement of the rotor position and rotation speed, to provide data for the control electronics. In order that the motor shall move one step as shown in FIG. 11, it is necessary that a magnetization course takes place in the profiles or lamella blocks 30, 35 as appears from FIG. 13. This course is quite similar with the course indicated in FIG. 6, and can be described as follows: In FIG. 13 are indicated the pole directions for the two coils, respectively termed left coil and right coil. The polarities are determined by the electric current directions in the coils. A start situation is shown at the bottom, where the left coil is polarized in one direction, i.e. with its south pole toward the right, and the right coil for the moment polarized in the same direction, i.e. with its south pole toward the right. At a time t 1 the current direction is changed in the left coil, so as to change the pole directions. At this time, i.e. t 1 , no change occurs for the right coil.
At a time t 2 (which is determined by the regulator, and which time is not necessarily equal to 2t 1 ), the current direction in the right coil is turned around, while the left coil remains as before. Thus, the pole direction changes for the right coil, while the left coil maintains its pole direction.
At a new time t 3 , the pole direction is changed around again for the left coil, while the pole direction of the right coil is maintained, and this keeps on and on. The times for alternation are adjusted by the regulator on the basis of measurements of the position, speed and rotation direction of the rotor part.
Reference numeral 37 refers to rings having notches on the outside and the inside, for fixation and holding the lamella blocks 30, 35.
The manner of arranging profiles now indicated in accordance with the present invention, makes the magnetic flux in the flux gaps 36 take on a direction which is the same as the rotation direction of the motor, and not substantially in a slanted direction, which was the case in the previous experimental embodiment.
The annular cores 8 below coils 6, 7 consists preferentially of a spun coil of thin sheet metal filling both spaces found between the lower parts of the T- and Γ-profiles.
The operation manner of the motor in accordance with the invention is quite analogous to what has been described above regarding the development embodiment, and need not be repeated. Besides, in the same manner as mentioned in connection with the development embodiment, it is possible to construct a wider motor, having several coils and correspondingly several T-profiles arranged therebetween. On each outside there will always be arranged Γ-profiles with top beams pointing inward. For the rest, T-profiles will be standing between the coils. The operation manner for energizing the coils will then follow an extended scheme in the same manner as previously mentioned.
An important additional characteristic of the motor here described, is that it is used in a vehicle, will be able to charge the batteries when moving downhill, in a reversed working mode, i.e. it is able to work as a generator. Thus, this motor may also be used as a magnetic braking device.
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An electric motor consisting of an inside stator part and a rotor part placed outside and concentrically in relation to the stator part, has a high number of permanent magnets (13) on the inside of the rotor part. The magnetic fields from these permanent magnets interact with magnetic fields between flux-conducting lamella blocks (30, 35) engaging the coil cores (8) on the stator. The lamella blocks (30, 35) are T- and Γ-shaped with top beams (25, 27) pointing in directions parallel to the axis, and the top beams (25, 27) are positioned to provide substantially circumferentially directed magnetic fields in flux gaps (36) therebetween. The magnetic fields in the flux gaps (36) between the top beams (25, 27) are reversed in successive order, and under time control from an electronic regulator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of international application PCT/EP2014/072452, filed Oct. 20, 2014 which claims priority from German Patent Application No. DE102013020504.2 filed Dec. 11, 2013, the disclosures of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a self-piercing rivet for connecting high-strength steels, with a head which has a head diameter and with a shank which has a shank diameter, wherein, at the foot end opposite the head, the shank has an axial recess which has an axial depth, and wherein, at the foot end the shank has a flat surface section.
[0003] Furthermore, the present invention relates to a self-piercing riveted joint with at least one upper workpiece and one lower workpiece, of which at least one is formed from a high-strength steel, and with a deformed self-piercing rivet of the type referred to above, the head of which bears against the upper workpiece.
[0004] Finally, the present invention relates to a method for producing such a self-piercing riveted joint, with the steps of providing a workpiece arrangement which has at least one upper and one lower workpiece, and of driving a self-piercing rivet of the type referred to above into the workpiece arrangement with a punching force.
[0005] A self-piercing rivet of the form referred to above is known from EP 1 229 254 A2. In this document, it is proposed to provide a self-piercing riveted joint with at least two joining parts made of a high-strength steel, which are connected to each other by means of a semi-tubular self-piercing rivet which is formed from steel and which has a rivet head and an adjoining rivet shank with a rivet foot on the end side, wherein the rivet foot is of truncated design in the initial state before the joining operation. The shape of the self-piercing rivet is in this case intended to be identical to the shape of a self-piercing rivet as is known also for joining light metal workpieces, specifically from EP 0 833 063 A1. The truncated design of the rivet foot is intended to achieve a favourable deformation behaviour of the semi-tubular self-piercing rivet during the joining of the high-strength joining parts, wherein the endeavour of the rivet shank to expand is reduced in comparison to a pointed rivet foot. The expansion here is intended to take place only when the rivet shank pierces with the rivet foot into the lower joining part. The joining parts are intended to have a tensile strength of greater than 500 N/mm 2 to up to 1500 N/mm 2 . The tensile strength of the semi-tubular self-piercing rivet used is intended to lie within a range of between 1200 and 1400 N/mm 2 , but can even reach values of up to 2000 N/mm 2 .
[0006] In order to ensure a suitable expansion behaviour, the quotient from the axial depth of the shank cavity and the outside diameter of the rivet foot is to lie between 0.3 and 0.7. At too small an axial depth of the shank cavity, the rivet shank will not expand sufficiently after perforating the upper steel sheet.
[0007] A further semi-tubular self-piercing rivet is known from WO 2007/132194 A1. The shank here is to be provided with a central blind hole bore, wherein the ratio of a difference between an outside diameter and an inside diameter of the shank in the region of the bore to the outside diameter of the shank is intended to lie within the range of 0.47 to 0.52.
[0008] Furthermore, EP 2 314 890 A2 discloses a semi-tubular self-piercing rivet for connecting high-strength and super-high-strength steels, wherein a head diameter is generally smaller than or equal to 1.3 times the shank diameter.
[0009] However, as before, prior-art self-piercing riveted joints, with which high-strength or super-high-strength steels are connected, may have diverse problems. Firstly, the extent of the expansion may not be symmetrical with respect to a rivet axis. Furthermore, the shank may be compressed and twisted. In some cases, it is not even possible to press the rivet into the workpiece arrangement, with it even being possible for the self-piercing rivet to be fractured.
BRIEF SUMMARY OF THE INVENTION
[0010] Against this background, it is an object of the invention to specify an improved self-piercing rivet, an improved self-piercing riveted joint and an improved self-piercing riveting method, which are suitable for connecting high-strength and super-high-strength steels.
[0011] This object is achieved in the case of the self-piercing rivet referred to at the beginning in that the ratio of axial depth of the recess to shank diameter is smaller than 0.3, in particular smaller than 0.28, and particularly preferably smaller than 0.25, or even smaller than 0.2.
[0012] The ratio of axial depth of the recess to shank diameter is preferably greater than 0.05, and preferably greater than 0.1, and in particular greater than 0.12.
[0013] Furthermore, the above object is achieved by a self-piercing riveted joint with an upper workpiece and with a lower workpiece, of which at least one is formed from a high-strength steel, and with a deformed self-piercing rivet, the head of which bears against the upper workpiece, wherein the self-piercing rivet is in particular a self-piercing rivet according to the invention.
[0014] Finally, the above object is achieved by a method for producing a self-piercing riveted joint, in particular a self-piercing riveted joint of the type referred to above, with the steps of providing a workpiece arrangement which has at least one upper and one lower workpiece, and of driving a self-piercing rivet of the type according to the invention into the workpiece arrangement with a punching force.
[0015] By means of the configuration according to the invention of the self-piercing rivet, a deformation of the self-piercing rivet that is less focused on an expansion of the rivet shank is produced during the self-piercing riveting method. Rather, the effect achieved by the relatively short axial depth of the recess is that the connection is formed by an upsetting operation of the rivet, said upsetting operation being caused in particular by the counter pressure of the high-strength steel of the workpiece arrangement. The undercut which is thereby formed can be relatively small in this case. However, owing to the high-strength materials, even a relatively small undercut is sufficient in order to realize the required connection strength.
[0016] In addition, the effect achieved by the relatively small axial depth of the recess is that the self-piercing rivet obtains a significantly greater stability which makes it possible to pierce through even high-strength and super-high-strength steels.
[0017] A contribution to the new manner of producing self-piercing riveted joints is provided by the flat surface section at the foot end. In other words, it is preferred if the generally annular end side of the foot end, which end side is also referred to as a cutting edge, is of at least proportionally flat design, specifically is preferably oriented perpendicularly to a longitudinal axis of the self-piercing rivet.
[0018] The upper workpiece of the workpiece arrangement is preferably produced from steel and has a tensile strength which is preferably greater than 800 N/mm 2 , in particular greater than 1000 N/mm 2 . The tensile strengths at least of the upper workpiece can be up to 1500 N/mm 2 and beyond.
[0019] The tensile strength of the lower workpiece—without heating—is preferably limited to approximately 600 N/mm 2 .
[0020] In other words, even forming steels, such as are known under the name “Usibor®”, in which, before a heat treatment, the microstructure consists in particular of a ferritic—pearlitic structure, can be joined with the required connection strength by the self-piercing rivet according to the invention.
[0021] It goes without saying that the strength or hardness of the self-piercing rivet is correspondingly adapted. Furthermore, it goes without saying that the self-piercing rivet is a semi-tubular self-piercing rivet which is produced in particular rotationally symmetrically and/or as a single piece from steel.
[0022] A small radius of 0.5 mm or less is preferably provided at the transition from the shank to the head in order to keep the setting forces as small as possible.
[0023] The minimum rivet length is preferably the thickness of the upper workpiece plus a length which is preferably greater than 2 mm and in particular equal to 3 mm. The maximum rivet length preferably lies within the range of the thickness of the workpiece arrangement.
[0024] The object is therefore completely achieved.
[0025] It is particularly preferred if the recess is frustoconical in longitudinal section.
[0026] In this alternative, the diameter of the recess in the region of the foot end is preferably greater than the diameter in the region of a base of the recess. In this embodiment, the base of the recess is preferably flat, but can also be curved concavely or convexly.
[0027] According to a further preferred embodiment, the recess is arch-shaped in longitudinal section.
[0028] The arch shape here can be produced by a single radius, and therefore the recess is in the shape of an arc of a circle in longitudinal section.
[0029] However, it is particularly preferred if the recess is in the shape of a pointed arch or a gothic arch in longitudinal section.
[0030] Such an arch shape is produced by two arcs constructed from circles and having a point.
[0031] It is preferred here if the point is rounded by means of a radius in a suitable manner.
[0032] Furthermore, it is preferred in the case of the pointed arch shape if the center points of the respective arcs, as the respectively assigned arch, each lie on different sides—as seen in longitudinal section—of a longitudinal center axis of the self-piercing rivet.
[0033] In the two embodiments referred to above—frustoconical or arch-shaped, it is advantageous for the punching forces acting from the head end to be suitably introduced into the foot end.
[0034] Overall, it is furthermore preferred if the recess does not have a cylindrical section.
[0035] A cylindrical section in the recess can result in instability and possibly in fracturing at very high punching pressures.
[0036] The stability of the self-piercing rivet can be increased overall by omitting a cylindrical section within the recess.
[0037] According to a further embodiment which, in conjunction with the precharacterizing clause of claim 1 , constitutes a separate invention, the recess has a recess volume, wherein a ratio of recess volume to volume of the shank is smaller than 0.25, in particular smaller than 0.18 and/or is greater than 0.05, in particular greater than 0.1.
[0038] The recess volume in this case is calculated starting from the foot end of the self-piercing rivet. The volume of the shank is that volume of the shank at which the shank has a uniform outside diameter, i.e. exclusively a possible transition section to a head of the self-piercing rivet, but including the recess volume which is consequently contained in the volume of the shank.
[0039] The relatively small recess volume results, firstly, in great stability of the self-piercing rivet. Secondly, a punched-out piece detached from the upper workpiece is not received by the recess, but rather is pressed in front of the rivet by the rivet during the punching operation. The effect which can advantageously be achieved by this means is that greater deformation of material takes place within a die of a self-piercing riveting tool instead of deformation in the recess.
[0040] According to a further preferred embodiment, the flat surface section is designed as an annular surface section and has a radial width in cross section, wherein the ratio of radial width of the annular surface section to shank diameter is greater than 0.05 and/or is smaller than 0.25.
[0041] The self-piercing rivet is preferably produced from a steel with a hardness of at least 500 HV10 (1630 MPa), in particular with a hardness of at least 650 HV10, in particular with at least 700 HV10. The hardness is generally smaller than 800 HV10.
[0042] In the self-piercing riveted joint according to the invention, it is preferred if the axial thickness of the upper workpiece is greater than or equal to the axial depth of the recess in the undeformed state.
[0043] Furthermore, it is advantageous in the case of the self-piercing riveted connection according to the invention if a punched-out piece is detached from the upper workpiece, and if less than 50% of the volume of the punched-out piece is located within the deformed recess, in particular less than 30%, preferably less than 25% and particularly preferably less than 20%.
[0044] This results in the self-piercing rivet being designed in such a manner that it is substantially upset, as a result of which the volume of the recess is reduced, and therefore the punched-out piece is substantially pushed in front of the rivet during the self-piercing riveting operation.
[0045] Material of the lower workpiece can thereby be suitably displaced within the die by means of the punched-out piece, and therefore said material flows behind an undercut in the shank of the self-piercing rivet.
[0046] All in all, it is furthermore advantageous if the shank of the deformed self-piercing rivet forms an undercut in relation to forces in the direction of the head, wherein the ratio of undercut to shank diameter is smaller than 0.1 and/or is greater than 0.01.
[0047] This results in the extent of the undercut being comparatively small. However, such a small undercut is sufficient when connecting high-strength steels in order to realize the necessary connection strength.
[0048] According to a further preferred embodiment of the self-piercing riveted joint, the ratio of axial length of the self-piercing rivet after deformation and of axial length of the self-piercing rivet before deformation is greater than 0.8 and/or is smaller than 0.95.
[0049] This results in the self-piercing rivet only being upset to a comparatively small extent because of the predetermined hardness thereof, which likewise leads to a relatively small undercut in the radial direction.
[0050] This also results in the minimum length of the self-piercing rivet preferably being produced from the thickness of the upper workpiece plus a value of preferably 3 or 3.5 mm, whereas the maximum length of the self-piercing rivet is preferably calculated by the overall thickness of the workpiece arrangement plus 1 mm or is equal to the overall thickness of the workpiece arrangement.
[0051] In the case of the method according to the invention it is advantageous if the workpiece arrangement is supported on a die with a die volume into which at least the lower workpiece is driven, wherein the ratio of die volume to a volume of the self-piercing rivet is greater than or equal to 1.0 and/or is smaller than or equal to 1.5.
[0052] The die volume is the volume into which material at least of the lower workpiece flows during the self-piercing riveting operation, wherein the upper edge of the die recess provided for this purpose is substantially flush with a supporting surface. The shape of the die recess here is preferably frustoconical, with a relatively large diameter in the region of the supporting surface and a smaller diameter in the region of a base of the die volume.
[0053] Overall, the following can furthermore be noted in addition. In the case of conventional self-piercing riveting, the formation of the undercut is a feature which is relevant to the quality of the connection strength. Owing to the high strength of the rivet according to the invention, this feature no longer holds true by itself. The rivet requires a relatively strong upper workpiece, the punched-out piece of which then upsets the rivet and presses it somewhat apart in the process. In contrast to rivets from the prior art, the undercut in the connection is not produced by conventional expansion, but rather is produced by an upsetting operation of the rivet, the upsetting operation being caused by the counter pressure of the high-strength steel. A further differentiation criterion with respect to conventional rivets is the range of use which, as a rule, begins only at a tensile strength of the upper workpiece of 800 N/mm 2 , in particular of 1000 N/mm 2 . Steels of this strength category have found use in vehicle manufacturing because of the increased use of lightweight structures made from super-high-strength sheets. The range of use of the self-piercing rivet according to the invention downwards is preferably limited by a minimum punching force—the force for perforating/piercing the high-strength workpiece arrangement—of 8 kN. Above said force, a sufficient upsetting (not primarily spreading) of the self-piercing rivet begins, and the required degree of upset, which is preferably at least 0.15 mm, is achieved. In order to assess the connection quality, the degree of upset should also be taken into consideration in addition to the formation of an undercut. The degree of upset is calculated from the axial length of the self-piercing rivet before deformation minus the axial length of the self-piercing rivet after deformation, i.e. in the settled state.
[0054] It goes without saying that the features referred to above and those which have yet to be explained below are usable not only in the respectively stated combination, but also in different combinations or on their own without departing from the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] Exemplary embodiments of the invention are illustrated in the drawing and are explained in more detail in the description below. In the drawing:
[0056] FIG. 1 shows a longitudinal sectional view through an embodiment of a self-piercing rivet according to the invention;
[0057] FIG. 2 shows a longitudinal sectional view through a further embodiment of a self-piercing rivet according to the invention; and
[0058] FIG. 3 shows a longitudinal sectional view through a self-piercing riveted joint produced by means of the self-piercing rivet of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] A rotationally symmetrical semi-tubular self-piercing rivet is illustrated schematically in longitudinal section and denoted in general by 10 in FIG. 1 .
[0060] The self-piercing rivet 10 is produced from a strong steel and preferably has a hardness of greater than 500 HV. The self-piercing rivet is in particular produced by pressure deformation.
[0061] The self-piercing rivet 10 has a head 12 and a shank 14 adjoining the latter in the axial direction. The shank 14 merges into the head 12 via a transition section 16 . An end of the shank 14 that is opposite the head 12 is designed as a foot end 18 in FIG. 1 .
[0062] A flat surface section 20 is formed at the foot end 18 , said surface section being designed as an annular surface section, the outside diameter of which is limited by an outside diameter of the shank 14 and the inside diameter of which is limited by an edge of a recess 22 which extends from the foot end 18 in the direction of the head 12 .
[0063] In FIG. 1 , the recess 22 is of frustoconical design and, starting from the foot end 18 , has a conically extending recess transition section 24 and a recess base 26 . The recess base 26 can be of flat design, as illustrated, but may also be of concave or convex design.
[0064] Furthermore, the following dimensions are shown in FIG. 1 , wherein the preferred values for said dimension are in each case also plotted in the table below:
[0000] Designation Abbreviation Preferred value Note Axial length, self-piercing LR 5 mm rivet Length, shank LS 3.6 mm Axial height, head LH 0.5 mm Axial depth, recess LB 1 mm Diameter, head DH 7.75 mm Outside diameter, shank DS 5.5 mm Recess diameter at the foot DB 4.5 mm end Recess diameter at the base DB′ ~2.5 mm Radial width, annular BF 0.5 mm surface Section Cone angle, recess αB ~40° i.e. 25°-50° Cone angle, transition αH ~27° i.e. 20°-50° section
In the case of the self-piercing rivet of FIG. 1 , the ratio of axial depth LB of the recess 22 to the shank diameter DS is approximately 0.18.
[0065] The ratio of radial width BF to the shank diameter DS is approximately 0.09.
[0066] Furthermore, the ratio of the recess volume to the volume of the shank is approximately 0.135, wherein the volume of the recess is approximately calculated at
[0000] VB =( LB ·π)/3·[( DB/ 2) 2 +DB·DB ′+( DB′/ 2) 2 ],
[0000] and wherein the volume of the shank is calculated at
[0000] VS =π·( DS/ 2) 2 ·LS.
[0067] The volume VS of the shank consequently includes the recess volume VB.
[0068] The values, which are indicated in the table above, for the respective dimensions and angles can preferably each deviate within the scope of the invention upwards and downwards by at least 20%, preferably upwards and downwards by 10% in each case.
[0069] A radius RB which is formed at the transition between the recess transition section 24 and the recess base 26 is furthermore shown in FIG. 1 . The value of RB can be, for example, 0.35 mm. The value of DB′ is an approximate value which lies approximately in the center of the recess RB, as seen in the radial direction.
[0070] Furthermore, a radius RH which forms the transition between the conical transition section 16 and the shank 14 is shown in FIG. 1 . The value of RH can be, for example, 0.5 mm or less.
[0071] An alternative embodiment of a self-piercing rivet according to the invention is illustrated in FIG. 2 and is likewise generally denoted by 10 . The self-piercing rivet 10 of FIG. 2 corresponds generally in respect of construction and function to the self-piercing rivet 10 of FIG. 1 . Identical elements are therefore indicated by the same reference numbers. Essentially the differences are explained below.
[0072] The recess 22 of the self-piercing rivet 10 of FIG. 2 is not frustoconical, as in the case of the self-piercing rivet 10 of FIG. 1 , but rather is of arch-shaped design. In more precise terms, the recess 22 in FIG. 2 is in the shape of a pointed arch in longitudinal section, the pointed arch being assembled from two arcs of a circle which form a point on the longitudinal axis. The origins of the arcs of the circle lie in each case on that side of the longitudinal axis which is opposite the arc of the circle thereof. In the region of the point which is formed by the two arcs of the circle, the recess is rounded with a radius which can be, for example, 0.5 mm. This radius is indicated schematically in FIG. 2 by R 1 .
[0073] The radius of the two arcs of the circle is indicated schematically in FIG. 2 by R 2 and can be, for example, approximately 4 mm.
[0074] In the case of the self-piercing rivet 10 of FIG. 2 , the maximum axial depth LB of the recess 22 is preferably approximately 1.5 mm, and therefore a ratio LB/DS of approximately 0.273 is produced.
[0075] The shank diameter DS and the shank axial length LS and also other dimensions can be identical to those of the self-piercing rivet 10 of FIG. 1 .
[0076] A self-piercing riveted joint 30 produced by means of the self-piercing rivet 10 of FIG. 1 is illustrated schematically in longitudinal section and is denoted in general by 30 in FIG. 3 .
[0077] The self-piercing rivet joint 30 connects a workpiece arrangement 32 which contains at least one upper workpiece 34 and one lower workpiece 36 , of which at least the upper workpiece can be produced in the form of steel sheet from high-strength or super-high-strength steels.
[0078] It is illustrated in FIG. 3 that the self-piercing rivet 10 * has cut a punched-out piece 38 out of the upper workpiece 34 and has pressed said punched-out piece in front of itself during the self-piercing riveting operation. The remaining base thickness between the lower side of the punched-out piece and the lower side of the lower workpiece 36 is denoted by 40 . This may be, for example, greater than 0.5 mm.
[0079] Furthermore, a radial undercut of the deformed shank 14 * is shown in FIG. 3 . The self-piercing rivet 10 * has been upset, in particular in the region of the foot end, because of the relatively hard material of the upper workpiece 34 , and therefore the material of said self-piercing rivet has flowed somewhat outwards radially in the region of the foot end. Owing to the great hardness of the self-piercing rivet 10 * too, the undercut 42 is nevertheless very small and may be, for example, smaller than 0.5 mm, but is, as a rule, greater than 0.05 mm. Correspondingly, the ratio of undercut 42 to shank diameter DS is preferably within a range of 0.1 to 0.01.
[0080] Finally, FIG. 3 shows a projecting length 44 by which the head 12 * protrudes in relation to the upper side of the upper workpiece 34 . The projecting length 44 is preferably smaller than the axial height LH of the self-piercing rivet 10 in the undeformed state.
[0081] Furthermore, FIG. 3 shows the axial length LR* of the deformed self-piercing rivet 10 *. In the example illustrated, said length can be, for example, approximately 4.4 mm. The ratio of axial length LR* of the self-piercing rivet 10 * after deformation and axial length LR of the self-piercing rivet 10 before deformation is preferably greater than 0.8 and/or smaller than 0.95.
[0082] As stated, the self-piercing rivet 10 * has been upset in the region of the foot end, and therefore the remaining volume of the remaining recess 22 * is relatively small. Accordingly, in the embodiment illustrated, at most a portion of 50%, in particular at most a portion of 25%, of the volume of the punched-out piece 38 is accommodated within the deformed recess 22 *.
[0083] The axial thickness of the upper workpiece 34 is denoted by L 34 . Said thickness can be greater than or equal to the axial depth LB of the self-piercing rivet 10 in the undeformed state. The axial thickness of the lower workpiece 36 is denoted by L 36 . Said thickness is preferably greater than L 34 . The lower workpiece 36 is preferably softer than the upper workpiece 34 .
[0084] FIG. 3 furthermore schematically illustrates a die 50 of a self-piercing riveting tool, by means of which an axial force (punching force) 52 is exerted on the upper side of the head 12 of the self-piercing rivet 10 during the self-piercing riveting operation. The recess of the die 50 is of approximately frustoconical design. The somewhat softer material of the second workpiece 34 is pressed away radially by the punched-out piece 38 and the die 50 and in this case flows behind the undercut 42 such that the self-piercing riveted joint 30 provides an interlocking connection between the workpieces 34 , 36 .
[0085] The volume of the die recess is preferably greater than or equal to the volume of the self-piercing rivet 10 in the undeformed state. In particular, the ratio of the die volume to the volume of the self-piercing rivet 10 is preferably greater than or equal to 1.0 and/or smaller than or equal to 1.5.
[0086] The minimum punching force 52 is preferably 8 kN.
[0087] The minimum length of the self-piercing rivet 10 in the undeformed state is produced form the thickness L 34 plus a value which can be, for example, 3 or 3.5 mm. The maximum length of the self-piercing rivet 10 in the undeformed state can be equal to the overall thickness L 34 +L 36 , or a value which is formed to be equal to the overall sheet thickness+a value of, for example, 1 mm.
[0088] The upper workpiece 34 preferably has a tensile strength in the region of greater than 800 N/mm 2 , in particular greater than 1000 N/mm 2 . The lower workpiece 36 preferably has a tensile strength of smaller than 600 N/mm 2 . The self-piercing rivet 10 preferably has a (Vickers) hardness of more than 650 HV.
[0089] Although exemplary embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
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A self-piercing rivet for connecting high-strength steels. The rivet having a head which has a head diameter (DH); a shank which has a shank diameter (DS); and, located at the foot end of the shank opposite the head, the shank has radially outward a flat surface section and radially inward an axial recess defining an axial depth (LB). The ratio of axial depth (LB) of the recess to the shank diameter (DS) is smaller than 0.3.
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This is a continuation of U.S. patent application Ser. No. 08/594,923 filed Jan. 31, 1996 now U.S. Pat. No. 5,690,791.
FIELD OF THE INVENTION
The present invention relates to a press section of a paper machine, through which the paper web has a substantially closed and supported draw and which press section comprises an extended-nip zone followed by an equalizing-nip zone in the running direction of the web. In the equalizing-nip zone, the asymmetry of roughness, that was formed in the web to be pressed in the preceding press nip or nips, is equalized while dewatering of the web does not occur, at least not to a substantial extent.
BACKGROUND OF THE INVENTION
One of the most important quality requirements of paper and board is uniformity of the structure both on the micro scale and on the macro scale. The structure of paper, in particular of printing paper, must also be symmetric. The good printing properties required from printing paper mean equal good smoothness, evenness, and certain absorption properties of both faces of the paper. The properties of paper, such as the symmetry of surface roughness and density, are affected to a considerable extent by the operation of the press section of the paper machine, which operation also has a decisive significance on the uniformity of the profiles of the paper in the cross direction and in the machine direction.
Increased running speeds of paper machines create new problems to be solved, which problems are mostly related to the runnability of the machine. Currently, running speeds of up to about 1500 meters per minute are employed. At these running speeds, so called closed press sections, which comprise a compact combination of press rolls fitted around a smooth-faced center roll, usually operate satisfactorily. As examples of such press sections should be mentioned the current assignee's "Sym-Press II"™ and "Sym-Press O"™ press sections.
From the point of view of energy economy, dewatering taking place by pressing is preferable to dewatering taking place by evaporation. For this reason, attempts should be made to remove a maximum amount of water out of the paper web by pressing in order that the proportion of water to be removed by evaporation can be made as small as possible. Increased running speeds of paper machines, however, create new, so far unsolved problems expressly for the dewatering taking place by pressing, because the press impulse cannot be increased sufficiently by the means known from the prior art. This inability to increase the press impulse results from the fact that at high speeds, the nip times in roll nips remain inadequately short and, on the other hand, the peak pressure of pressing cannot be increased beyond a certain limit without destruction of the structure of the web.
In the prior art press sections, the single-felt last press nip tends to produce a poor symmetry of roughness, in particular with fine paper and with LWC and MWC base paper. The problem is emphasized when the press impulse is high, as is the case with an extended-nip press in the last press position. For example, with MWC base paper, with the assignee's test paper machine, when non-calendered, for top-face/bottom-face Bendtsen roughness the value of 0.52 was obtained, when the press load was about 800 kN per meter in a "Sym-Belt S"™ press section, when the length of the press shoe was about 152 mm, and when the smooth press roll was in the upper position of the single-felt press nip. This high asymmetry of roughness constitutes a limitation for the extent of press load, for the dry solids content that can be achieved, and for the wet strength.
It is known in the prior art to employ so-called equalizing presses in connection with various press sections, including extended-nip press sections, by means of which attempts are made to equalize the above asymmetry of roughness. With respect to these prior art equalizing presses, reference is made, for example, to the assignee's Finnish Patent No. 64,823 (which corresponds to U.S. Pat. No. 4,560,946, the specification of which is incorporated by reference herein), to published German Patent Application No. 4,321,406 A1 of Messrs. J. M. Voith GmbH, and to German Utility Model No. G 9,206,340.3 of Messrs. Sulzer-Escher Wyss GmbH. By means of the equalizing presses known from these publications mentioned above, it has, however, not been possible to solve the problems related to asymmetry of roughness in a satisfactory manner, in particular not in connection with a supported transfer of the web.
Of the cited publications mentioned above, the German Utility Model is likely the most closely related to the present invention, and in the equalizing press described in this Utility Model, the lower press roll in the equalizing press curves the transfer belt and the web over a considerably large angle. Moreover, in connection with the same lower press roll, a web transfer nip has been formed by means of a suction roll. Thus, in this construction, it is impossible to make use of differences in speed, by whose means it would be possible to tighten the web after the equalizing press so as to eliminate the effects of elongation of the web taking place in the equalizing press. Moreover, in these constructions, there is a relatively abrupt angle of change in direction in a sensitive area directly after the equalizing press which, for its part, restricts the speed of operation of the press.
Moreover, the prior art press sections provided with an equalizing press in a paper machine have occupied quite a large space, in particular in the machine direction, and in the prior art constructions, it has not been possible to utilize the various components in an optimal manner.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to avoid these drawbacks of prior art press constructions.
It is another object of the invention to further develop the prior art most closely related to the present invention, i.e., a press section including an equalizing nip.
It is still another object of the invention to provide a new and improved press section with an equalizing nip in a paper machine.
In view of achieving the objects stated above and others, in the press section in accordance with the invention, an extended-nip zone and an equalizing-nip zone are formed between three press components which are interconnected in a compact way so that the extended nip is formed by a press component that is provided with a flexible mantle together with a press roll provided with a rigid mantle which also partially defines the equalizing-nip zone, together with a smooth-faced equalizing-press roll. After the equalizing-nip zone, the web has a free draw or free draws or the run of a transfer fabric, on which draw/draws or run, by means of a difference in speed, the stretch of the web in the machine direction, taking place in the equalizing-press nip, can be compensated for and the web can be kept appropriately tensioned. The difference is speed is realized between the web travel speed after the equalizing-nip zone and the web travel speed before the equalizing-nip zone.
In the press section of the present invention, an extended-nip press is used, in which one of the press components is, for example, a hose roll with a resilient mantle, and the other press component defining the extended-nip press is a rigid-mantle press roll, the equalizing nip being formed against the rigid-mantle press roll. Thus, the press roll of the extended-nip press operates, at the same time, in two different functions, i.e., as a press component both in the extended nip and in the equalizing nip, which makes the construction highly favorable and compact. Thus, in the press section in accordance with the invention, advantages are realized in that the press section can be made smaller and with fewer components than conventional press sections with an equalizing press nip.
Furthermore, owing to the equalizing nip arranged in accordance with the invention, both sides of the web are provided with smoothness properties of substantially the same level, i.e., the symmetry of roughness discussed above is carried into effect. Thus, the achievement of a symmetry of roughness does not constitute a limitation for the extents of press loads, for the dry solids content that can be achieved, or for the wet strength, which was the case in similar prior art press sections.
In the invention, it has been possible to create such a press section including an equalizing nip which is very compact in particular in the machine direction, so that if necessary, for example in the case of modernizations of paper machines, it can be arranged in the place of an existing compact press section.
In one preferred embodiment of the invention, the web is transferred from the last dewatering extended nip in the press section on a transfer belt as a linear run through the equalizing press so that the joint run of the transfer belt and the web after the equalizing nip continues as a substantially straight run. On the open draw or draws of the web after the equalizing nip or on the run of the transfer belt and the web, the web and the transfer fabric can be stretched to some extent so that the elongation of the web inevitably taking place in the equalizing press can be compensated for and the web be kept appropriately tight.
In other embodiments of the invention, it is possible to employ a particular transfer belt which transfers the paper web from the equalizing-nip zone to the dryer section of the paper machine. In such embodiments, the transfer belt is preferably arranged so that the equalizing-press roll is placed inside the loop of the transfer belt. The outer face of this transfer-belt loop has suitable properties of smoothness and adhesion, and its elastic properties are suitable for the purpose, so that, when the difference in speed is utilized in accordance with the invention, elongation of the web taking place in the equalizing-press nip in the machine direction can be compensated for and the web can be kept appropriately tight.
Thus, in its most basic embodiment, the press section of a paper machine in which a paper web is pressed, comprises first and second press rolls arranged in nip-defining relationship to form an extended nip through which the web passes. The first press roll has a flexible mantle and the second press roll has a rigid mantle. A third press roll is arranged in nip-defining relationship with the second press roll to form an equalizing-nip zone through which the web passes after the extended-nip zone. The third press roll comprises a smooth-faced equalizing-press roll. As discussed above, the web is stretched in the equalizing-nip zone to equalize asymmetry of roughness formed in the web at least in the extended-nip zone before the equalizing-nip zone as well as in the preceding nips. The press section also includes compensation means arranged after the equalizing-nip zone for changing the speed of the web such that the web has a different running speed after the equalizing-nip zone than before the equalizing-nip zone to compensate for stretching of the web taking place in the equalizing-press nip and to tension the web. The compensation means may comprise means for providing the web with at least one free draw immediately after the equalizing-nip zone or means for carrying the web on a transfer fabric immediately after the equalizing-nip zone.
The present invention also relates to a method for pressing a web in a press section of a paper machine which comprises the steps of forming an extended nip between first and second press rolls, the first press roll having a flexible mantle and the second press roll having a rigid mantle, passing the web through the extended nip forming an equalizing-nip zone between a third press roll and the second press roll, the third press roll comprising a smooth-faced equalizing-press roll, passing the web through the equalizing-nip zone after the extended-nip zone to stretch the web in order to equalize asymmetry of roughness formed in the web at least in the extended-nip zone before the equalizing-nip zone, and changing the speed of the web such that the web has a different running speed after the equalizing-nip zone than before the equalizing-nip zone to compensate for the stretching of the web taking place in the equalizing-press nip and to tension the web. The method may include the steps of providing the web with a single free draw immediately after the equalizing-nip zone or providing the web with at least two free draws immediately after the equalizing-nip zone or carrying the web on a transfer fabric immediately after the equalizing-nip zone.
In the following, the invention will be described in detail with reference to some exemplifying embodiments of the invention illustrated in the figures in the accompanying drawing. However, the invention is by no means strictly confined to the details of the illustrated embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings are illustrative of embodiments of the invention and are not meant to limit the scope of the invention as encompassed by the claims.
FIG. 1 is a schematic side view of an embodiment of the invention in which there is first a closed press portion of the "Sym-Press II"™ type, which is followed by a compact press portion in accordance with the invention, comprising an extended nip and an equalizing nip.
FIG. 2 is an illustration similar to FIG. 1 of an embodiment of the invention in which the paper web to be pressed is brought straight from the forming wire on an upper pick-up press fabric into the extended nip in the press section in accordance with the invention.
FIG. 3 shows a modification of the press section shown in FIG. 2 in which two opposite fabrics have been passed through the extended-nip zone.
FIG. 4 is a schematic illustration of a modification of the press sections shown in FIGS. 2 and 3 in which the web is transferred from the equalizing-nip zone to the dryer section by means of a particular transfer-belt loop.
FIG. 5 is a schematic illustration of a modification of the press shown in FIG. 1, in which the web is transferred from the equalizing-nip zone to the dryer section using a particular transfer-belt loop.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the accompanying drawings wherein the same reference numerals refer to the same or similar elements, as shown in FIG. 1, after the web former of forming section in the paper machine, the press section in the paper machine comprises a compact combination of press members such as press rolls 10,11,12 and 13, which rolls form three dewatering press nips N 1 , N 2 and N 3 with each other, i.e., rolls 10 and 11, rolls 11 and 12, and rolls 12 and 13 are in nip-defining relationship with one another. Roll 12 is termed a "center roll" in view of its central location and properties with respect to the other rolls. The first nip N 1 in the running direction of the web is provided with two felts. After the nip N 1 , the web W is transferred on a pick-up felt (not shown) through suction zones 11a and 11b into the second nip N 2 , after which the web follows the smooth face 12' of the center roll 12 of the press into the third nip N 3 which is formed between the press rolls 12 and 13. After the nip N 3 , the web W is separated from the center roll 12 by means of another press roll 14 which is arranged with respect to the center roll 12 to form a low-load transfer nip N S with the center roll 12. By means of the roll 14, the web W is transferred onto the lower fabric 17 in the area of suction zones 15a and 15b of a transfer-suction roll 15 in nip-defining relationship with the roll 14. The rolls 14 and 15 form either a press nip N 4 or a corresponding low-load transfer nip with one another. In FIG. 1, the rolls 10,11,12 and 13 form a press section of the so-called "Sym-Press II"™ type. Instead of this, it is also possible to use the assignee's press section of the "Sym-Press O"™ type or one or several separate roll nip(s) and/or extended nip(s). After the transfer suction roll 15, the web W is transferred on the top face of the press fabric 17 through an extended-nip zone NP in the press section in accordance with the invention.
The extended-nip zone NP shown in FIGS. 1-5 is accomplished, for example, by means of the assignee's "Sym Belt Press"™, the details of whose construction are illustrated, e.g., in FIG. 10 in the assignee's Finnish Patent Application No. 905798 corresponding to the current assignee's U.S. Pat. No. 5,389,205, the specification of which is incorporated by reference herein. With regard to its principal features, the construction of the press is such that the extended nip NP is composed of a flexible hose mantle 20' and a rigid backup roll 21. The hose mantle 20', which is placed inside the loop of dewatering fabric 17,53, is preferably hollow-faced. Inside the hose mantle 20', there is a hydrostatically and/or hydrodynamically lubricated glide shoe 23, and the hydraulic loading means placed in connection with the shoe press the glide shoe 23 against the rigid backup roll 21. The backup roll 21 is a press roll, for example the assignee's adjustable-crown "Sym-Z Roll"™, which has a smooth or hollow-faced cylindrical mantle 21'.
As shown in FIG. 1 herein, the flexible-mantle 20' hose roll 20 or equivalent is placed as the lower roll, and the upper roll is a rigid roll 21 which is expressly provided with a smooth face 21'. After the extended-nip zone NP, the upper press roll 21 forms an equalizing nip NT together with a smooth-faced 31' equalizing-press roll 31. The roll 31 is provided with a drive 31a of its own. The equalizing-press roll 31 is mounted on the bearing supports 32 which are connected with the frame part 104 by means of horizontal articulation shafts 33. The bearing supports 32 are connected with actuators 34 by whose means it is possible to produce a compression pressure in the equalizing nip NT and, when necessary, to open the nip, for example, in connection with threading of the web W. After the equalizing nip NT, the web W follows the smooth face 31' of the roll 31. Alter this, there is a free draw W 0 of the web on which the web W can be kept tight so as to compensate for elongation of the web taking place in the equalizing nip NT. This is accomplished, e.g., by varying the rotational speed of the rolls defining the free, open draw W 0 to provide a speed difference between the speed of the web as it runs over the two rolls.
In the embodiment shown in FIG. 2, the rigid roll 21 has a smooth cylinder mantle 21', whereas in the embodiment shown in FIG. 3 the mantle 21' of the rigid roll 21 can be smooth or hollow-faced. After a paper guide roll 35, the web W is transferred into the dryer section of the paper machine onto the lower face of a drying wire 38 after its guide roll 36, to which wire the web is made to adhere by means of transfer-suction boxes 37. The transfer-suction boxes 37 are followed in the web travel direction by a first drying cylinder 40 or by a corresponding lead-in cylinder of the dryer section, which is placed in a position higher than the other drying cylinders in the first group with single-wire draw in the dryer section. The drying cylinder 40 or equivalent is followed by a reversing suction roll 41 and, after that, by a contact-drying cylinder 42, which is placed in a "normal" height position in the first group with single-wire draw.
The press section shown in FIGS. 2 and 3 differs from that shown in FIG. 1, in the respect that the press section does not include an initial press portion of the "Sym-Press II"™ type, but the paper web W is separated from a forming wire 50 before its drive roll 51 on a suction zone 52a of a pick-up roll 52 and is transferred on the lower face of a pick-up fabric 53 through the extended-nip zone NP. After the extended-nip zone NP, the paper web W is separated from the pick-up fabric 53, which operates as the upper water-receiving press fabric in the extended nip NP. The pick-up fabric 53 is guided by guide rolls 54. Furthermore, the extended-nip zone NP shown in FIGS. 2 and 3 differs from that shown in FIG. 1 in the respect that, in FIGS. 2 and 3, the flexible-mantle 21' hose roll 20 is placed as the upper press component, and the lower press component is a rigid-mantle press roll 21, in whose interior there is a series 24 of glide shoes for crown regulation.
In FIG. 2, after the extended-nip zone NP, the web W follows the smooth face 21' of the press roll 21 into the equalizing nip NT, which is formed by the press roll 21 and by the equalizing-press roll 31 which has a smooth cylinder face 31'. After the equalizing nip NT, the web W continues to follow the smooth face 21' of the press roll 21, from which it is separated as a free draw W 0 by means of a driven 35a paper guide roll 35 while making use of a suitable difference in speed and of tension. The drive means 35a of the paper guide 35 are controlled to provide a difference in speed of the web, i.e., the web will travel at a different speed over the paper guide roll 35 and over the equalizing-press roll 31. The roll 31 in the equalizing nip NT is mounted on bearing supports 32, which are again attached to a projection part 104 of a frame 103 by means of horizontal articulation shafts 33. The equalizing nip NT can be loaded and opened by means of actuators 34 which are coupled between the bearing support 32 and the frame 103. The paper guide roll 35 is followed by a second free draw W 1 of the web W, by whose means the web W can be tensioned further by means of the first drying cylinder 40 or the corresponding lead-in cylinder while making use of the drive 40a of the drying cylinder 40. After this, the web W is transferred on the cylinder 40 to a position underneath the drying wire 38 and further onto a reversing suction cylinder 41 and onto a contact-drying cylinder 42.
Differing from FIG. 2, in FIG. 3 the extended-nip zone NP is provided with a lower fabric 17a which runs through the extended-nip zone NP and the equalizing nip NT while guided by guide rolls 55. The fabric 17a is preferably a transfer belt which substantially does not receive water. The web W follows the belt after the equalizing nip NT on its run 17a', on which run it is possible to employ a difference in speed that stretches the transfer belt 17a. In this manner, it is possible to compensate for elongation of the web W taking place in the equalizing nip NT in the machine direction, in a way similar to what takes place on the free draw W 0 in FIG. 1 or on the free draws W 0 and W 1 in FIG. 2. After the substantially vertical downward draw 17a' of the transfer belt 17a, the web W is transferred onto the drying wire 38 by the effect of the suction zone 56a of the transfer-suction roll 56, and further onto the first drying cylinder or a corresponding lead-in cylinder, which is placed in a position lower than the contact-drying cylinders 42 in the first group with single-wire draw. In the other respects, the construction shown in FIG. 3 is similar to the construction shown in FIG. 2 and described above.
FIGS. 4 and 5 are illustrations more schematic than FIGS. 1, 2 and 3 of two embodiments of the invention, in which a particular loop of a transfer belt 17A, 17B is used for transferring the web W from the equalizing-nip zone NT to the dryer section. FIG. 4 is mainly similar to the embodiments shown in FIGS. 2 and 3 in the respect that the hose roll 20 is placed above in the extended nip NP. According to FIG. 4, after the extended nip NP, the web W is transferred on the smooth face 21' of the press roll 21 to the equalizing-nip zone NT, through which a particular loop of transfer belt 17A runs, which belt loop is guided by guide rolls 56. The latter press roll 31 in the equalizing-nip zone NT is placed inside the transfer-belt loop 17A. After the equalizing nip NT, the web W is transferred further on the downwardly inclined straight run 17A' of the transfer belt 17A, on which run, while making use of a difference in speed, it is possible to compensate for elongation of the web W taking place in the equalizing nip NT in the machine direction and to keep the web W appropriately tight. After the run 17A', the web W is transferred by means of the loop of transfer belt 17A over the guide roll 56 to the transfer zone TS, where the web W is transferred onto the smooth face 40' of the drying cylinder 40.
FIG. 5 is substantially similar to the embodiment shown in FIG. 1, in which the hose roll 20 is placed below the rigid press roll 21. After the extended nip NP, the web W follows the smooth face 21' of the press roll 21 into the equalizing nip NT, through which a particular loop of transfer belt 17B runs. After the equalizing nip NT, the web W is transferred on the transfer belt 17B over the press roll 31 onto the downwardly inclined run 17B' of the loop of transfer belt 17B, on which run, while making use of a difference in speed, it is possible to compensate for elongation of the web W taking place in the equalizing-press nip NT in the machine direction and to keep the web W appropriately tight. After the run 17B', the web W is transferred in the transfer zone TS onto the drying wire 38, which runs over the turning sector of the reversing-suction cylinder 41, which turning sector is provided with a hollow face 41' subjected to a vacuum. The outer faces of the particular transfer belts 17A,17B employed in FIGS. 4 and 5 have smoothness and adhesion properties suitable in view of the operation of the equalizing nip NT and in view of transfer of the web W further. The transfer belt 17A,17B is also a belt which does substantially receive water, and it has elastic properties suitable for the purposes stated above.
The press section in accordance with the invention is usable even at very high web speeds. According to a preliminary estimate, an embodiment as shown in FIGS. 1 and 2, in which there is/are an open draw W 0 or draws W 0 W 1 of the web W, can be used up to a running speed of about 1700 meters per minute. For running speeds higher than this, the fully closed draws of the web W through the press section and further to the dryer section, as shown in FIGS. 3, 4 and 5, are available.
FIGS. 1, 2 and 3 are also schematic illustrations of the frame construction 100 of the press section, which comprises vertical frames 101, 102 and 103 and a connecting upper horizontal frame 105.
As shown in FIG. 1, the hose roll 20 of the extended nip NP is supported by means of its bearing supports 25, intermediate parts 29, and the lower frame 30 between the vertical frames 101 and 102. The bearing supports 26 of the upper press roll 21 are connected by means of intermediate parts 27 to the bearing supports 25 of the hose roll 20 to receive the high loading forces at the extended nip NP, which loading forces are produced by means of series of press shoes 23 and 24. In the embodiments shown in FIGS. 2 and 3, the upper hose roll 20 is coupled by means of its bearing supports 25 and the intermediate parts 29 with the top portion of the vertical frame 101, and similarly the bearing supports 26 of the lower press roll 21 are supported on the lower base part 106. In the other respects, the frame constructions are in themselves known from the prior art and provided with openable intermediate pieces 107 necessary, for example, for replacement of the press fabrics 17;17a,53,53.
Attempts have been made to optimize the geometry of the compact combination of rolls comprising the extended nip NP and the equalizing nip NT both in respect of utilization of space and in respect of undisturbed draw of the web W also at high web speeds (about 1500 to about 2000 meters per minute). For these purposes, it is preferable that the press plane T--T passing through the extended nip NP is inclined at a small angle a in relation to the direction of arrival of the web W. The magnitude of the angle of inclination a is generally from about 10° to about 15°, preferably 10°. In FIG. 1, the equalizing nip NT is preferably placed on the latter upper quarter of the press roll 21 at a distance of the center angle b from the plane T--T. The angle b is generally selected in the range of from about 70° to about 80°, preferably about 75°.
In the press section geometry as shown in FIG. 1, it is preferable that, when the equalizing nip NT is placed above the extended nip NP, in which case the substantial or principal direction of the run of the web after the extended nip NP is upwardly inclined, the first drying cylinder 40 or the corresponding lead-in cylinder is placed at a position higher than the normal position, or the substantial or principal direction of the first single-wire draw is arranged downwardly inclined in the running direction of the web. The situation is contrary in the embodiments shown in FIGS. 2 and 3, in which the equalizing nip NT is placed below the extended nip NP, in which case the substantial direction of the web after the extended nip NP towards the dryer section is downwardly inclined, in which case the first drying cylinder 40 or the last lead-in cylinder is arranged at a level lower than the normal position (the dimension ΔH indicated in FIGS. 2 and 3).
The diameter D1 of the flexible-mantle 20' hose roll 20 or equivalent at the extended-nip zone has been chosen in the range of from about 1400 mm to about 2000 mm, depending on the width of the machine. The diameter D2 of the rigid-mantle 21' press roll 21 at the extended-nip zone NP has been chosen in the range from about 1200 mm to about 1600 mm, depending on the width of the machine. The diameter D3 of the smooth-faced 31' press roll 31 at the equalizing nip NT has been chosen in the range of from about 700 mm to about 1200 mm, depending on the width of the machine.
The examples provided above are not meant to be exclusive. Many other variations of the present invention would be obvious to those skilled in the art, and are contemplated to be within the scope of the appended claims.
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A press section of a paper machine through which a paper web has a substantially closed and supported draw including an extended-nip zone and an equalizing-nip zone following the extended-nip zone in the running direction of the web. In the equalizing-nip zone, the asymmetry of roughness is equalized that was formed in the web to be pressed in the preceding press nip or nips, while not dewatering the web to a substantial extent. The extended-nip zone and the equalizing-nip zone are formed between three press components which are interconnected in a compact way so that the extended nip is formed by a press component provided with a flexible mantle together with a press roll provided with a rigid mantle. The press roll with the rigid mantle also forms the equalizing-nip zone together with a smooth-faced equalizing-press roll. After the equalizing-nip zone, the web has at least one free draw or runs on a transfer fabric, on which draw(s) or run, by a difference in speed, the stretch of the web in the machine direction, taking place in the equalizing-press nip is compensated for and the web is kept appropriately tensioned.
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BACKGROUND OF THE INVENTION
The invention relates to a transmitter with a quadrature modulator and a power amplifier, which is linearised by what is known as a Cartesian feedback with a quadrature modulator.
EP 0 706 259 A1 discloses a transmitter in which a baseband input signal is applied via two differential amplifiers to a quadrature modulator, which effects a quadrature modulation of the in-phase component and the quadrature-phase component of the complex input signal. The signal is applied to an up-converter, which brings the signal from the baseband up to the transmission frequency. Power amplification takes place in a downstream power amplifier. A feedback loop is provided in order to compensate for the non-linearity of this power amplifier, generally known as a Cartesian feedback. Located in this feedback loop, firstly, is a down-converter which converts the transmission signal uncoupled from the output of the power amplifier back down to the baseband. Located in the baseband is a quadrature demodulator, which separates the feedback signal into a feedback in-phase component and a feedback quadrature-phase component. The feedback in-phase component together with the in-phase component of the input signal is forwarded to a first differential amplifier connected upstream of the quadrature modulator. Likewise, the feedback quadrature-phase component together with the quadrature-phase component of the input signal is applied to a second differential amplifier. The non-linearities of the power amplifier are compensated through the feedback signal as a result.
In order to compensate the DC components of the quadrature modulator, document EP 0 706 259 A1 proposes operating a training sequence during which no input signal is applied to the transmitter. The output signal of the two differential amplifiers is integrated in a respective integrator and applied to a respective sample and hold circuit connected downstream of the integrator. During the training sequence, the sample and hold circuit is in the sampling state and applies a compensation signal to a negative feedback input of the co-operating differential amplifier such that the direct voltage components of the associated arm of the quadrature modulator are compensated. During normal transmission mode, the sample and hold circuit is in the hold state and applies the compensation level determined during the training run to the input of the respective differential amplifier. Document EP 0 706 259 A1 also proposes running another training sequence, during which switches provided on the output of the quadrature modulator are opened, to determine the phase shift for a phase shifter provided between a local oscillator and the quadrature modulator by detecting the output signal of the quadrature modulator in this state with two different input signals.
When using a transmitter which operates on the principle of Cartesian feedback in aeronautical radio communications, particularly with digital aeronautical radio communications operating in TDMA-simplex in accordance with the VDL standard (VHF digital link), a problem arises in that it is very difficult to switch rapidly between transmission mode and reception mode because on switching from transmission mode to reception mode the power amplifier and the local oscillator have to be completely disabled in order to prevent radiation in the receiver. However, the high-frequency feedback loop between the outputs and the compensation inputs of the differential amplifiers necessarily has to be broken in the process. When the power amplifier and the local oscillator are re-enabled as the operating mode is switched from reception to transmission, the feedback loop therefore has to be re-built, which leads to undesirable signal jumps during the switch from reception to transmission. Whilst transmission is interrupted, control of the feedback loop would be adjusted to the positive or negative control end. When re-enabled, the full transmission power would immediately be applied. Document EP 0 706 259 A1 does not suggest any means by which this problem can be eliminated.
SUMMARY OF THE INVENTION
Accordingly, the underlying objective of the invention is to propose a transmitter with a power amplifier, linearised on the principle of Cartesian feedback, which enables rapid switching from transmission to reception mode, and to specify a corresponding method for switching this transmitter from transmission mode into a transmission-interrupt mode or reception mode.
In terms of the transmitter, this objective is achieved by the characterising features of claim 1 and in terms of the method by the characterising features of claim 10 respectively, in conjunction with the known generic features.
The invention is based on the principle whereby, connected in parallel with the high-frequency signal path formed by the quadrature modulator, the power amplifier and the quadrature demodulator is another direct signal path, via which the output of the differential amplifier is connected to the feedback input when switching from transmission mode to reception mode, bypassing the quadrature modulator, the power amplifier and the quadrature demodulator. The output of the differential amplifier is therefore connected to its feedback input at all times—during transmission mode via the high-frequency signal path and during reception mode via the direct (DC) signal path. The switch from reception to transmission is preferably operated so that when switching from transmission mode to reception mode, the direct (DC) signal path is closed first of all, before the high-frequency signal path is opened. On switching from transmission mode into reception mode, the sequence is reversed accordingly. This avoids signal jumps when switching from transmission to reception.
Advantageously, two additional differential amplifiers are provided respectively in both the in-phase signal path and the quadrature-phase signal path, by means of which compensating voltages can be coupled into the signal paths in order to compensate both the DC offset of the quadrature modulator and the DC offset of the quadrature demodulator. As a result, in the disabled state when no signal is present on the I and Q input, the voltage value OV is obtained at the input and output of the differential amplifier enabling the DC signal path to be activated surge-free.
The quadrature modulator is compensated when the high-frequency signal path is closed. The quadrature demodulator, on the other hand, is compensated with the high-frequency signal path open and the DC signal path closed. Compensation is operated in such a way that the output voltage at the differential amplifiers used for compensation purposes is minimised. This can be accomplished with very little complexity in terms of measurement and at a high measuring rate. In addition, the quadrature demodulator can be trimmed whilst the high-frequency signal path is still closed, in which case the output power of the power amplifier when the input signal is disabled is used as the measured value, i.e. can be measured by means of a logarithmic detector.
A simplified example of an embodiment of the invention will be described in more detail below with reference to the drawings. Of the drawings:
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a block diagram depicting an example of one embodiment of the transmitter proposed by the invention;
FIG. 2 is a detail from the transmitter illustrated in FIG. 1 ; and
FIG. 3 is a schematic diagram of the output power of the transmitter as a function of time with a view to explaining a preferred compensating method.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block diagram illustrating the operating principle of an example of a first embodiment of the transmitter proposed by the invention.
A digital signal processor (DSP) 2 generates a complex input signal for a quadrature modulator 3 , which consists of an in-phase mixer 4 , a quadrature-phase mixer 5 and a summer 6 as well as a phase shifter 7 . The complex input signal consists of an in-phase component I and a quadrature-phase component Q, the in-phase component I being forwarded to the in-phase mixer 4 and the quadrature-phase component Q to the quadrature-phase mixer 5 . The output signal of a local oscillator 8 is applied to the phase shifter 7 and the phase shifter 7 forwards this oscillator signal to the in-phase mixer 4 without any phase shift and to the quadrature-phase mixer 5 with a phase shift of 90°.
Connected downstream of the quadrature modulator 3 is a power amplifier 9 , which amplifies the power of the quadrature modulated signal to the transmission power of the transmitter 1 and forwards it via a circulator 10 , a power detector 11 and a transmit-receive switch 12 to an antenna 13 . In the embodiment illustrated as an example in FIG. 1 , the digital signal processor 2 simultaneously serves as a control unit for switching from transmission to reception mode and controls the transmit-receive switch 12 so that the antenna is connected to the power amplifier 9 in transmission mode and to a receiver denoted by RX in reception mode. The circulator 10 connected to the terminating resistor 14 is used to prevent feedback of any reflected transmission power into the power amplifier 9 .
Located in the signal path between the power amplifier 9 and the antenna 13 is an output coupler 15 which couples the output signal of the power amplifier 9 into a feedback loop 16 . Located in the feedback loop 16 is a selector switch 17 , by means of which an input 18 of a quadrature demodulator 19 can be selectively connected to the output coupler 15 or a terminating resistor 20 . A logarithmic power detector 39 is disposed between the output coupler 15 and the selector switch 17 . The quadrature demodulator 19 consists of a signal splitter 21 , which splits the input signal evenly between an in-phase mixer 22 and a quadrature-phase mixer 23 . A phase shifter 24 is also provided, to which the output signal of the local oscillator 8 is forwarded via an adjustable phase shifter 25 . The phase shifter 24 operates in the same way as the phase shifter 7 and forwards a non-phase-shifted oscillator signal to the in-phase mixer 22 and an oscillator signal phase-shifted by 90° to the quadrature-phase mixer 23 , the oscillator signal having been previously phase-shifted overall by a phase angle φ by a phase shifter 25 .
A feedback in-phase component I′ is generated at the output of the in-phase mixer 22 and a feedback quadrature-phase component Q′ at the output of the quadrature-phase mixer 23 . The in-phase component I of the input signal is sent to the (+) input of a first differential amplifier 26 whilst the feedback in-phase component I′ is sent to the (−) input of the first differential amplifier 26 . In the same way, the quadrature-phase component Q of the input signal is applied to the (+) input of a second differential amplifier 27 whilst the feedback quadrature phase component Q′ is applied to the (−) input of the second differential amplifier 27 . As a result of this feedback arrangement, generally referred to as a Cartesian feedback, linearisation errors of the power amplifier 9 are compensated by the quadrature demodulator 19 and the differential amplifiers 26 and 27 disposed in the feedback loop 16 . However, care should be taken to ensure that the feedback signal I′, Q′ is forwarded to the differential amplifiers 26 and 27 with a phase shift of 0° relative to the input signal I, Q. The correct phase position is adjusted by the adjustable phase shifter 25 , whose phase angle φ can be varied via the digital signal processor by means of a control signal.
Since both the quadrature modulator 3 and the quadrature demodulator 19 have a DC offset, this DC offset needs to be compensated accordingly.
A third differential amplifier 28 is used for this purpose, disposed between the in-phase mixer 22 of the quadrature demodulator 19 and the first amplifier 26 . A fourth differential amplifier 29 is provided between the quadrature-phase mixer 23 of the quadrature demodulator 19 and the second differential amplifier 27 . Whilst the feedback in-phase component I′ is forwarded to the (+) input of the third differential amplifier 28 , a first compensating voltage V I1 , is applied to the (−) input of the third differential amplifier 28 so that the DC offset of the I′ component of the quadrature demodulator 19 is compensated at the output of the third differential amplifier 28 . Similarly, the feedback quadrature-phase component Q′ is applied to the (+) input of the fourth differential amplifier 29 whilst a fourth compensating voltage V Q1 is forwarded to its (−) input.
A fifth differential amplifier 30 is used to compensate the DC offset of the quadrature modulator 3 , the (+) input of which is forwarded to the output of the first differential amplifier 26 whilst a third compensating voltage V I2 is applied to its (−) input. A sixth differential amplifier 31 is also provided, the output of which is connected to the quadrature-phase mixer 5 of the quadrature modulator 3 and the (+) input of which is applied to the output of the second differential amplifier 27 . A fourth compensating voltage V Q2 is applied to the (−) input of the sixth differential amplifier 31 . The compensating voltages V I1 , V Q1 , V I2 and V Q2 are shown as controllable voltage sources in FIG. 1 for the sake of clarity in the drawing but in practice, these compensating voltages may be internally generated in the digital signal processor 2 .
Switching rapidly between transmission mode and reception mode using a feedback loop 16 operated on the Cartesian feedback principle causes a problem in that the high-frequency signal path of the loop, consisting of the quadrature modulator 3 , the power amplifier 9 , the quadrature demodulator 19 and the differential amplifiers 26 and 27 , has to be interrupted when the switch is made from transmission mode to reception mode because the power amplifier 9 and the local oscillator 8 have to be disabled. When the power amplifier 9 and the local oscillator 8 are re-activated and the high-frequency signal path restored via the feedback loop 16 , a switching surge is produced because the voltages of the control system, in other words the output voltages of the two differential amplifiers 26 , 27 , act in the positive or negative control sense when the high-frequency signal path is open. This leads to an unacceptable jump in power to the maximum possible transmission power of the power amplifier 9 . If, as is the case in applications using VDL digital aeronautical radio (VHF digital link), only a short switching time is available, the Cartesian feedback system cannot be used without taking specific measures. In a TDMA system (such as VDL, for example), the power of the adjacent channel must not be adversely affected by burst mode operation. The definition of the VDL standard theoretically permits the transmitter to be enabled and disabled free of interference. The feature proposed by the invention guarantees an ideal interference-free spectrum in the sampled range.
In order to get round this problem, the invention proposes that, in addition to the high-frequency signal path from the output of the differential amplifiers 26 and 27 to the (−) input of the differential amplifiers 26 and 27 via the quadrature modulator 3 , the power amplifier 9 and the quadrature demodulator 19 , two direct DC signal paths 32 and 33 be provided, which connect the output of the respective associated differential amplifier 26 or 27 directly to the (−) input of the respective differential amplifier 26 or 27 . In the embodiment illustrated as an example here, the direct DC signal paths 32 and 33 consist respectively of a controllable switch 34 or 35 , which may be provided in the form of field effect transistors, for example, and a resistor 36 or 37 connected in series.
The switch from transmission mode to reception mode as proposed by the invention is made in such a way that before the high-frequency signal path is opened, the switches 34 and 35 are firstly closed so that both the high-frequency signal path via the feedback loop 16 and the direct DC signal paths 32 and 33 are operating. Then, the switch 17 is activated by the digital signal processor 2 so that the input 18 of the quadrature demodulator 19 is no longer connected to the output coupler 15 but to the terminating resistor 20 , which means that the high-frequency signal path via the feedback loop 16 is broken. Since there is therefore no longer any input signal at the input of the quadrature demodulator 19 , the level at the (−) input of the first and second differential amplifiers 26 and 27 is defined by the feedback of the DC signal path 32 or 33 and the constant output voltage of the third and fourth differential amplifiers 28 and 29 . Even before the high-frequency signal path is opened by reversing the switch 17 , the current supply (bias) of the power amplifier 9 can be shut off. The transmit-receive switch 12 at the input of the antenna 13 can already be switched, once the I/Q input signal has been reduced (ramping), before the switches 34 , 35 and 17 are activated and before the current supply of the power amplifier 9 is broken, as a result of which a good breaking isolation is immediately obtained. Reflections occurring at the transmit-receive switch 12 are forwarded via the circulator 10 to the terminating resistor 14 . Finally, the local oscillator 8 is switched off.
When switching to transmission mode, the sequence is operated in reverse order.
Firstly the local oscillator 8 is enabled and the current supply (bias) connected to the power amplifier 9 . The high-frequency signal path via the feedback loop 16 is then closed by switching the selector switch 17 . The switches 34 and 35 are then opened so that the DC signal paths 32 and 33 are broken again. The transmit-receive switch 12 is switched so that the output of the power amplifier 9 is connected to the antenna 13 .
The system of overlapping switching between DC signal path and high-frequency signal path as proposed by the invention ensures that no signal jumps occur during switching because the output of the first and second differential amplifier 26 or 27 is constantly connected to its (−) input either via the high-frequency signal path or via the DC signal path 32 or 33 . Consequently, there is always a defined signal level at the (−) input of the differential amplifiers 26 and 27 .
FIG. 2 is a more detailed circuit diagram illustrating the connections of the differential amplifiers 26 , 27 , 28 , 29 , 30 and 31 , only the signal path for the quadrature-phase component Q, in other words the differential amplifiers 29 , 27 and 31 , being shown. An identical circuit is provided for the in-phase component I.
The input terminal 41 is connected to the output of the quadrature-phase mixer 23 of the quadrature demodulator 19 and internally with the (+) input of the differential amplifier 29 . Between the (+) input of the differential amplifier 29 and the circuit earth 42 is a resistor 43 . Another resistor 44 is disposed between the (−) input of the differential amplifier 29 and the circuit earth 42 , the compensating voltage V Q1 being forwarded to the (−) input of the differential amplifier 29 via a series resistor 45 . Between the output of the differential amplifier 29 and its (−) input is another resistor 46 . The output of the differential amplifier 29 is connected to the (−) input of the differential amplifier 27 via a series resistor 47 .
The quadrature-phase component Q of the complex input signal is applied to the (+) input of the differential amplifier 27 via a terminal 48 . Between the terminal 48 and the circuit earth 42 is another resistor 49 . A further resistor 50 is provided between the output of the differential amplifier 27 and the circuit earth 42 . Between the output of the differential amplifier 27 and the (−) input of the differential amplifier 27 is a serially-connected RC-element, consisting of the capacitor 51 and the series resistor 52 . Connected in parallel therewith is the DC signal path 33 , which consists of the controllable switch 35 and the series resistor 37 . Consequently, by closing the controllable switch 35 , a potential equalisation is produced between the output of the differential amplifier 27 and its (−) input. The measurement voltage V QM lies on the output of the differential amplifier 27 at the measuring point 53 , the importance of which will be explained in more detail below.
The wiring of the differential amplifier 31 is identical to the wiring of the differential amplifier 29 and the layout of the resistors 54 – 57 corresponds to the layout of the resistors 44 – 47 . The correction value for the quadrature-phase mixer 5 of the quadrature modulator 3 can be taken from the output terminal 58 . A RC-element consisting of the capacitor 59 and the resistor 60 connected in parallel therewith is disposed at the output terminal 58 . The RC-element defines the bandwidth of the high-frequency signal path.
The potential at the (+) input of the differential amplifier 29 is U 1 , whilst the potential at the output of the differential amplifier 29 or at the (−) input of the differential amplifier 27 is U 1 −V Q1 . Similarly, the potential at the output of the differential amplifier 27 or at the (+) input of the differential amplifier 31 is U 2 +V Q2 , which means that a potential of U 2 is set at the output of the differential amplifier 31 . The variable compensating voltages V Q1 and V Q2 are set by an interactive compensating process so that the potential at the (−) input and at the output of the differential amplifier 27 is respectively zero, i.e. U 1 −V Q1 =0 and U 2 +V Q2 =0. Since the potential at the (−) input and output of the differential amplifier 27 is uniformly zero, there are no switching surges when the switch 35 is operated and the DC signal path 32 can be switched on and off surge-free.
FIG. 3 illustrates the method proposed by the invention as a means of switching between the transmission mode and a transmission-interrupt mode or reception mode. A compensating process proposed by the invention which may advantageously be used within the context of the invention will simultaneously be explained with reference to this schematic timing diagram. FIG. 3 gives a logarithmic presentation of the output power P of the power amplifier 9 as a function of time t.
The VDL standard prescribes that at the start of the transmission period, a start signal should firstly be transmitted for a period of 3 data symbols, the complex input signal exclusively having an in-phase component I but no quadrature-phase component Q. Within this time period, denoted by 71 , the phase angle φ for the phase shifter 25 can therefore be measured. Since only an in-phase component I is transmitted during period 71 , the voltage at the measuring point 53 would have to be zero. The phase angle φ can therefore be selectively modified before the next transmission period (burst) so that the measurement voltage at the measuring point 53 is optimised to a smallest possible value. This phase angle φ is then maintained until the next transmission period and can be further optimised in the subsequent transmission period.
Data are transmitted between the instants t 2 and t 3 . At instant t 3 , the actual transmission process is terminated. In accordance with the VDL standard, situations arise in which a rapid switch has to be made between transmission mode and reception mode within a few 100 μs. This is indicated by line 75 in FIG. 3 . In this case, the procedure is as described above: the transmit-receive switch 12 is switched and the DC signal paths 32 and 33 are firstly established by closing the switches 34 and 35 . The current supply (bias) of the power amplifier 9 is then switched off and the input 18 of the quadrature demodulator 19 switched from the output coupler 15 to the terminating resistor 20 . Finally, the local oscillator 8 is disabled.
In VDL operation, however, there are also situations which permit a slower switching between transmission mode and reception mode, where there are approximately 2.5 ms within which to effect automatic compensation. This automatic compensation process is described below.
The quadrature demodulator 19 is trimmed during the period 72 as part of an optional trimming process. This trimming may also be dispensed with if necessary. To this end, the input signal I/Q is firstly reduced to zero so that the power amplifier generates only a minimal residual power P 2 . The compensating voltages V I1 , and V Q1 , which compensate the DC offset of the quadrature demodulator 19 , are optimised so that a minimal residual power P 2 is detected at the logarithmic power detector 39 . Since there is no input signal I/Q, the ideal output power P 2 is zero and an existing output signal will essentially be determined from the DC offset of the quadrature demodulator 19 .
In the subsequent period 73 , the quadrature modulator 3 is adjusted in that the measurement voltage V IM of the in-phase component is measured at the measuring point 61 and the measurement voltage V QM of the quadrature-phase component at the measuring point 53 in FIG. 1 . Again with this measurement, both the in-phase component I and the quadrature-phase component Q of the input signal generated by the digital signal processor 2 are zero so that the measured voltage V QM is essentially derived from the DC offset of the quadrature modulator 3 . By adjusting the voltages V I2 and V Q2 , the measurement voltages V IM and V QM are minimised towards zero. As a result, the DC offset of the modulator 3 is compensated.
The measurement is taken during period 72 and 73 during which the high-frequency signal path still closed, i.e. the switches 34 and 35 are still open and the selector switch 17 connects the input 18 of the quadrature demodulator 19 to the output coupler 15 . Furthermore, the voltage supply (bias) for the power amplifier 9 is still connected.
At instant t 4 , the two switches 34 and 35 are firstly closed, after which the selector switch 17 is switched to the terminating resistor 20 so that the DC signal paths 32 and 33 are now active but not the high-frequency signal path. Before the selector switch 17 is operated, the current supply to the power amplifier 9 is switched off.
Since the input signal at the quadrature demodulator 19 is zero as a result and because the digital signal processor 2 continues to generate an input signal I,Q of zero, a measurement voltage V IM and V QM measured at the measuring points 53 and 61 is essentially generated as a result of the DC offset of the quadrature demodulator 19 . By shifting the compensating voltages V I1 , and V Q1 in the period 74 , this DC offset and hence the measurement voltage V IM or V QM can be minimised. The values of the compensating voltages V I1 , V Q1 , V I2 , V Q2 found as a result of this compensating procedure can be used for the next transmission period.
At instant t 5 , the level of the local oscillator 8 is additionally reduced in order to prevent radiation in the receiver. This further enhances isolation between the transmitter and the receiver.
The invention is not restricted to the embodiments illustrated as examples here. In particular, the compensating steps may also be run in a different sequence or individual compensating steps dispensed with.
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The invention relates to a transmitting device ( 19 ) including a quadrature modulator ( 3 ) for carrying out the quadrature modulation of a complex input signal (I, Q) and including a power amplifier ( 9 ) connected in outgoing circuit to the quadrature modulator ( 3 ). A quadrature demodulator ( 19 ) for carrying out the quadrature demodulation of the output signal of the power amplifier ( 9 ) is provided for a feedback loop. A first differential amplifier ( 26 ) and a second differential amplifier ( 27 ) are connected in incoming circuit to the quadrature modulator ( 3 ). The input signal and the fed back quadrature modulated signal are supplied to the inputs of the differential amplifiers. When switching over from the transmit mode to a transmit-interruption mode, the output of the first and second differential amplifiers ( 26, 27 ) can be directly connected to the compensation input (−) of the first or second differential amplifier ( 26, 27 ) via a direct signal path ( 32, 33 ) while bypassing the quadrature modulator ( 3 ), the power amplifier ( 8 ) and the quadrature modulator ( 19 ).
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No. 60/411,906, filed Sep. 19, 2002 by Dan Stoianovici and Louis R. Kavoussi.
STATEMENT AS TO FEDERALLY SPONSORED RESEARCH
This invention was made with Government support under Grant No. 1 R21 CA88232-01A1 and entitled “Multi-Imager Compatible Robot For Prostrate Access,” which was awarded by the National Institute of Health. The Government may have certain rights in this invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to motors that provide rotary motion. More particularly, one embodiment of the present invention relates to a motor which is constructed from materials that can be used in all classes of medical imaging equipment and that generates precise, high torque, backlash-free rotary motion without using electricity.
2. Description of Prior Art
Noninvasive, diagnostic imaging techniques, such as ultrasound, x-ray and magnetic resonance imaging (MRI) are widely used in medicine. They are used to produce cross-sectional images of a patient's organs and other internal body structures.
MRI typically involves the patient lying inside a large, hollow cylinder containing a strong electromagnet, which generates a strong and uniform magnetic field that causes the electrons in a patient's body to spin in a uniform and predictable manner. The MRI equipment can then manipulate the spinning electrons and use the resulting information to generate an image of the inside of a patient's body.
However, difficulties are encountered in obtaining accurate images when disruptions and deflections in the magnetic field are experienced due to the presence in the field of materials that produce a magnetic field and/or are susceptible to producing their own magnetic fields when placed within an external magnetic field.
One source of magnetic field distortion can be equipment such as motors that are in the vicinity of the MRI machine. Motors are generally formed with materials that produce a magnetic field. Examples of such materials that are commonly used in motors include iron and brass. Thus, when placed in the field generated by the MRI machine, the motors can cause artifacts in the image of the patient's body.
Other forms of medical imaging (e.g., x-ray and ultrasound imagers) are also seen to have similar problems of distortions in their output images due to the presence of motors in the vicinity of the imaging equipment.
Prior attempts to provide a motor that can be used in such imaging environments have involved the use of piezoelectric elements to provide the motor's power. See U.S. Pat. Nos. 5,233,257 and 6,274,965.
Despite these efforts, there still exists a need for improved motors that can be placed near medical imaging equipment with minimal risk of creating artifacts. There is a related need for a motor that does not produce a magnetic field. There is yet another need for a motor that has a low susceptibility of being induced to produce a magnetic field. Additionally, there is a need for a rotary motor of the type that is not powered by electricity.
3. Objects and Advantages
There has been summarized above, rather broadly, the prior art that is related to the present invention in order that the context of the present invention may be better understood and appreciated. In this regard, it is instructive to also consider the objects and advantages of the present invention.
It is an object of the present invention to provide a rotary motor that can be used for medical applications which require the motor to be located in or in close proximity to medical imaging equipment.
It is another object of the present invention to provide a rotary motor that can be used in a surgical environment.
It is yet another object of the present invention to provide a motor that can provide precise, high torque, backlash-free rotary motion.
It is still another object of the present invention to provide a rotary motor that does not utilize electrical power or electrical components for operation.
It is a further object of the present invention to provide a precise rotary motor whose motion can be monitored by sensors located at a site that is distant from the location of the motor itself.
It is an object of the present invention to provide a rotary motor that can be powered by other than electrical means.
These and other objects and advantages of the present invention will become readily apparent as the invention is better understood by reference to the accompanying summary, drawings and the detailed description that follows.
SUMMARY OF THE INVENTION
Recognizing the medical needs for the development of a precise rotary motor that can be used in medical imaging environments, the present invention is generally directed to satisfying the needs set forth above. In accordance with the present invention, the foregoing need can be satisfied by providing an especially designed motor that is suitable for use in a medical imaging room.
In a preferred embodiment, such a motor has: (a) a centrally located means for actuating a radial wave, (b) a deformable flexspline having an inner surface and a toothed outer surface, with the flexspline coaxially aligned with the central axis of the radial wave actuating means and oriented such that the flexspline inner surface is proximate the outer boundary surface of the actuation means, and with the flexspline toothed outer surface having a first specified number of teeth, (c) a circular spline having a toothed inner surface, the spline having an outer boundary surface and being coaxially aligned with the central axis and oriented such that the spline toothed inner surface is proximate the flexspline's toothed outer surface, with the spline inner surface having a second specified number of teeth which is different than the first specified number of teeth in the flexspline, wherein the actuation means is operable so that the action of its radial wave causes at least one of the flexspline teeth to engage at a point the toothed side of the circular spline in such a manner that an engagement point passes as a wave around the inner perimeter of the circular spine, with the movement of this engagement point causing the flexspline to rotate around its central axis.
In a preferred embodiment, this radial wave actuating means has: (a) a central ring having an outer, boundary surface and a center point, (b) a plurality of diaphragm pistons, each having a fluid containing cavity, (c) a diaphragm that covers each piston's and top action surface, with these pistons being mounted along the perimeter of the ring's boundary surface so that their action surfaces move radially as the amount of fluid in the cavities is increased, (d) a coaxially aligned planetary gear having an inner surface and a toothed outer surface with a first specified number of teeth, (e) a wave generator gear having an outer surface and a toothed inner surface and oriented such that the wave generator toothed inner surface is proximate the planetary gear's toothed outer surface, with the wave generator gear having a second, specified number of teeth which is different than the planetary gear's first specified number of teeth, and (f) a ring bearing whose inner surface is proximate the wave generator gear outer surface.
In another preferred embodiment, such a motor has: (a) a central ring, (b) a plurality of diaphragm pistons, each having a fluid containing cavity, a diaphragm that covers the cavity and a top action surface, with the pistons being mounted along the perimeter of the ring boundary surface and configured so that their action surfaces move radially from the ring's center point as the amount of fluid in the cavities is increased, (c) a coaxially aligned planetary gear having an inner surface and a toothed outer surface with a first specified number of teeth, (d) a coaxially aligned inner gear having an outer surface and a toothed inner surface and oriented such that the inner gear's toothed surface is proximate the planetary gear's toothed surface, with the inner gear having a second, specified number of teeth which is different than the first specified number of teeth in the planetary gear, and (e) a ring bearing whose inner surface is proximate the inner gear outer surface, wherein by a specified flow of fluid through the pistons the planetary gear is caused to move relative to the ring center point so that a portion of the planetary gear outer surface contacts the inner surface of the inner gear in such a manner that at least one of the planetary gear teeth engages at a point the toothed side of the inner gear in such a manner that the engagement point passes as a wave around the inner perimeter of the inner gear, this movement of the engagement point causing the inner gear to rotate around the ring center point.
Thus, there has been summarized above, rather broadly, the present invention in order that the detailed description that follows may be better understood and appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of any eventual claims to this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B illustrate the operation of a pair of coupled hydraulic cylinders for remotely actuating a linear motion.
FIG. 2 illustrates the operation of three sets of coupled hydraulic cylinders for remotely actuating a rotary motion.
FIGS. 3A and 3B illustrate the use of rollers and a cam bearing for connecting the piston rods of the hydraulic cylinders shown in FIG. 2 with an elliptical drive cam.
FIG. 4 illustrates the components of and principle of operation of a standard harmonic drive gear.
FIG. 5 is a plan view of a preferred embodiment of the harmonic motor of the present invention which utilizes an elliptical bearing or wave generator that is driven by hydraulic cylinders that are sequentially operated.
FIG. 6 is a plan view of a “radial wave actuator” for a preferred embodiment of the present invention, wherein this actuator replaces the elliptical, wave generator of FIG. 5 with sequentially activated pairs of diaphragms that directly deform the flexspline.
FIG. 7 is a plan view of a “tangential wave actuator” for a preferred embodiment of the present invention, wherein this actuator replaces the elliptical wave generator of FIG. 5 with sequentially activated groups of inflatable cylinders that deform a wave generator ring that drives the flexspline.
FIGS. 8A and 8B presents a side view and a cross sectional view of a harmonic planetary motor embodiment of the present invention.
FIG. 9 shows an illustration of the pump that is used to drive a harmonic planetary motor.
FIGS. 10A and 10B presents a side view and a cross sectional view of a planetary motor embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining at least one embodiment of the present 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.
In general, the present invention relates to motors that are made with materials that have low magnetic susceptibility and produces minimal, if any, magnetic fields. For example, materials such as plastics, glass, ceramics, rubbers, etc.
The invention of the present invention is based on two principles of transmission: (a) the coupled, fluid actuated pistons or cylinders for supplying linear motion at a remote location, and (b) the harmonic drive transmission for providing extremely precise, zero-backlash speed reduction capabilities.
Two versions of the coupled, fluid actuated pistons are schematically represented in FIG. 1A and 1B . The “double acting” method presented in FIG. 1A includes two cylinders connected port-to-port on their similar sides by two closed circuits. The fluid agent inside these circuits could be either pneumatic or hydraulic. An external force applied on the rod of the “pump cylinder” is transmitted through the compression of the agent into linear force at the piston of the “motor cylinder”, like in the braking system of cars.
The force transmission ratio of the motor-pump cylinder coupling may be expressed as:
Force
Transmission
Ratio
=
T
=
F
m
F
p
=
S
M
S
P
=
S
m
S
p
Equation
1
where, F m and F p are the forces acting on the motor and pump rods respectively, and S M , S m , S P , S p are the surface areas on the sides of both pistons, as represented in FIG. 1 . Scaling may be achieved by using different cylinder sizes for the pump and motor.
Using an incompressible agent (hydraulic actuation case) and considering that the system operates at low pressure levels for which the deformation of the hydraulic circuit is negligible, the displacement ratio may be expressed as the inverse of the force ratio:
x
m
x
p
=
1
T
Equation
2
where, x m and x p are the displacements of the motor and pump pistons, respectively. Equation 1 also reveals the size constraint of the cylinders in order to match the volumes displaced on both sides of the piston chambers.
The “spring return” principle presented in FIG. 1B is similar but uses a single connection line between the cylinders thus reducing to half the number of conduits required. This can be significant in the case of multiple motors. The back draw is the limitation and variability of force in one direction given by the spring (of elastic constant k ) used in the motor cylinder:
F m = F p - F s ⇒ T = F p - k x m F p Equation 3
Several characteristics of the cylinder coupling actuation principle are essentially related to medical imaging compatibility:
(a) The scheme allows for the operation of the motor cylinder from a remotely located pump cylinder. This allows the motor located in the imaging field to be operated from a pump located in a control room. (b) The simplicity of the motor allows for its construction of imaging environment compatible materials. The fluid agent used is also nonrestrictive. (c) The motion of the motor rod can be predicted by measuring motion at the pump. Accuracy of measurement is increased by using hydraulic agent (incompressible) and low expandability circuitry. This eliminates the need of performing complicated motion encoding in close proximity of the imaging field.
These characteristics show that this remote actuation principle is well suited for performing linear motion actuation in a medical imaging environment. The method may also be extrapolated for rotary motion, as presented next.
Rotational output may be achieved by using at least three coupled pistons or cylinders engaging an elliptical shaft as presented in FIG. 2 . In this schematic three sets of cylinders 3 – 6 , 4 – 7 , and 5 – 8 are linearly coupled as presented in the previous section. The cylinders are equally spaced around the elliptical cams 1 and 2 of the pump 60 and motor 70 respectively. Rotating the cam 1 of the pump causes the pistons 3 , 4 , and 5 to move, engaging their coupled pistons 6 , 7 , and 8 respectively, thus turning the motor cam 2 . In this way, the pump and the motor shafts are coupled, so that ideally their rotation angles are equal Θ m =Θ p . Proper design of the cams and cylinder sizes ensure that the volume in the hydraulic circuits remains constant for any pump Θ p and motor Θ m rotation angles.
As for the cylinder coupling for linear motion, an incompressible fluid is required in order to achieve high accuracy of motion since rotational precision is directly related to the linear precision of the pistons. A low compressibility fluid is also required for high speed operation. This also allows for performing remote measurement of the motor shaft rotation using a pump encoder.
A stepper pneumatic motor could be achieved by replacing the pump arrangement presented in FIG. 2 with a simple pneumatic source and distributor that successively pulse pressurizes the three pistons of the motor, much like a radial engine used in old propeller airplanes.
The cam pump presented in FIG. 2 can also be replaced by (at least) three cylinders operated independently by linear drives such as voice coils. These should be synchronized and optimized for maximum dynamic performance under computer control.
In all cases, tight seal cylinders should be used since agent leakage would degrade kinematic performance. For this reason the use of diaphragm cylinders is recommended over the piston type. Diaphragm cylinders are also suitable since the stroke required is relatively small and such cylinders can be easily made of medical imaging compatible materials.
Remote position sensing can also be achieved with this coupling principle. For a theoretically zero driven torque, the pump and motor rotations are in phase. The phase shift Φ depends on the load connected to the motor shaft. This can be quantified by monitoring line pressures (P 1 , P 2 , P 3 ,K) and then used to evaluate the phase shift, thus:
Θ m =Θ p −Φ( P 1 ,P 2 ,P 3 ,K ) Equation 4
This is essentially important for applications in which encoding of the motor shaft is not feasible or difficult to implement, as for medical imaging environment applications.
The disadvantage of this principle is related to the sliding of the piston ends on the elliptical cams during motion, which induces sliding friction at the contact surfaces thus reducing mechanical performance and causing wear. Design implementations of this principle require the inclusion of either rollers 9 at the end of the pistons or preferably a series of ball bearings 10 mounted on the perimeter of the cam. See FIGS. 3A and 3B .
A harmonic drive transmission is a rotational-rotational transmission implementing torque coupling with concentric elements. A radial, rather than a rotation, tooth mesh is created by flexing one element to create an inward and outward, radial tooth motion, which allows a spline-like tooth engagement.
A harmonic drive transmission's precision and efficiency make it suitable for accurate positioning and precise motion control. The basic principle of the harmonic drive is illustrated in FIG. 4 . It presents three basic elements: A rigid circular spline or the internal gear 11 , a flexspline represented by the thin gear 12 , and an elliptical wave generator 13 which is surround by a ball bearing 10 having inner 10 a and outer 10 b races. Commonly, the input is applied to the wave generator 13 . The output is either the circular spline 11 , as represented in FIG. 4 , in which the flexspline 12 and the generator 13 are grounded, or vice versa ( 11 grounded and 12 output).
The circular spline 11 has an even number of internal teeth (N S ), is circular, and rigid. The flexspline 12 also presents an even number of teeth (N F ), but fewer than the spline (typically N F =N S −2), presents a thin cross-section, and is constructed of flexible materials so that it can be deformed to an oval shape by the wave generator 13 . The wave generator is an elliptical bearing presenting a major axis 14 and a minor axis 15 . The teeth engage at the major axis and are fully disengaged at the minor axis. The flexspline 12 is deformed by the bearing 10 to an elliptical shape changing its orientation with the rotation of the inner ring of the bearing, the drive input, thus rotating the axes of the ellipse. This causes the gear engagement region to rotate in phase with the input. Since the flexspline 12 has (N S −N F ) fewer teeth than the circular spline 11 , one revolution of the input causes a relative motion of N S −N F teeth between them. For the common case of two teeth difference, the output rotates one tooth-arc for each 180° of input rotation. In general, the transmission ratio of the harmonic drive can be expressed as:
T
=
ω
W
ω
S
=
N
S
N
S
-
N
F
Equation
5
If the spline 11 is considered the base, the direction of the output ω S is reversed with respect to the input ω W .
Equation 5 shows that the harmonic drive exhibits high transmission ratios from 50:1 and up. Preload in the direction of the major axis and almost pure radial tooth engagement allow harmonic drives to operate with low or zero backlash for long duty cycles, without preload adjustments or significant wear. Reliability and life are also high. Since torque is transmitted by pure coupling, the efficiency of the transmission is normally in the 80–90% range. The gearing design ensures that approximately 10% of the total teeth are engaged at any rotation, minimizing the effect of tooth-to-tooth error, thus rendering excellent positioning accuracy and repeatability.
The above characteristics make the harmonic drive an ideal candidate for precision surgical robotics. In addition, the presence of the elliptical wave generator 13 readily associates functionality with the elliptical coupling presented above, especially for the cam bearing case presented in FIG. 3B .
One embodiment of the present invention merges the principles of elliptical coupling and harmonic drive by using cylinder couplings to actuate a wave generator or actuator to act as what is herein referred to as a harmonic motor. A first embodiment is shown in FIG. 5 .
Pistons 6 , 7 , and 8 act on the outer race of the bearing 10 , similar to the principle presented in FIG. 3B . The wave generator 13 is rotated by sequential pulsing of the pistons, either by using an elliptical pump arrangement or by pumps actuated independently. A set of mirrored cylinders may also be respectively connected on the same fluid circuits for reducing radial load.
The main difference compared to the harmonic drive disclosed herein is that the input energy is given by the fluid of the pistons and not a rotational input, thus rendering a rotary motor rather than a transmission. The motor inherits the mechanical performance of the cylinder coupling and harmonic drive, making it optimally suited for precision actuation and medical imaging compatibility.
The harmonic motor is also safe to use in surgical applications, especially when driven by a hydraulic agent such as distilled water or even saline. All hydraulic circuits are closed and can be made leak proof by using diaphragm cylinders. The fluid pulses back and forth in the circuits and the system may be operated at low pressures. Should a hydraulic circuit fail, the motor stalls. Moreover, the drive can be made backlash free and it is non-backdrivable if the pump is non-backdrivable.
Another embodiment of the present invention, the “static wave actuator version of the harmonic motor,” presents simpler construction and minimizes the number of moving elements by replacing the elliptical bearing 10 with an arrangement of cylinders which act as a active wave generator. The flexspline remains fixed but its oval shape is dynamically driven by cylinder couplings. Two types of wave actuators are defined based on the direction that the cylinders act, radial and tangential.
FIG. 6 presents a schematic of the radial wave actuator and the flexspline 12 . For simplicity the rigid, circular spline 11 has not been represented in this schematic being similar to the one represented in FIG. 5 .
The radial wave actuator comprises a flexible outer ring 19 , a series of at least six diaphragm cylinders 6 , 7 , 8 , 16 , 17 , 18 and a rigid cylinder ring 20 or platform. The flexspline 12 and the outer ring 19 are assembled or even constructed of in single part. Pairs of opposite cylinders are linked on the same fluid circuits connecting the radial wave actuator to a sequential pump through the ports 21 , 22 , and 23 .
In unpressurized state the flexspline-outer ring assembly exhibits circular shape concentric with the cylinder ring 20 . When pressure is applied in a circuit the flexspline 12 is deformed along the direction of the pressurized cylinders causing the gear teeth to engage in that direction. FIG. 6 represents the wave actuator pressurized in port 21 inducing an oval shape spline with 14 and 15 as major and minor axes respectively.
The other two circuits rotate the major elliptical axis to their respective directions. The three 120° spaced axes of the cylinders are primary axes and their number directly determines the precision of motion. However, increasing the number of the cylinder pairs has practical limitations and significantly increases complexity.
The following method allows for doubling the number of axes for the same number of cylinders. The method is based on the observation that if a thin ring is pushed from inside out on opposite sides, it deforms aligning the major axis in that direction. But if the ring is squeezed in the same places, the major axis is reversed 180°. Thus, by pulling the diaphragms inward (rather then pushing outward) a new set of secondary axes is created normal to the primary ones, as represented in FIG. 6 .
To avoid operating below the atmospheric pressure (for pulling), the diaphragms are preloaded so that in unpressurized state they exert elastic pull on the outer ring 19 . This shifts the operating point above atmospheric pressure in a similar way that spring return pistons operate. This simple method uses the elasticity of the diaphragm in place of the classic return spring. Reducing the pressure below the central operating point causes the flexspline to engage at the secondary axis.
By independently operating each circuit the major axis can be oriented along any of the primary and secondary axes. With careful design of the sequential pump, coupled operation of the cylinders can orient the ellipse in arbitrary orientations providing smooth and precise motion of the rigid spline output.
Diaphragm cylinders are well suited for this application not only for their leak proof operation but also for implementing the spring return. For this reason the diaphragm should be manufactured of materials with good elastic properties. Moreover, as it can be easily observed in the exaggerated oval shape of FIG. 6 , during motion the piston and cylinder axes lose coaxially. Thus, compliant (elastic) diaphragms are also accommodating this misalignment.
A schematic of another embodiment of the present invention in the form of a tangential wave actuator with a flexspline 12 is presented in FIG. 7 . For simplicity the rigid, circular spline 11 has not been represented being similar to the one represented in FIG. 5 . The tangential wave actuator comprises a special flexible wave ring 24 and a series of twelve inflatable cylinders 25 a – 25 l (at least six inflatable cylinders are required). The flexspline 12 and the wave ring 24 are assembled so that relative tangential slipping is unrestricted at their points of contact. Pairs of four opposite cylinders are connected on the same fluid circuits connecting the actuator to a sequential pump through the ports 21 , 22 , and 23 .
The wave generator ring 24 has a special construction presenting twelve equally spaced lobes 24 a – 24 1 attached to a thin and elastic inner structure or membrane 26 . Semi-cylindrical cavities 27 a – 27 l are created between adjacent lobes for placing the inflatable cylinders (pillows) 25 a – 25 l . The outer surface of the lobes is constructed of elliptical surface that matches the region at the major axis of the flexspline ellipse.
Actuated oval shape of rotating major 14 and minor 15 axes is induced by sequentially pressurizing the inflatable cylinders 25 a – 25 l . When pressure is applied to a circuit, opposite groups of inflatable pillows expand enlarging the gap between adjacent lobes. This deforms the wave generator ring to an oval shape with the major axis aligned in the direction of the pressurized axis. The orientation of the major axis is then rotated by sequential and coupled operation of the three circuits.
A hollow shaft cylindrical construction is common for the harmonic motor of the present invention. This allows for mounting and/or passing the fluid circuit tubing for the inflatable cylinders through the inside of the motor.
In a prototype version of a harmonic motor with a tangential wave actuator, the rigid spline 11 , the flexspline 12 , and the wave generator 24 are constructed of plastic materials. The inflatable cylinders 25 are silicone rubber tubes with closed ends, which have been connected in three groups of circuits using ⅛″ ID PVC tubing. The harmonic drive using a 100 teeth rigid spline and a 98 teeth flexspline implements a 50:1 transmission. The motor presents a hallow shaft, cylindrical shape. The overall size of the motor is 60 mm×25 mm with a 25 mm bore and it weighs only 50 g.
Prototype versions of the present invention's harmonic motors have been thoroughly tested to ensure that they are compatible with a wide rage of medical imaging environments. These motors have proven themselves to be the first Zone 1 multi-imager compatible motors. That is, the motor can precisely operate within the imager field of any known class of imaging equipment while the imager is acquiring images. This includes the class of MR imagers for which all existing types of motors (electric, piezoelectric, ultrasonic) are either incompatible or can not be set in close proximity of the magnetic field, operational or not. All previously reported MRI compatible robots inhabit MRI Zone 4 (one meter from iso-center or beyond the 20 mTesla line) and, in consequence, have limited manipulation ability within Zones 1 and 2 .
FIGS. 8–9 show another of the preferred embodiments of the present invention. This embodiment is referred to herein as a harmonic planetary motor. It uses pneumatic/hydraulic pressure pulses to generate precise, backlash-free rotary motion.
As shown in the side and sectional views of FIGS. 8A and 8B , the central part of this embodiment is a cylinder body 29 presenting three radial cylinders 30 . Three diaphragm 31 pistons 32 having top action surfaces 32 a are attached to the cylinder body with the cylinder caps 33 . Each cylinder is pressurized through a nozzle 34 linked to a port 35 . The pistons are attached with the screws 36 to a rigid planetary gear 37 engaging an internal or wave generator gear 38 .
The outer surface 39 of the wave generator gear 38 is elliptical acting as a wave generator for the next motion stage, the harmonic transmission. A ring bearing 40 with rollers 41 and a cage 42 acts between the outer surface 39 of the gear 38 and the inner surface 43 of the flexspline 12 . The rigid spline 11 is attached to the case 44 of the module. The output of the motor is taken from the flexspline 12 through a passive spline 45 presenting an internal rigid spline.
This motor operates by fluid pressure being sequentially applied on the three diaphragm pistons 32 using a remotely located pneumatic/hydraulic commutation mechanism. This engages the planetary gear 37 in a coupled motion around the cylinder body 29 , thus engaging the rigid wave generator gear 38 . The planetary gear 37 does not rotate but rather balances on a round trajectory around the cylinder 29 in a quasi-translational motion, its rotation being prevented by the diaphragm 31 connections to the cylinder base 29 .
For each full pressure cycle the wave generator gear 38 rotates with one tooth angle, assuming that the difference in the number of teeth in the planetary and wave generator gears is one. This rotation is further demultiplied through the combined action of the surrounding flexspline 12 and spline 11 so that the output of the module rotates through a spline tooth angle for each half turn of the wave generator 38 , assuming that the difference in the number of teeth between the spline and flexspline two.
This motor assembly is constructed of nonmagnetic and dielectric materials such as mica-glass and toughened zirconia ceramics, polyimide plastics, and Buna-N rubber. Six small custom-made titanium screws 36 are also used.
The planetary gear 37 in this assembly is constructed such that it has one more tooth than the wave generator gear 38 . Thus when the perimeter of the planetary gear 37 is caused to effectively walk the contact point with the wave generator's inner surface for a complete 360 degree revolution, the wave generator will advance through an angular rotation that is equal to 360 degrees divided by the number of teeth in the wave generator.
In this situation we have a harmonic planetary motor that acts to rotate a harmonic drive gear consisting of the circular spline 11 , flexspline 12 , and a wave generator 38 . One of the advantages of this configuration is the higher degree of precision that can be obtained in controlling the angular output that is experienced in the rotation of the flexspline. The magnitude of the output is seen to be:
α
OUT
360
=
360
N
WG
(
N
RS
-
N
FS
)
N
RS
degrees
where, N WG ,N PG ,N RS ,N FS ,N PS are the number of teeth for the wave generator 38 , planetary gear 37 , rigid spline 11 , flex-spline 12 , and a passive spline respectively, and where:
N WG =N PG −1
N RS =N FS +2
N PS =N FS
FIG. 9 shows an illustration of the pump that is used to drive the harmonic motor of the present invention. In this situation, a pressure commutation mechanism is provided by three computer-controlled, proportional pneumatic valves generating a sequence of three sinusoidal waves of 120° phase shift. Such hydraulic actuation is capable of higher speed performance due to the incompressibility of the agent, and is also safer for surgical applications. The pump 46 comprises a cam 47 of cylindrical outer surface eccentrically mounted on a rotating shaft activated by the electric motor 48 through a bevel gear transmission. The inner part 49 of the cam presents a special shape (somewhat elliptical) so that two rollers 50 and 51 can simultaneously roll on the inner and outer sides of the cam implementing a dual acting (push-pull) piston stroke. The rotation of the cam causes the pistons of the three cylinders 52 to move in an eccentrically coupled phase, as required for the planetary motor. The pressure waves are then sent to the motor through the ports 53 .
The motor of the present invention is also safe to use for medical applications since it is electricity free and presents a small size making it readily applicable for the construction of image-guided robots to operate within the confined space of various imagers, including closed bore tunnel types. This technology could potentially have a broad impact on the development of new image-guided motorized systems that could open new capabilities for diagnosis and treatment of prostate cancer and other diseases.
For example, this motor can be used for the construction of a multi-imager compatible robot for precise prostate access. Presently, prostate access for biopsy or therapy delivery can only be accomplished manually with or without the aid of template-like devices. A manual approach has intrinsic inaccuracies and is associated with variability among individual surgeons. A mechanism to precisely, repetitively, and reliably access the prostate is required to improve clinical outcome of classic procedures (i.e. biopsy, brachytherapy) and to create a basis upon which novel cancer therapies could be deployed and evaluated.
FIGS. 10A–10B show another of the preferred embodiments of the present invention. This embodiment is referred to herein as a planetary motor. It uses pneumatic/hydraulic pressure pulses to generate precise, backlash-free rotary motion. This motor differs from the previously described harmonic planetary motor by its exclusion of the harmonic transmission stage and the improved design of the planetary gear of the present embodiment.
As shown in the side and sectional views of FIGS. 10A and 10B , the central part of this embodiment is a cylinder body 29 presenting three radial cylinders 30 . Three diaphragm 31 pistons 32 are attached to the cylinder body with cylinder caps 33 . Each cylinder 30 is pressurized through a nozzle 34 linked to a port 35 . The pistons 32 are attached with titanium screws 36 to a rigid planetary gear 37 engaging a ceramic internal gear 38 a which, in this embodiment, is the output of this motor.
A cylindrical needle bearing 40 with ceramic rollers 41 and a plastic cage 42 supports the internal ceramic gear 38 within the ceramic case 44 . The motor is powered by a hydraulic commutation pump 46 similar to the one previously described, fluid pressure waves being sequentially applied on the three cylinders. These act on the pistons 32 and the planetary gear 37 in a coupled motion about the cylinder body 29 thus engaging the internal gear 38 a . The planetary gear 37 does not rotate but translates on a circular trajectory about the cylinder body 29 . The gear 38 a advances one tooth on each pressure cycle.
Although the foregoing disclosure relates to preferred embodiments of the invention, it is understood that these details have been given for the purposes of clarification only. Various changes and modifications of the invention will be apparent, to one having ordinary skill in the art, without departing from the spirit and scope of the invention.
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A motor suitable for use in a medical imaging environment has (a) a centrally located means for actuating a radial wave, (b) a deformable flexspline having an inner surface and a toothed outer surface with a first specified number of teeth, and (c) a circular spline having a toothed inner surface with a second specified number of teeth which is different than the first specified number of teeth in the flexspline, wherein the actuation means is operable so that the action of its radial wave causes at least one of the flexspline teeth to engage at a point the toothed side of the circular spline in such a manner that an engagement point passes as a wave around the inner perimeter of the circular spine, with the movement of this engagement point causing the flexspline to rotate around its central axis.
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FIELD OF THE INVENTION
[0001] The current invention is drawn to the field of the production of phenol and acetone by the decomposition of cumene hydroperoxide. More specifically, the present invention is drawn to a method for the safe handling of concentrated cumene hydroperoxide in a process for production of phenol and acetone by the decomposition of cumene hydroperoxide.
BACKGROUND OF THE INVENTION
[0002] The production of phenol and acetone by decomposition of cumene hydroperoxide is well known and has been in practiced commercially since the 1950's. Cumene hydroperoxide (CHP) itself is produced from the oxidation of cumene in a so-called oxidizer unit. The CHP thus produced is then concentrated in a distillation unit, typically to a concentration of 60% to 92% depending on the process. The concentrated CHP is then fed a decomposer (or cleavage) unit, where the acid decomposition of the CHP to phenol, acetone and other products such as alpha-methylstyrene occurs. In many cases, the concentrated CHP is diluted with cumene, acetone or water prior to being fed to the decomposer.
[0003] In some process designs it is desirable to accumulate a working volume of concentrated CHP from the distillation unit in an intermediate accumulation vessel and supply the decomposer unit from this working volume rather than directly from the distillation unit. In this design, the accumulated working volume is constantly turned over as concentrated CHP is fed from the accumulation vessel to the decomposer unit and fresh material is received by the accumulation vessel from the distillation unit.
[0004] The goal of accumulating a working volume to supply the decomposer is to provide a source of concentrated CHP to the decomposer unit in the event that an upset in the oxidizer and/or distillation unit temporarily interrupts the production of concentrated CHP. This is especially important in processes that conduct the decomposition of CHP in a boiling medium, where start-up or restart of the process after an upset is a hazardous operation. Even in non-boiling processes it can be of benefit to supply a working volume of concentrated CHP to avoid cavitation of pumps and transfer lines in the event of an interruption of the supply of CHP from the oxidizer and/or distillation unit.
[0005] Even though it is recognized as desirable to accumulate a working volume of concentrated CHP as described, this practice in itself presents special hazards. The decomposition of concentrated CHP is an extremely exothermic reaction, releasing approximately 1,421,000 joules/kg of heat for an 80 percent by weight solution. In some designs several thousand gallons of concentrated CHP may be accumulated. The potential for a catastrophic release of energy in the event of a mishap is therefore of great concern. A number of existing methods of accumulating working volumes of concentrated cumene hydroperoxide are not adequate to address this safety issue.
[0006] In a typical configuration for a process utilizing a boiling CHP decomposition unit, the accumulated volume of previously cooled CHP is simply stored in an unmodified tank or drum while only allowing a fraction of the accumulated volume to be used as a true working volume. In such designs the majority of the stored material exists as a stagnant volume with no circulation or mixed flow except for the natural in and out flow. Further such designs do not provide a means for direct cooling of the stored volume.
[0007] It would therefore be desirable to provide a method for storing a working volume of concentrated cumene hydroperoxide that alleviates the safety issues associated with storing extremely large volumes of stagnant concentrate without cooling.
SUMMARY OF THE INVENTION
[0008] The present invention provides an improved method for accumulation of a working volume of concentrated cumene hydroperoxide (CHP) in a process for the production of phenol and acetone by the acid catalyzed decomposition of CHP. The method of the current invention alleviates the safety issues associated with many current designs for accumulation of a working volume of concentrated CHP.
[0009] The method according to the current invention achieves this improvement through the use of a tube and shell type heat exchanger as the accumulation vessel in place of the unmodified tank or drum employed in typical designs. The heat exchanger may be oriented in either a vertical or horizontal position depending on the requirements and space constraints of a particular plant design. In a preferred embodiment the heat exchanger is a u-tube type heat exchanger and is oriented in a vertical position. The tube pitch of the heat exchanger can be varied depending on the requirements of a particular plant, but is typically about 2 inches.
[0010] Further the heat exchanger may be installed so that the concentrated CHP is carried on either the shell side or the tube side of the heat exchanger, with the heat transfer fluid carried on the tube side or shell side respectively in each case. Preferably, the concentrated CHP is carried on the shell side of the heat exchanger, with the heat exchange fluid carried on the tube side. Where the concentrated CHP is carried on the shell side of the heat exchanger, the interior of the heat exchange shell may be equipped with baffles, which induce a mixed flow of the accumulated volume through the heat exchanger.
[0011] Additionally, the heat exchanger/accumulation vessel is preferably equipped with at least one temperature sensor and at least one level sensor.
[0012] By substituting a tube and shell heat exchanger for the unmodified tank or drum used in typical designs, it is possible to apply constant cooling to the accumulated working volume of concentrated CHP. Further, by providing baffles on the interior of the heat exchanger, a mixed flow is induced in the accumulated material as it moves through the heat exchanger. Also, by its very design the tube and shell heat exchanger allows the entire accumulated volume to be used as working volume, thereby eliminating large quantities of stagnant material inherent in current designs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 : Illustrates an exemplary tube and shell type heat exchanger that can be employed as an accumulation vessel according to the current invention.
[0014] FIG. 2 : Illustrates an overhead view of a tube bundle in an exemplary tube and shell type heat exchanger that can be employed according to the current invention.
[0015] FIG. 3 : Illustrates the measurement of tube pitch in a tube and shell heat exchanger.
[0016] FIG. 4 : Illustrates a cross-section of an exemplary tube and shell type heat exchanger that can be employed as an accumulation vessel according to the current invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] By utilizing a tube and shell type heat exchanger in place of the unmodified drum or tank used as an accumulation vessel for a working volume of concentrated CHP in typical current designs, the method according to the current invention alleviates a number of hazards inherent in current designs.
[0018] First, the use of a tube and shell heat exchanger according to the current invention allows constant direct cooling to be applied to the working volume of concentrated CHP. Second, by providing baffles on the interior of the tube and shell heat exchanger, a winding path of flow may be created for the concentrated CHP when it is carried on the shell side of the heat exchanger, which induces a mixed flow in the accumulated volume as it moves through the accumulation vessel. Third, because the entire volume stored in the tube and shell heat exchanger can be used as a working volume, the total accumulated volume necessary is less than in current designs.
[0019] The actual working volume of concentrated CHP that is accumulated in the accumulation vessel will depend on the requirements of the particular plant in which the method according to the current invention is carried out. However, the accumulated working volume should generally be sufficient to provide an uninterrupted supply of concentrated CHP to a decomposer unit for a minimum of 2.5 minutes at the typical feed rate for the decomposer unit involved in the event of an interruption of the supply of concentrated CHP from the distillation unit. Therefore the size and dimensions of the heat exchanger used in a particular application of the method according to the current invention will vary depending the requirements of the process and plant involved. Concentrated CHP as used in the method of the current invention is typically in the range of about 60 percent to about 92 percent by weight cumene hydroperoxide.
[0020] The selection of materials of construction for a heat exchanger to be used in the method according to the present invention is within the ability of one of ordinary skill in the art in phenol production. However, the preferred material of construction is stainless steel. Grades of stainless steel that are useful as materials of construction include, but are not limited to, 304SS and 316SS.
[0021] Referring to FIG. 1 , an exemplary tube and shell type heat exchanger 10 that may be used according to the current invention is shown. The heat exchanger 10 is essentially cylindrical in shape and is provided with inlet 12 for admitting heat exchange fluid to the tube bundle and outlet 14 for returning heat exchange fluid exiting the tube bundle to the cooling loop. The heat exchanger 10 is further provided with inlet 16 for admitting concentrated CHP from a distillation unit to the shell side of the heat exchange unit. Outlet 18 is provided for transferring concentrated CHP from a working volume to a CHP decomposer (cleavage) unit. Outlet 20 is provided as a pressure vent. As stated, the size and dimensions of a heat exchanger used in a particular implementation of the method according to the current invention will vary, and choice of an appropriate heat exchanger is within the ability of a skilled engineer.
[0022] The heat exchanger 10 in FIG. 1 is illustrated in the preferred orientation according to the current invention. That is, with the major axis of the heat exchanger oriented in the vertical direction. Also according to the preferred embodiment of the current invention, the heat exchanger is a u-tube type heat exchanger, although other configurations of the tube bundle are considered within the scope of the invention. Alternatively, the heat exchanger may be oriented with the major axis in the horizontal position. In this alternative embodiment the locations of the inlets and outlets for the heat exchange fluid and the concentrated CHP would be rearranged accordingly.
[0023] Both the CHP and the heat exchange fluid may be carried on either the shell side or the tube side of the heat exchanger according to the current invention. However, in the preferred embodiment of the invention the concentrated CHP is carried on the shell side of the heat exchanger and the heat exchange fluid is carried on the tube side.
[0024] Referring to FIG. 2 , an overhead view of the tube bundle 20 of an exemplary u-tube type heat exchanger 22 according to the preferred embodiment of the invention is illustrated. The tube bundle 20 is laid out in the disk defined by the circumference of the heat exchanger 22 .
[0025] The tube pitch in any of the tube and shell heat exchangers used according to the current invention may be set at a higher pitch than standard heat exchangers of a tube and shell type. This allows for a greater working volume of CHP to be accumulated when the CHP is carried on the shell side than would be possible in a standard tube and shell heat exchanger of similar size. The tube pitch, i.e. the spacing of the individual tubes in the bundle can however be varied depending on the size of the heat exchanger, the desired working volume and the rate of flow of CHP through it. An exemplary tube pitch according to the current invention is about 2 inches. The tube pitch is an installation specific variable that can be adjusted depending on the requirements of the plant where the method according to the invention is carried out. If an installation requires a short, squat exchanger, an increased pitch may be used to address vessel volume needs. If an installation uses a longer heat exchanger, the tube pitch may be decreased in order to reduce the volume of CHP otherwise inventoried at a higher tube pitch.
[0026] Referring to FIG. 3 , a triangle 30 connecting three adjacent tubes in a tube bundle is illustrated. The tube pitch is measured as the distance separating the center point of two adjacent tubes in the tube bundle.
[0027] Referring to FIG. 4 , a cross section of a u-tube type heat exchanger 40 that may be used according to a preferred embodiment of the current invention is shown. The u-tubes have been omitted from the drawing for clarity. As shown in FIG. 4 , preferably the heat exchanger 40 used according to the current invention is equipped with internal baffles 42 . The baffles 42 create a winding path for the concentrated CHP as it travels from the inlet 44 of the heat exchanger to its outlet 46 . By creating a winding path for the CHP as it travels through the heat exchanger, a mixed flow can be induced in the CHP. The number of baffles provided in the heat exchanger will vary depending on the needs of a particular process, but the number and spacing should be sufficient to provide a winding path of flow for the CHP. The determination of the number of baffles required to provide a winding path of flow is within the ability of a skilled engineer. The goal is to minimize the number of baffles, yet still provide winding flow. The actual number and spacing of baffles required will depend upon the dimensions of the installed heat exchanger, a long shell heat exchanger will require more baffles than a shorter vessel.
[0028] In addition, it may be desirable to provide the tube and shell heat exchanger with at least one level sensor and at least one temperature sensor.
[0029] The method according to the current invention has thus been described in general terms. Those of ordinary skill in the art will be able to modify and adapt the teachings of the present disclosure to suit the needs of a particular plant for the production of phenol by the acid catalyzed decomposition of CHP without departing from the present invention. All such modifications and adaptations are considered within the scope of the present invention, which is defined by the claims appended hereto.
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The present invention provides a method and apparatus for in-process handling of concentrated cumene hydroperoxide (“CHP”) in a process for the production of phenol and acetone by the decomposition of CHP. The method of the present invention makes use of a tube and shell type heat exchanger as a vessel to accumulate a working volume of concentrated CHP from a distillation unit. Concentrated CHP is then fed to a decomposer unit from the accumulated working volume. Use of a tube and shell type heat exchanger improves safety over designs that make use of an unmodified tank or drum.
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FIELD OF THE INVENTION
The present invention relates generally to the field of storage containers, and pertains, more specifically, to a method and apparatus for lifting and handling a storage container, loading it onto a road vehicle, transporting it to a given location, and unloading the container from the vehicle.
BACKGROUND OF THE INVENTION
Industry often has requirements to lift and transport containers. Many freight yards and ocean shipping docks use cranes of various types with lifting cables that attach to the corner brackets that are found on most shipping containers. Methods and apparatus for lifting and transporting containers are known and, heretofore, have been configured in different ways. Some examples of container handling systems in the prior art are seen in the following U.S. patents:
Dousset, U.S. Pat. No. 3,541,598, shows two end-fitted structures, called portals, which are wheeled and have hydraulic jacks. They are attached at upper and lower corners of the container. There are no longitudinal frame elements, only transverse ones. The container thus serves as a structural frame, and must be strong enough to support typically up to 15,000 pounds of cargo. There is no method or apparatus for moving and positioning the portals from the vehicle to the container, and back. This is apparently done by hand, a difficult and dangerous task. There is no structure to quickly and safely lock the portals onto the vehicle for transport, with or without the container.
Fossing, U.S. Pat. No. 5,006,031, also uses two structures, but they are connected together after lifting. The two-wheeled sections, with hydraulic jacks, are attached to the longitudinal sides of the container, not the ends. Cross pieces are connected beneath the container. The attachment brackets have an H-shape.
Bury, U.S. Pat. No. 3,881,689, discloses a four-sided frame for lifting camper bodies. It is U-shaped to fit around the body and has a cross bar fitted across the open end. The jacks are mechanical, and raise the container with respect to the frame. There is no method or apparatus for moving and positioning the frame from the vehicle to the body, and back. The camper body cannot be lowered to the ground. The frame must be dismantled by hand and stored or carried on the vehicle.
Dafnis, U.S. Pat. No. 2,197,375, illustrates a wheeled lifter and transporter for railroad cars. The frame is disposed over the top of the container, not around it. Hydraulic jacks fit below projecting brackets on the car, raising the car with respect to the frame. There is no transport vehicle.
Lion, U.S. Pat. No. 2,937,879, shows a container with built-in hydraulic jacks with wheels, at each corner. The container structure serves as a frame. There is no transport vehicle.
Fulmer, U.S. Pat. No. 3,243,193, discloses an attachable running gear to be fitted to the ends of a container. It consists of a pair of brackets and wheels. The brackets are attached to the ends of the container, then connected together underneath. Hydraulic jacks raise the container.
Concha, U.S. Pat. No. 4,297,068, also discloses an attachable running gear to be fitted to the ends of a container. It consists of a pair of brackets and wheels, with hydraulic jacks.
Gross, U.S. Pat. No. 4,712,966, illustrates a liftable and transportable rack for stackable cargo. There is no closed container or box-like structure. A pair of wheeled brackets with hydraulic jacks fit into the rack ends.
Riedl, U.S. Pat. No. 4,765,594, displays four separate wheel and jack assemblies that are attached to the corners of the container. The jacks are rack and pinion type. The assemblies are not interconnected.
Fulmer, Concha, Riedl, and Fossing show no transport vehicle. The wheels mounted to the container form a trailer.
While the above-described inventions serve to lift and move a container, they are awkward to position around the container. They show difficulty in moving the frame and container into position. The prior art devices disclose no way of changing the width of the frame to provide clearance around the vehicle. They have no way of releasably attaching the frame to the vehicle for safe transport.
Accordingly, there is a need to provide a means for easy positioning of the frame around the container, and for moving and positioning the frame and the container together.
There is a further need to provide a method to adjust the width of the frame under power to clear the vehicle and the container when moving and positioning the frame.
There is a yet further need to provide a means for releasably attaching the frame to the vehicle for safe transport.
SUMMARY OF THE INVENTION
The present invention is a hydraulically actuated mobile carrier frame which wraps around a storage container of standard size and lifts the container from the ground onto a transport vehicle, and subsequently back to the ground. Containers are typically 8 feet wide by 8 feet high by 16 feet long, and weigh up to 15,000 lbs. The carrier frame is not a permanent part of the vehicle, but is normally stored on the vehicle. The actuators of the present invention are actuated by gasoline engine driven hydraulic pumps mounted on the carrier frame. The carrier frame has swivel wheel assemblies incorporating hydraulic motors and a chain and sprocket drive arrangement installed to the lower end of the front upright members for providing a self-propelled and steerable carrier frame.
The above features, as well as further features and advantages, are attained by the present invention which may be described briefly as an apparatus for lifting and transporting a container having right and left sides and front and rear ends, the apparatus comprising: a carrier frame having right and left longitudinal elements juxtaposed with the right and left sides, respectively, of the container, each longitudinal element extending between opposite first and second ends, the carrier frame having front and rear transverse elements juxtaposed with the front and rear ends, respectively, of the container, each transverse element extending between opposite right and left ends, the left ends of the front and rear transverse elements being adjacent to the first and second ends, respectively, of the left longitudinal element, and the right ends of the front and rear elements being adjacent to the first and second ends, respectively, of the right longitudinal element, the carrier frame further including a plurality of generally vertical upright members attached to the carrier frame, each upright member extending between opposite upper and lower ends; bearing means, attached to each upright member lower end, for ground bearing and relative movement of the upright members with the ground; elevating means for elevating and lowering the carrier frame with respect to the ground; a transport vehicle, having a platform suitable for transporting the container and carrier frame simultaneously; steering and mobility means, connected to the carrier frame, for self-propelled mobility and directional movement of the carrier frame; and supporting means, connected to the carrier frame and to the container, for supporting the container by the carrier frame.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be more fully understood, while still further features and advantages will become apparent, in the following detailed description of preferred embodiments thereof illustrated in the accompanying drawing, in which:
FIG. 1 is a side elevational view of a transport vehicle transporting a storage container and a carrier frame constructed in accordance with the invention;
FIG. 2 is a plan view of the transport vehicle, storage container, and carrier frame of FIG. 1;
FIG. 3 is a sectional view of the transport vehicle, storage container, and carrier frame of FIG. 1, the section being taken along lines 3--3 of FIG. 1;
FIG. 4 is a side elevational view of the transport vehicle, storage container, and carrier frame of FIG. 1, showing the upright elements extended to the ground and the carrier frame and container elevated above the transport vehicle platform;
FIG. 5 is a plan view of FIG. 4, showing the transport vehicle, storage container, and carrier frame of FIG. 1;
FIG. 6 is a side elevational view of the storage container and carrier frame of FIG. 1, showing the carrier frame and container elevated above the level of the transport vehicle platform;
FIG. 7 is a plan view of FIG. 6;
FIG. 8 is a side elevational view of the storage container and carrier frame of FIG. 1, showing the carrier frame and container lowered with the container resting upon the ground;
FIG. 9 is a side elevational view of the storage container and carrier frame of FIG. 1, showing the carrier frame elevated above the level of the transport vehicle platform with the container resting upon the ground;
FIG. 10 is a plan view of FIG. 9;
FIG. 11 is a side elevational view of the storage container and carrier frame of FIG. 1, showing the carrier frame elevated above the level of the transport vehicle platform with the container resting upon the ground, and the carrier frame separated from the container;
FIG. 12 is a plan view of FIG. 11; and
FIG. 13 is a front sectional elevational view of the carrier frame of FIG. 1, showing the carrier frame lowered, the section taken along lines 13--13 of FIG. 8.
FIG. 14 is a side elevational view of the carrier frame of FIG. 1, showing the carrier frame with self-contained gasoline engine driven hydraulic pumps and relative height position of the rear transverse element.
FIG. 14A is a sectional elevation view of the carrier frame of FIG. 14 depicting the gasoline engine driven hydraulic pumps.
FIG. 14B is a sectional elevation view of the carrier frame of FIG. 14 depicting the rear transverse element.
FIG. 15 is a perspective view of the preferred embodiment of the steering and mobility means depicting front swivel wheel assembly including the hydraulic motor and sprocket chain drive.
FIG. 16 is a side elevational view of the carrier frame of FIG. 1 passing over the container.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing, and especially to FIGS. 1,2,4, and 5, an apparatus for lifting and transporting a container 34 having right and left sides, 30 and 32 respectively, and front and rear ends, 31 and 33 respectively, is shown at 20. The apparatus includes a carrier frame 24 having fixed right 26 and left 28 longitudinal elements juxtaposed with the right 30 and left 32 sides, respectively of the container 34. The right longitudinal element 26 extends between opposite first 36, and second 38 ends. The left longitudinal element 28 extends between opposite first 40, and second 42 ends. The carrier frame 24 has front 44 and rear 46 transverse elements juxtaposed with the front 31 and rear 33 ends, respectively, of the container 34. The front transverse element 44 extends between opposite right 48 and left 50 ends. The rear transverse element 46 extends between opposite right 52 and left 54 ends. The left end 50 of the front transverse element 44 is adjacent to the first 40 end of the left longitudinal element 28. The left end 54 of the rear transverse element 46 and the right end 52 of the rear transverse element 46 are fixed to respective upright members 56 at sufficient height to allow the apparatus to be moved over container 34 while extended, then lowered down for attachment of carrier frame 24 to the container 34. The right end 48 of the front transverse element 44 is adjacent to the first end 36 of the right longitudinal element 26.
The carrier frame 24 includes four generally vertical upright members 56 attached to the carrier frame 24, each upright member 56 extending between opposite upper 58 and lower 60 ends. Wheels 62 are attached to each upright member lower end 60, for ground 110 bearing and relative movement of the upright members 56 with the ground 110. The upright members 56 each comprise a tubular fixed element 64 attached to the carrier frame 24 and a tubular sliding element 66 mounted for sliding movement within the fixed element 64.
Elevating means, specifically a plurality of actuators 68, is mounted within the upright members 56, for elevating and lowering the carrier frame 24 with respect to the ground 110. Each actuator 68 has opposite first 70 and second 72 ends. The first end 70 is attached to the upright member fixed element 64. The second end 72 is attached to the upright member sliding element 66. Thus, upon being actuated in an extending direction as shown by arrow 74 in FIG. 13, the actuators 68 will slideably extend the sliding element 66 from within the fixed element 64 in a telescoping manner, so as to elevate the carrier frame 24. Conversely, upon being actuated in a retracting direction as shown by arrow 76 in FIG. 13, the actuators 68 will slideably retract the sliding element 66 into the fixed element 64 in a telescoping manner, so as to lower the carrier frame 24.
A transport vehicle 78, such as a specially modified truck, is provided and has a platform 80 suitable for transporting the container 34 and carrier frame 24 simultaneously.
Although the use of steering and mobility means 120 as depicted in FIG. 15 is a preferred embodiment, a winch 98 and cable 100 can alternatively or in conjunction with the mobility and steering means 120 be connected to the carrier frame 24, for moving and positioning the carrier frame 24 with respect to the container 34, and for moving and positioning the carrier frame 24 and container 34 together with respect to the vehicle 78. In this embodiment, the winch 98 is typically mounted on the front transverse element 44, as shown in FIG. 13. The winch 98 is typically operated by an electric motor 102, which is powered by a storage battery 104. The electrical connections for these parts are not shown in the drawing, but are known to anyone skilled in the art.
Supporting means 82 are connected to the carrier frame 24 and to the container 34 for supporting the container 34 by the carrier frame 24. Typically, the supporting means will be four chains 82 each affixed on one end to the carrier frame 24. A hook is located on the other end of each chain 82 for engaging an eye (not shown) on the container 34.
The carrier frame 24 includes a pair of guide wheels 122, each wheel being mounted for rotation on a generally vertical axis on an upright member 56 adjacent the rear transverse element 46, with the guide wheels 122 facing inward toward the container 34. As the carrier frame 24 is being moved into position around the container 34, the guide wheels 122 roll against the container 34 to reduce friction therewith, and thus facilitate positioning the carrier frame 24 with the container 34.
The front 44 and rear 46 transverse elements are selectively adjustable in length, so as to allow expansion of the carrier frame 24 to clear the vehicle 78 and the container 34 for positioning, and contraction of the carrier frame 24 into close juxtaposition with the vehicle 78 and the container 34 for transport.
The front transverse element 44 further comprises a tubular fixed element 84, and a tubular sliding element 86 mounted for sliding movement within the fixed element 84. An actuator 88 is mounted within the front transverse element 44. The actuator 88 has opposite first 90 and second 92 ends, the first end 90 being attached to the fixed element 84, and the second end 92 being attached to the sliding element 86. Thus, upon being actuated in an extending direction as shown by arrow 94 in FIG. 13, the actuator 88 will slideably extend the sliding element 86 from within the fixed element 84 in a telescoping manner, so as to expand the carrier frame 24. Conversely, upon being actuated in a retracting direction as shown by arrow 96 in FIG. 13, the actuator 88 will slideably retract the sliding element 86 into the fixed element 84 in a telescoping manner, so as to contract the carrier frame 24.
All of the actuators, in the upright elements and in the front and rear transverse elements, are typically hydraulic cylinder type actuators. The actuators are actuated by gasoline engine driven hydraulic pumps 112 mounted on the carrier frame. The hoses, valves, etc., are not shown in the drawing, but are well known, and can be adapted by anyone skilled in the art. Alternatively, the actuators may be electric motor driven screw type actuators.
As shown on FIGS. 14-16. steering and mobility means 120 are included with the front upright members lower ends 60. A preferred embodiment of the steering and mobility means includes swivel connection 116 and a hydraulic motor 114 wherein the drive shaft of the hydraulic motor 114 is connected to wheels 62 with a sprocket gear and chain drive 118. Rear transverse element 46 is shown in a position sufficient to clear the height of container 34 as depicted in FIGS. 14B and 16.
The vehicle platform 80 includes notches 108 on either side to receive and releasably retain the upright members 56 upon contraction of the carrier frame 24 into close juxtaposition with the vehicle 78, thereby locking the carrier frame 24 to the vehicle 78, allowing safe transport.
The method of using the invention will now be briefly described. In order to unload the container 34 upon arrival of the vehicle 78 at a job site, the actuators 68 in the upright members 56 will extend, thereby lowering the wheels 62 to the ground 110, and elevating the carrier frame 24 and container 34 above the vehicle 78. The front 44 and rear 46 transverse element actuators will be extended, thus expanding the carrier frame 24 outward from the locking notches 108. The vehicle 78 will then be driven out from under the carrier frame 24 and container 34, and the actuators 68 will lower the carrier frame 24 and container 34 until the container 34 rests upon the ground 110. The supporting chains 82 will be disconnected from the container 34, and the actuators 68 will elevate the carrier frame 24 to a height greater than that of the platform 80. The winch 98 and cable 100 will be connected between the carrier frame 24 and the vehicle 78. The winch 98 and cable 100 will move and position the carrier frame 24 over the vehicle 78. In the preferred embodiment, the carrier frame 24 will be moved over the vehicle 78 using the steering and mobility means 120. The front 44 and rear 45 transverse element actuators will be retracted. The actuators 68 will retract and lower the carrier frame 24 onto the vehicle 78, and continue retracting so as to raise the wheels 62 off the ground 110, thus contracting the carrier frame 24 into the locking notches 108.
In order to load the container 34 onto the vehicle 78, the actuators 68 in the upright members 56 will extend, thereby lowering the wheels 62 to the ground 110, and elevating the carrier frame 24 above the vehicle platform 80. The winch 98 and cable 100 will be connected between the carrier frame 24 and the container 34. The winch 98 and cable 100 will move and position the carrier frame 24 into juxtaposition with the container 34. In the preferred embodiment, the carrier frame 24 will be moved and positioned into juxtaposition with the container 34 by the steering and mobility means 120. The actuators 68 will then lower the carrier frame 24 adjacent to the ground 110, and the supporting chains 82 will be connected to the container 34. The actuators 68 will elevate the carrier frame 24 and container 34 to a height greater than the vehicle platform 80. The winch 98 and cable 100 will be connected between the carrier frame 24 and the vehicle 78. The winch 98 and cable 100 will move and position the carrier frame 24 and container 34 over the vehicle platform 80. In the preferred embodiment, the carrier frame 24 and container 34 will be moved and positioned over the vehicle platform 80 by the steering and mobility means 120. The actuators 68 will retract and lower the carrier frame 24 and container 34 onto the vehicle platform 80, and continue retracting so as to raise the wheels 62 off the ground 110, thereby loading the container 34. Front transverse element 44 and rear transverse element 46 are retracted, locking carrier frame 24 into notches 108. Vertical uprights 56 fit into notches 108 for securing carrier frame 24 to platform 80.
It is to be understood that the above detailed description of embodiments of the invention is provided by way of example only. Various details of design and construction may be modified without departing from the true spirit and scope of the invention as set forth in the appended claims.
Now that the invention has been described,
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A hydraulically actuated mobile carrier frame wraps around a storage container of standard size and lifts the container from the ground onto a transport vehicle. The carrier frame subsequently returns the container to the ground. The carrier frame stays with the vehicle. The carrier frame can be expanded transversely to clear the vehicle for loading and unloading, then contracted into notches in the vehicle platform to be releasably locked to the vehicle for over the road transport.
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CROSS-REFERENCE
This application claims priority from Non-Provisional patent application Ser. No. 14/662,342 filed on Mar. 19, 2015 and from Provisional Patent Application Ser. Nos. 62/062,441 filed on Oct. 10, 2014 and 62/067,612 filed on Oct. 23, 2014.
FIELD OF THE INVENTION
This invention relates to a quick release attachment for mounting accessories (e.g., a scope, light, bayonet, etc.) on the Picatinny or tactical rail of a firearm.
BACKGROUND
Many individuals and firearm enthusiasts desire to mount one or more interchangeable accessories, such as a scope, light, bayonet and the like, onto their firearms. Historically, this has been accomplished by fixedly mounting the accessory to the Picatinny or tactical rail of the firearm, which is essentially a bracket that can be attached to a firearm and which provides a standard mounting platform for a desired attachment. However, heretofore, the process of mounting such accessories to the Picatinny rail has required the use of external tools, and has been both awkward and time-consuming. Moreover, the inability to timely attach a desired accessory to a firearm, or switch accessories, can be dangerous for the user. For example, in combat, a soldier's inability to quickly attach a bayonet to his firearm could result in death or serious injury to the soldier.
Consequently, there is a long felt need in the art for a device that enables a user to quickly and securely attach/detach an accessory (e.g., a scope, light, bayonet, etc.) to the Picatinny or tactical rail of a firearm without the use of external tools. There is also a long felt need for a device that is capable of being locked/unlocked with a single hand, thereby allowing the user to retain possession of the firearm with his remaining hand. Finally, there is a long felt need for a device that accomplishes all of the forgoing objectives, and that is relatively inexpensive to manufacture and safe and easy to use.
SUMMARY
The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
The subject matter disclosed herein, in one aspect thereof, is a device for enabling a user to quickly and securely attach/detach an accessory (e.g., a scope, light, bayonet, etc.) to the Picatinny or tactical rail of a firearm. In a preferred embodiment of the present invention, the device comprises a lower portion, an upper portion, and a locking mechanism, wherein said locking mechanism further comprises a handle portion, at least one latch with a spring attached thereto, and at least one lock that is repositionable by the movement of said at least one latch.
To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and is intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the present invention securely attached to a Picatinny rail of a firearm.
FIG. 2 is a perspective view of the device of FIG. 1 detached from a Picatinny rail of a firearm.
FIG. 3A is a side elevational view of the device of FIG. 1 securely attached to a Picatinny rail of a firearm.
FIG. 3B is a cross-sectional view of the device depicted in FIG. 3A at cut line 3 B- 3 B.
FIG. 4A is a front elevational view of the device of FIG. 1 .
FIG. 4B is a cross-sectional view of the device depicted in FIG. 4A at cut line 4 B- 4 B.
FIG. 5 is a perspective view of the lower portion and locking mechanism of the device depicted in FIG. 1 .
FIG. 6 is a perspective view of an alternative embodiment of the present invention wherein the locking mechanism further comprises a button lock to reduce the likelihood of an accidental release of the locking mechanism.
FIG. 7A is a rear elevational view of the alternative embodiment of the present invention depicted in FIG. 6 .
FIG. 7B is a side cross-sectional view of the device depicted in FIG. 7A at cut line 7 B- 7 B.
FIG. 8 is an exploded view of the alternative embodiment of the present invention depicted in FIG. 6 .
FIG. 9 is a partially exploded view of an alternative embodiment of the present invention.
FIG. 10A is a front elevational view of the additional alternative embodiment of the present invention depicted in FIG. 9 .
FIG. 10B is a side cross-sectional view of the device depicted in FIG. 9 at cut line 10 B- 10 B.
FIG. 11A is a top perspective view of the lower portion and locking mechanism of the device depicted in FIG. 9 in a locked position.
FIG. 11B is a top perspective view of the lower portion and locking mechanism of the device depicted in FIG. 9 in an unlocked position.
FIG. 12A is a bottom perspective view of the lower portion and locking mechanism of the device depicted in FIG. 9 in a locked position.
FIG. 12B is a bottom perspective view of the lower portion and locking mechanism of the device depicted in FIG. 9 in an unlocked position.
DETAILED DESCRIPTION
The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details.
Referring initially to the drawings, FIG. 1 depicts a perspective view of the side slide lock and quick release device 100 of the present invention securely attached to a Picatinny rail 20 of a firearm (not shown), and FIG. 2 depicts a perspective view of the device 100 of the present invention detached from Picatinny rail 20 . By way of background, Picatinny rail 20 is an elongated bracket that may be attached to a firearm to provide a standard mounting platform for accessories and attachments such as a scope, light, bayonet and the like. Rail 20 is typically comprised of a plurality of raised, spaced apart lugs or ridges 22 along its top or upper surface, with channels 24 located between and formed by said ridges 22 , and a rail flange 26 extending along each side of rail 20 .
The side slide lock and quick release device 100 of the present invention is preferably comprised of a lower portion 110 , an upper portion 120 removably attached to said lower portion 110 through the use of fasteners 130 , and a locking mechanism 140 for detachably securing device 100 to rail 20 without the need for external tools. As best illustrated in the FIGS., lower portion 110 is an elongated member having a top surface 111 , a bottom surface 112 , opposing side surfaces 113 , a rear 115 , a front 116 , a rear fence 117 and a forward fence 118 , wherein said rear fence 117 and said forward fence 118 extend downwardly from said bottom surface 112 for mating engagement with rail 20 , as described more fully below.
Lower portion 110 further comprises one or more continuous openings 1112 that extend between top surface 111 and bottom surface 112 , and from a first side surface 113 in the direction of a second side surface 113 , for receipt of a portion of locking mechanism 140 , as described more fully below. Top surface 111 may also comprise a plurality of spaced apart openings 1114 for receipt of fasteners 130 to fixedly attach lower portion 110 to upper portion 120 .
As previously described, lower portion 110 is comprised of a pair of generally parallel, spaced apart fences 117 , 118 that extend downwardly from said bottom surface 112 for mating engagement with rail 20 . More specifically, rear fence 117 protrudes downwardly from one side of bottom surface 112 towards the front 116 of lower portion 110 and extends substantially along the length of lower portion 110 . Similarly, forward fence 118 protrudes downwardly from the opposite side of bottom surface 112 towards the rear 115 of lower portion 110 and is generally parallel to rear fence 117 , but that only extends partially along the length of lower portion 110 , as best shown in FIG. 5 , due to the presence of one or more continuous openings 1112 . Rear fence 117 further comprise a generally v-shaped groove 119 extending along a substantial portion of the length of rear fence 117 for mating engagement with rail flange 26 of rail 20 . Likewise, when locking mechanism 140 is engaged, forward fence 118 and a portion of locking mechanism 140 also form a generally v-shaped groove extending along a portion of the length of said forward fence 118 for mating engagement with rail flange 26 of rail 20 , as best shown in FIG. 4A .
Upper portion 120 is also a generally elongated member that is comprised of a top 121 , an opposing bottom 122 , a pair of opposing side slots 124 , a rear end 125 and a front end 126 . Similar to Picatinny rail 20 , top 121 is also comprised of a plurality of raised, spaced apart lugs or ridges 1210 , with channels 1212 located between and formed by said ridges 1210 .
Bottom 122 is generally flat and preferably corresponds in shape and size with top surface 111 of lower portion 110 as shown in the Figures, with the exception of (i) an elongated longitudinal opening or channel 1220 formed therein for receipt of a portion of locking mechanism 140 and (ii) one or more spring channels 123 formed therein for receipt of a spring, both of which are explained more fully below. Channel 1220 preferably extends along a partial length of bottom 122 from rear 115 in the direction of front 116 . Each of said spring channel(s) 123 also preferably extends a partial length of bottom surface 122 to coincide with the positioning of springs, as described more fully below.
Opposing side slots 124 are similar to rail flanges 26 in rail 20 , and preferably extend between rear end 125 and front end 126 and are useful for attaching accessories (such as a scope, light, bayonet, etc.) to device 100 in generally the same manner that accessories (not shown) would ordinarily be attached to rail 20 . Opposing side slots 124 may further comprise a plurality of spaced apart openings 1240 extending through bottom 122 . The number and placement of openings 1240 preferably correspond to the number and placement of openings 1114 in lower portion 110 for receipt of fasteners 130 , which are used to fixedly attach upper portion 120 to lower portion 110 , as best shown in FIGS. 1-3 .
Locking mechanism 140 is preferably comprised of an elongated arm portion 142 , a handle portion 144 for engaging or dis-engaging locking mechanism 140 , one or more locks 146 and one or more springs 147 . In a preferred embodiment of the present invention, arm portion 142 is further comprised of a front latch 1420 and a rear latch 1425 positioned in series and sized to fit and slide longitudinally within channel 1220 . Each of latches 1420 , 1425 further comprise a radially shaped continuous opening 1426 therein for receipt of a cam, as explained more fully below and depicted in FIG. 5 . Handle portion 144 may be attached to rear latch 1425 via fasteners 145 .
Each of locks 146 are generally block-like in shape and further comprise a cam 1460 that extends upwardly from a top surface 1462 of lock 146 , as best shown in FIG. 5 . More specifically cam 1460 is positioned in opening 1426 of latches 1420 , 1425 so that when said latches 1420 , 1425 are repositioned longitudinally within channel 1220 , cams 1460 cause each of locks 146 to move in and partially out of continuous openings 1112 in lower portion 110 .
A spring 147 is positioned atop of each of front latch 1420 and rear latch 1425 as shown in FIG. 5 and secured to said latches via a spring post 148 and a spring pin 149 . More specifically, each of springs 147 is comprised of a first end 1472 and a second end 1474 , with said first end 1472 being fixedly attached to said spring post 148 via spring pin 149 . Springs 147 are biased in the general direction of the length of device 100 , as best shown in FIG. 5 and, when fully assembled, springs 147 are contained and confined within spring channels 123 of upper portion 120 .
In the further preferred embodiment of the present invention depicted in FIGS. 6, 7A and 7B , locking mechanism 140 further comprises a button lock 150 for reducing the likelihood of an accidental or premature release of locking mechanism 140 . More specifically, button lock 150 comprises a button portion 152 , a pin 154 and an arm 156 , wherein button portion 152 and arm 156 are preferably integrally formed and pivot about pin 154 . Button lock 150 is engaged/disengaged by partially rotating button portion 152 about pin 142 , as described more fully below. Button portion 152 resides in a recess 159 in handle portion 144 , as best shown in FIG. 6 . When in the disengaged position, arm 156 resides in a recess 158 in arm portion 142 . When in the engaged position, arm 142 extends outwardly from recess 158 to contact rear end 125 of upper portion 120 to prevent locking mechanism 140 from accidentally or prematurely releasing, as described more fully below.
For purposes of further clarity, FIG. 8 is an exploded view of the alternative embodiment of the present invention depicted in FIG. 6 . As shown in FIG. 8 , device 100 may further comprise an insert device 180 that may be secured to, and extend downwardly from, the bottom surface 112 of lower portion 110 with fasteners 181 . Insert device 180 further comprises an insert portion 182 with an opening 1820 therein for receipt of a spring 184 and a ball 186 . As more fully described below, insert device 180 is inserted into a select one of channels 24 of Picatinny rail 20 when device 100 is installed on rail 20 , and biased spring 184 and ball 186 apply pressure against a select one of ridges 22 of rail 20 .
FIG. 9 through FIG. 12B depict an additional alternative embodiment of the present invention in which locking mechanism 140 further comprises an arm 210 and related components for retaining handle portion 144 in a desired position while installing device 100 onto rail 20 , as more fully described below. More specifically, FIG. 9 is a partially exploded view of an alternative embodiment of the present invention and shows locking mechanism 140 further comprised of a pin 200 , arm 210 , a spring 220 and a pair of spacers 240 . In this particular embodiment, and as shown in FIG. 9 , lower portion 110 further comprises in top surface 111 a pin channel 202 for receipt of pin 200 , an arm channel 212 that preferably extends between top surface 111 and bottom surface 112 for receipt of arm 210 , and one or more spacer channels 242 for receipt of spacers 240 . Additionally, rear latch 1425 further comprises an aperture 1427 therein for receipt of a portion of arm 210 , as more fully described below.
As best shown in FIG. 9 , arm 210 is further comprised of a first end 2102 , an opposing second end 2104 , an opening 2105 for receipt of pin 200 and a spring seat 2106 for receipt of spring 220 , as more fully described below. More specifically, pin 200 is inserted into opening 2105 and extends from each side thereof to reside in pin channel 202 and permit arm 210 to pivot about pin 200 as arm 210 resides in arm channel 212 and extends beyond bottom surface 112 of lower portion 110 , as shown in FIG. 12B . Each of spacers 240 reside in a respective spacer channel 242 and prevent pin 200 from being prematurely removed from pin channel 202 . Further, spring 220 rests atop of spring seat 2106 adjacent to second end 2104 of arm 210 , and first end 2102 of arm 210 resides in arm channel 212 below aperture 1427 in rear latch 1425 , as explained more fully below.
More specifically, when device 100 is assembled and in the locked position (meaning the handle portion 144 is at its furthest point from rear 115 , as shown in FIGS. 10A &B, 11 A and 12 A), spring 220 , which is positioned in compression between spring seat 2106 on arm 210 and a spring channel 222 formed within bottom 122 of upper portion 120 , causes first end 2102 to pivot about pin 200 in the direction of rear latch 1425 , but is prevented from doing so until handle portion 144 is pushed in the direction of rear 115 thereby enabling aperture 1427 on rear latch 1425 to move into position to receive first end 2102 of arm 210 . Once received, handle portion 144 is prevented from moving out of the unlocked position (meaning that handle portion 144 is at its closest position to rear 115 , as shown in FIGS. 11B and 12B ) until such time as device 100 is placed onto rail 20 , which causes the portion of second end 2104 of arm 210 to pivot in the direction of spring 220 and spring 220 to compress between spring seat 2106 and spring channel 222 in upper portion 120 . As spring 220 compresses, first end 2102 of arm 210 leaves aperture 1427 and handle portion 144 returns to the locked position as shown in FIGS. 11A and 12A . In this manner, a user (not shown) is capable of installing device 100 onto rail 20 without having to both push the handle portion 144 towards device 100 and hold it there until device 100 is installed onto rail 20 at a desired location.
Having now described the general structure of a number of embodiments of device 100 , its function will now be described in general terms. A user (not shown) desiring to securely mount device 100 (as depicted in FIGS. 1-8 ) onto rail 20 would simply place device 100 (in an unlocked position—meaning the handle portion 144 is pushed in towards device 100 , as shown in FIGS. 1 and 2 ) at a desired position along and on top of rail 20 so that fences 117 , 118 clear rail flanges 26 and locks 146 and insert device 180 are capable of being inserted into a respective select one of said channels 24 . Once device 100 is placed on rail 20 , the user would then release handle portion 144 (which is compressing springs 147 ) in a direction opposite of rear 115 , thereby causing cams 1460 to travel clockwise within radial openings 1426 and each of locks 146 to securely engage Picatinny rail 20 . A user may then also desire to engage button lock 150 by partially rotating button portion 152 downwardly about pin 154 so that arm 156 extends upwardly from recess 158 to contact rear end 125 of upper portion 120 to prevent locking mechanism 140 from prematurely or accidentally disengaging.
Alternatively, a user (not shown) desiring to securely mount device 100 (as depicted in FIGS. 9 through 12B ) onto rail 20 would simply push handle portion 144 in the direction of rear 115 until first end of pivoting arm 210 engages aperture 1427 in rear latch 1425 and place device 100 (in an unlocked position—meaning the handle portion 144 is pushed in towards rear 115 , as shown in FIGS. 11B and 12B ) at a desired position along and on top of rail 20 so that fences 117 , 118 clear rail flanges 26 and locks 146 and insert device 180 are capable of being inserted into a respective select one of said channels 24 . Once device 100 is placed on rail 20 , arm 210 pivots about pin 200 so that first end 2102 of arm 210 leaves aperture 1427 thereby allowing handle portion 144 (which is compressing springs 147 ) to release in a direction opposite of rear 115 , thereby causing cams 1460 to travel clockwise within radial openings 1426 and each of locks 146 to securely engage Picatinny rail 20 . A user may then also desire to engage button lock 150 by partially rotating button portion 152 downwardly about pin 154 so that arm 156 extends upwardly from recess 158 to contact rear end 125 of upper portion 120 to prevent locking mechanism 140 from prematurely or accidentally disengaging.
Similarly, to unlock locking mechanism 140 (as depicted in FIGS. 1 through 8 ) to reposition device 100 along rail 20 or remove device 100 from rail 20 altogether, a user (not shown) would simply (i) disengage button lock 150 by partially rotating button portion 152 upwardly about pin 154 so that arm 156 retreats into recess 158 and (ii) push in handle portion 144 in the direction of rear 115 , thereby causing springs 147 to compress and cams 1460 to travel counter-clockwise within radial openings 1426 and each of locks 146 to disengage from Picatinny rail 20 . More specifically, as the user pushes in handle portion 144 and rear latch 1425 moves forward along channel 1220 it makes contact with front latch 1420 and causes the same to also move forward, thereby causing each of springs 147 to compress and the device 100 to become capable of being installed or removed from rail 20 . Once the device 100 has been installed, the compression force in the springs 147 causes each of front latch 1420 and rear latch 1425 to retreat to their original position.
Similarly, to unlock locking mechanism 140 (as depicted in FIGS. 9 through 12 ) to reposition device 100 along rail 20 or remove device 100 from rail 20 altogether, a user (not shown) would simply (i) disengage button lock 150 by partially rotating button portion 152 upwardly about pin 154 so that arm 156 retreats into recess 158 and (ii) push in handle portion 144 in the direction of rear 115 , thereby causing first end of pivoting arm 210 to engage aperture 1427 in rear latch 1425 and springs 147 to compress and cams 1460 to travel counter-clockwise within radial openings 1426 and each of locks 146 to disengage from Picatinny rail 20 . More specifically, as the user pushes in handle portion 144 and rear latch 1425 moves forward along channel 1220 it makes contact with front latch 1420 and causes the same to also move forward, thereby causing each of springs 147 to compress and the device 100 to become capable of being installed or removed from rail 20 . Once the device 100 has been installed, the compression force in the springs 147 causes each of front latch 1420 and rear latch 1425 to retreat to their original position.
Other variations are also within the spirit of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions, a certain illustrated embodiment thereof is shown in the drawings and has been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventor intends for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
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An improved device for enabling a user to quickly and securely attach and detach an accessory (e.g., a scope, light, bayonet, etc.) to the Picatinny or tactical rail of a firearm. In a preferred embodiment of the present invention, the device comprises a lower portion, an upper portion and a locking mechanism. The device is relatively inexpensive to manufacture and safe and easy to use.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of application Ser. No. 10/076,455, filed Feb. 19, 2002 now U.S. Pat. No. 7,039,347.
FIELD OF THE INVENTION AND RELATED ART
The present invention relates to an image forming apparatus employing an electrophotographic image formation method or an electrostatic recording method, and a toner supply container used with such an image forming apparatus. In particular, it relates to such an image forming apparatus as a copying machine, a printer, a facsimile machine, or the like and a toner supply container used with such an image forming apparatus.
In an image forming apparatus such as an electrophotographic copying machine, a printer, or the like, microscopic powder of toner has been used as developer. As the developer in an image forming apparatus is consumed, toner is supplied to the image forming apparatus with the use of a toner supply container.
Since toner is in the form of microscopic powder, there has been the problem that during a toner supplying operation, toner scatters and contaminates an operator and the area adjacent to the apparatus. Thus, there have been made a number of proposals regarding the method for preventing this problem, and some of them have been put to practical use. According to one of such proposals, a toner supply container is placed in the main assembly of an image forming apparatus (which hereinafter will be referred to as apparatus main assembly), and the toner within the toner supply container is discharged from the container by a small amount as necessary. In the case of this method, it is difficult to reliably and naturally (relying on gravity) discharge the toner. Thus, the provision of some type of means for stirring/conveying the toner is necessary.
The toner supply container disclosed in Japanese patent Application publication 7-113796 is approximately cylindrical in general shape. It is provided with a relatively small toner outlet, which is in one of the lengthwise end walls. It is also provided with a spiral toner stirring/conveying member, which is located within the container. This spiral member is externally driven; external driving force is transmitted to one of the lengthwise ends of this spiral member extended through the corresponding lengthwise end wall of the container. The other end, that is, non-driven end, of the spiral stirring/conveying member is left free.
The toner supply container disclosed in Japanese Laid-open patent Application 7-104572 also contains a toner agitator, which has a plurality of agitating blade formed of elastic substance. In this case, the force for conveying the toner in the direction parallel to the axial direction of the container is realized by giving the agitator blades a trapezoidal shape by varying the distance from the rotational axis to the tips of the agitator blades.
One of the lengthwise ends of each of the above described two stirring member in accordance with the prior arts is extended through the container wall at one of the lengthwise ends. Thus, the portion of the container wall through which the stirring member is extended needs to be provided with a bearing/sealing mechanism of some type. As for the structure of such a bearing/sealing mechanism, which is widely in use, a gear is attached to the lengthwise end of the stirring member, and a sealing member is sandwiched between the gear and container wall. As for the sealing member, generally, a piece of wool felt, or an oil seal, in the form of a donut is used.
This type of toner container is mounted within the main assembly of an image forming apparatus. In operation, as the toner stirring/conveying member within the toner container is rotationally driven by the force transmitted from the apparatus main assembly side, the toner within the container is conveyed within the container, and then, is continuously discharge by a small amount from the toner outlet of the container as necessary.
Japanese Laid-open patent Application 7-44000 discloses another toner supply container in accordance with the prior arts. According to this application, a toner supply container is approximately in the form of a cylindrical bottle; in other words, the toner supply container has: a toner outlet portion, with the smallest diameter, equivalent to the neck portion of a bottle; a toner holding portion equivalent to the main body of a bottle, and an approach portion, in the form of a circular frustum, equivalent to the portion of a bottle connecting the neck portion and main body of a bottle. The internal surface of the main body portion is provided with a single spiral rib, or a plurality of spiral ribs, which extend from one lengthwise end of the main body to the other. The outward end of the outlet portion is provided with a hole, through which the toner is discharged. In operation, as the toner supply container is rotated, the toner therein is conveyed by the spiral ribs toward the toner outlet, is guided (or lifted) into the toner outlet by the approach portion, and then, is discharged from the outlet hole.
Japanese Laid-open patent Application 10-260574 also discloses a toner supply container in accordance with the prior arts. This toner supply container is also approximately in the form of a cylindrical bottle. In other words, it has a toner outlet portion with the smallest diameter, equivalent to the neck portion of a bottle; a toner holding portion equivalent to the main body of a bottle, and an approach portion, in the form of a circular frustum, equivalent to the portion of a bottle connecting the neck portion and main body of a bottle. The internal surface of the main body portion is provided with a single spiral rib or plurality of spiral ribs which extend from one lengthwise end of the main body the other. The outward end of the outlet portion is provided with a hole, through which the toner is discharged. This toner supply container, however, is different from the preceding one in that its approach portion comprises a portion which rakes the toner upward as the toner is conveyed thereto, and a portion which guides the toner to the toner outlet as the toner is raked upward.
The immediately preceding two toner supply containers in accordance with the prior arts are different from the other preceding two toner supply containers in accordance with the prior arts in that they do not contain a stirring member. These immediately preceding two toner supply containers are also mounted within the main assembly of an image forming apparatus. They are different in that in order to convey the toner therein, the toner supply containers themselves are rotated by the driving force from the apparatus main assembly side.
The above described toner supply containers in accordance with the prior arts, however, suffer from the following problems.
First, in the case of the toner supply containers in accordance with the prior arts disclosed in Japanese Laid-open patent Applications 7-113796 and 7-104572, the portion of the toner supply container, through which the force for driving the stirring member is received, must be provided with a bearing/sealing mechanism. This requirement increases the components count, which in turn increases the assembly time and labor, increasing therefore manufacturing cost.
Further, in the case of such a bearing/sealing mechanism as the above described one, there is a possibility that toner is drawn into the bearing/sealing portion. If toner is drawn into the bearing/sealing portion, the toner particles are likely to be melted and agglutinate into larger toner particles, which derogatorily affects image quality if they happen to contribute to image development. This is problem, although it rarely occurs.
Secondly, in the case of the toner supply containers in accordance with the prior arts disclosed in Japanese Laid-open patent Applications 7-44000 and 10-260574, the toner supply containers do not have an internal stirring member. Therefore, they do not suffer from the above described problem related to a bearing/sealing mechanism. However, they suffer from the following problems, because their internal surfaces are provided with a single spiral rib, or a plurality of spiral ribs.
Since these toner supply containers do not contain an internal stirring member or the like for stirring the toner therein, there is a possibility that if they are subjected to vibrations during their shipment, or if they are stored for a substantial length of time under high temperature/humidity condition, the toner therein agglomerates, forming the so-called toner bridges. Without the presence of a toner stirring member, once the toner bridges are formed, the toner is not efficiently discharged. More specifically, the toner bridges are conveyed, without being collapsed, toward the outlet, by the spiral ribs on the internal surface of the toner supply container, possibly plugging up the toner outlet.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a toner supply container superior to a toner supply container in accordance with the prior arts, in both toner conveyance performance and toner stirring performance.
Another object of the present invention is to provide a toner supply container capable of unagglomerating the toner therein while conveying it.
These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic sectional view of the main assembly of the forming apparatus (electrophotographic image copying machine) in an embodiment of the present invention.
FIG. 2 is a perspective view of the electrophotographic copying machine shown in FIG. 1 .
FIG. 3 is a perspective view of the top portion of the electrophotographic copying machine shown in FIG. 1 , for showing how a toner supply container is mounted into the electrophotographic copying machine by opening the toner supply container exchange cover.
FIG. 4 is a perspective view of the toner supply container in the first embodiment of the present invention, in which a half of the cylindrical wall has been left out in order to show the interior of the container.
FIG. 5(A) is a sectional view of the toner supply container in the first embodiment of the present invention, at the plane inclusive of the axial line of the container, as seen from the front side of the copying machine, and FIG. 5(B) is a sectional view of the same container, at a plane A—A in FIG. 5(A) .
FIGS. 6(A) , 6 (B) and 6 (C) are schematic sectional views of the toner supply container in the first embodiment of the present invention, which show how the toner in the container is discharged from the container.
FIGS. 7(A) , 7 (B), and 7 (C) are perspective view, front view, and left side view, of the toner conveying member in the first embodiment of the present invention.
FIGS. 8(A) and 8(B) are sectional view, as seen from the front side of the copying machine, and plan view, as seen from the plane A—A in FIG. 8(A) , of the toner supply container in the first embodiment of the present invention, for describing the various structural components of the container.
FIGS. 9(A) and 9(B) are sectional view, as seen from the front side of the copying machine, and plan view, as seen from the plane A—A in FIG. 9(A) , of a toner supply container slightly different in internal structural component from the toner supply container in the first embodiment of the present invention.
FIG. 10 is an exploded perspective view of the toner supply container in the first embodiment of the present invention, for showing the assembly process thereof.
FIGS. 11( a ) and 11 ( b ) are schematic sectional views of the portion of a toner supply container in accordance the present invention, where its partition wall meets the internal wall of its cylindrical wall, and show the positional relationship between the partition wall and internal wall of the cylindrical wall.
FIG. 12 is an exploded perspective view of the toner supply container in another embodiment of the present invention, for showing the assembly process thereof.
FIGS. 13( a ) and 13 ( b ) are schematic plan and side views of the driving force transmission portion of a toner supply container in accordance with the present invention, and show the structure thereof.
FIGS. 14( a ) and 14 ( b ) are schematic plan and side views of the driving force transmission portion of another toner supply container in accordance with the present invention, and show the structure thereof.
FIG. 15 is a schematic sectional view of another driving force transmission portion of a toner supply container in accordance with the present invention, and its adjacencies, as seen from the front side of the copying machine.
FIGS. 16(A) , 16 (B), and 16 (C) are perspective view, side view, and plan view, of the toner supply container in the second embodiment of the present invention, in which the set of inclined ribs on one side of the conveying member and the set of inclined on the other side of the conveying member are disposed in mirror symmetry with respect to the toner conveying member.
FIGS. 17(A) , 17 (B), and 17 (C) are schematic sectional views of the toner supply container in the second embodiment of the present invention, which show how the toner in the container is discharged from the container, as the container is rotated in the clockwise direction.
FIGS. 18(A) , 18 (B) and 18 (C) are schematic sectional views of the toner supply container in the second embodiment of the present invention, which show how the toner in the container is discharged from the container, as the container is rotated in the counterclockwise direction.
FIG. 19 is a perspective view of a toner conveying member different in the configuration of the inclined rib from the conveying members in the first and second embodiment.
FIG. 20 is a perspective view of another toner conveying Member different in the configuration of the inclined rib from the conveying members in the first and second embodiments.
FIG. 21 is a perspective view of another toner conveying member different in the configuration of the inclined rib from the conveying members in the first and second embodiments.
FIG. 22 is a perspective view of another toner conveying member different in the configuration of the inclined rib from the conveying members in the first and second embodiments.
FIG. 23 is a perspective view of a toner conveying member different in the configuration of the inclined rib from the conveying members in the first and second embodiments.
FIGS. 24(A) and 24(B) are perspective phantom view and sectional view, respectively, of the toner supply container in another embodiment of the present invention, the toner outlet of which is in the cylindrical wall of the container.
FIGS. 25(A) and 25(B) are sectional view, as seen from the front side of the copying machine, and plan view, as seen from the plane A—A in FIG. 8(A) , of the toner supply container in the first comparative example of a toner supply container, the toner conveying member of which is not provided with holes.
FIG. 26 is a partially broken perspective view of the toner supplying container in the second comparative example of a toner supply container in accordance with the prior arts, the internal surface of the main body of which is provided with a single spiral rib, or a plurality of spiral ribs, for describing the various structural components of the container.
FIG. 27 is a graph which shows the toner discharge performances of the toner supply containers in the first and second embodiments, and the first comparative example.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the preferred embodiment of the present invention will be described with reference to the appended drawings.
First, referring to FIG. 1 , an electrophotographic copying machine, that is, an example of an image forming apparatus in which a toner supply container in accordance with the present invention is mounted, will be described regarding its structure.
(Electrophotographic Image Forming Apparatus)
In FIG. 1 , a referential code 1 designates the main assembly of an electrophotographic copying machine (which hereinafter will be referred to as apparatus main assembly).
Designated by a referential code 100 is an original, which is placed on an original placement glass platen 102 . An optical image in accordance with the image formation data of the original 101 is focused on an electrophotographic photoconductive member as an image bearing member (which hereinafter will be referred to as photoconductive drum) by the plurality of mirrors and lenses Ln of an optical portion 103 .
Designated by referential codes 105 – 108 are cassettes. Among the recording mediums p (which hereinafter will be referred to as “paper p”) placed in layers in these cassettes, the paper, the size of which matches the information inputted by an operator through a control panel 100 a shown in FIG. 2 , or the size of the original 100 , is selected based on the paper size information of the cassettes 105 – 108 . Incidentally, the choice of the recording medium is not limited to paper. For example, OHP or the like may be used as recording medium, as necessary.
The selected paper p is fed out of one of the cassettes 105 – 108 by the corresponding feeding/separating apparatus among feeding/separating apparatuses 105 A– 108 A, and is conveyed further to a registration roller 110 by way of a conveying portion 109 . The registration roller 110 allows the paper p to be further conveyed in synchronism with the rotation of the photoconductive drum 104 and the scanning timing of the optical portion 103 . Designated by referential codes 111 and 112 are transfer charging device and separation charging device, respectively. The toner image formed on the photoconductive drum 104 is transferred onto the paper p by the transfer discharging device 111 .
Then, the paper pi onto which the toner image has been transferred, is separated from the photoconductive drum 104 by the separation discharging device.
Thereafter, the paper p is conveyed by a paper conveying portion 113 to a fixing portion 114 bi in which the toner image on the paper p is fixed to the paper p by heat and pressure. Then, when the copying machine is in the single-sided copy 12 mode, the paper p is conveyed through an inverting portion 115 , and is discharged into a delivery tray 117 by a discharge roller 116 , whereas when in the two-sided copy mode, the paper p is conveyed to the registration roller 110 by controlling the flapper 118 of the inverting portion 115 , through re-feeding conveying paths 119 and 120 , and is discharged into the delivery tray 117 after being passed through the same path as the one through which the paper p is passed when in the single-sided copy mode.
More specifically, when in the two-sided mode, the paper p is only partially discharged from the apparatus main assembly by the discharge roller 116 , while being passed through the reverting portion 115 . In other words, as soon as the trailing end of the paper p passes the flapper 118 while the paper p is still being discharged from the apparatus main assembly, the flapper 118 is controlled and at the same time, the discharge roller 116 is reversely rotated to feed the paper p back into the apparatus main assembly. Thereafter, the paper p is conveyed to the registration roller 110 by way of re-feeding conveying paths 119 and 120 . Then, the paper p is discharged into the delivery tray 117 following the same path as the one through which the paper p is passed when in the single-sided copy mode.
In the apparatus main assembly 100 structured as described above, a developing portion 201 , cleaning portion 202 , a primary charging portion 203 , and the like, are disposed around the photoconductive drum 104 . The developing portion 201 develops, with the use of toner, an electrostatic latent image formed by exposing the peripheral surface of the photoconductive drum 104 by the optical portion 103 . A toner supply container 1 for supplying toner to the developing portion 210 is removably mounted in the toner supply container mounting portion of the apparatus main assembly.
The developing portion 210 is provided with a toner hopper 201 a and a developing device 201 b . The toner hopper 201 a has a stirring member 201 c for stirring the toner supplied from the toner supply container.
After being stirred by the stirring member 201 c -, the toner is sent to the developing device 201 b by a magnetic roller 201 d . The developing device 201 b has a development roller 201 f and a toner sending member 201 e . The toner is sent from the toner hopper 201 a to the toner sending member 201 e by the magnetic roller 201 d , and is sent further to the development roller 201 f by the toner sending member 201 e . Then, the toner is supplied to the photoconductive drum 104 by the development roller 201 f.
The cleaning portion 202 is for removing the toner particles remaining on the photoconductive drum 104 . The primary charging device 203 is for charging the photoconductive drum 104 . Designated by a referential code 15 in FIG. 2 is a toner supply container replacement cover, which constitutes a part of the exterior of the apparatus main assembly 100 . As a user opens the toner supply container replacement cover 15 , a toner supply container bed 50 is pulled out to a predetermined position by a driving system (unshown). The toner supply container 1 is placed on this container bed 50 . When a user takes the toner supply container 1 out of the apparatus main assembly, the user removes the toner supply container 1 on the container bed 50 after the container bed 50 is pulled out of the apparatus main assembly. The toner supply container replacement cover 15 is a dedicated cover for the placement or removal (replacement) of the toner supply container; in other words, it is opened or closed only for placing or removing the toner supply container 1 . As for the maintenance of the apparatus main assembly, it is carried out by opening a front cover 100 .
The toner supply container 1 may be directly placed in the apparatus main assembly or removed therefrom, without providing the apparatus main assembly with the container bed 50 .
Embodiment 1
Next, referring to FIGS. 4 and 5 , the toner supply container in the first embodiment of the present invention will be described. FIG. 4 is a partially broken perspective view of the toner supply container in the first embodiment of the present invention. FIG. 5(A) is a sectional view of the toner supply container, as seen from the front side of the copying machine, and FIG. 5(B) is a plan view of the toner supply container, as seen from the plane A—A in FIG. 5(A) .
(Toner Supply Container)
The toner supply container 1 is structured so that it is mounted into the image forming apparatus main assembly by a user, in the direction virtually parallel to the lengthwise direction of the main body of the container, from the sealing member 2 side of the container. When removing the toner supply container 1 , the toner supply container 1 is pulled out of the apparatus main assembly in the direction reverse to the direction in which it was mounted.
As shown in FIGS. 4 and 5 , the toner bottle 1 A (bottle or main body of the container) is generally hollow-cylindrical, and a cylindrical portion is formed projected from one end surface at its central position. The free end side of the cylindrical portion defines an opening 1 a for discharging the toner into the image forming apparatus (developing device) side.
Into the opening 1 a , a sealing member 2 for sealing the opening 1 a is press-fitted, and the sealing member 2 is slid in an axial direction of the toner bottle 1 A relative to the main body of the toner bottle 1 A to automatically open and close the opening 1 a.
In FIG. 4 , it is shown as being in the open position.
The description will be made as to the internal structure of the toner bottle 1 A.
The toner bottle 1 A is generally cylindrical and is placed substantially horizontally in the main assembly of image forming apparatus. The bottle 1 A is rotated by a rotational driving force from the main assembly 100 of the image forming apparatus through an engaging projection provided in the sealing member 2 and a feeding member 3 which will be described hereinafter.
A feeding member 3 generally in the form of a flat plate is provided in the toner bottle 1 A and divides the inside of the toner bottle 1 A into two parts, and it extends in the longitudinal direction of the bottle 1 A over its full length.
On each of the sides of the flat part of the feeding member 3 , there are provided a plurality of projections 3 a (guiding portion) which is extended inclined with respect to the rotation axis a—a of the bottle 1 A toward the opening (when the feeding member takes a position effective to guide the toner downwardly toward the opening, that is, when the feeding member 3 takes the position shown in (B) of FIG. 7 ). The flat plate-like region has a function of supporting the inclined projections. One end of the inclined projection 3 a closest to the opening 1 a continues to the cylindrical portion defining the opening 1 a . Finally, the toner slides down on a surface of the closest projection 3 a with the rotation of the feeding member 3 to the cylindrical portion and then is discharged through the opening 1 a . The one end of the projection 3 a closest to the opening 1 a may be extended to a neighborhood of the cylindrical portion.
As shown in FIG. 5 , (B), the projections 3 a are provided on both of the sides of the flat plate portions of the feeding member 3 in a rotational symmetry arrangement such that toner is fed toward the opening 1 a with a unidirectional rotation of the toner bottle. With each of 180° rotations of the feeding member together with the model, the toner lifted by the projections slides down on the surface of the projections, by which the toner is gradually fed toward the opening and to the opening.
Thus, when the feeding member rotates integrally with a bottle, two toner feeding operations and discharging operations are intermittently carried out. By a continuous high-speed rotation, the toner feeding and the discharging operations are carried out substantially continuously. Here, the rotation symmetry means such a substantially symmetry with respect to the rotation axis that projections 3 a on the respective sides of the feeding member 3 take substantially the same positions with each 180° rotations.
Referring to FIGS. 6 , 7 , the toner discharging principle of the toner supply container 1 of this embodiment will be described. FIG. 6 is a partially sectional view taken along a line A—A of FIG. 5 .
The toner bottle 1 A rotates integrally with the feeding member in the direction indicated by an arrow a. In the toner bottle 1 A, the toner particle exist in the bottom portion as indicated by dots. The plate-like portion of the feeding member 3 is provided with holes or openings which will be described hereinafter. The feeding member has a toner scooping or lifting portions constituted by the plate-like portion without the holes and the outside portions of the projections, as indicated by 3 y in FIG. 7 , (A). In the state shown in (A) of FIG. 6 , the lift portion is within the toner power at the bottom of the bottle. With the rotation of the bottle integrally with the feeding member 3 , the lift portion immersed in the toner powder gradually lifts the toner against the gravity.
More particularly, in this embodiment, the toner is lifted or raised in a space defined by the lift portion ( 3 y region in (A) of FIG. 7 ) and the inner surface, contacted thereto, of the bottle. The lift portion is defined by such a portion of the inclined projection as takes the upper position when the feeding member takes a position for guiding the toner downwardly toward the opening ( FIG. 7 , (B) for example).
The plate-like portion is disposed substantially in contact with the inner surface of the bottle over the entire length of the bottle, the toner can be efficiently lifted using the inner surface of the bottle.
The toner not lifted by the lift portion passes through the hole portion 3 c , and therefore, the toner is stirred in parallel with the lifting action.
With rotation of the bottle, a part of the toner scooped or lifted by the feeding member 3 , as shown in (B) of FIG. 6 , is guided downwardly toward the opening by the gravity with the aid of the inclined projections 3 a and a portion 3 x of the plate-like portion supporting them ((B) of FIG. 6 and t 2 in (B) of FIG. 7 ).
A part of the toner lifted by the lift portion of the feeding member 3 is not fed or guided toward the opening, but drops through the hole portion 3 c by the gravity ((B) of FIG. 6 , and t 1 in (B) of FIG. 7 ). Again, the toner can be stirred by the dropping through the hole portion 3 c together with the guiding and feeding of the lifted toner.
By repeating the above-described actions, the toner in the toner bottle 1 A is gradually fed toward the discharge opening, while being stirred. Finally, the toner is discharged through the opening 1 a from the portion above the inclined projection 3 a continuing to the opening 1 a , as shown in (C) of FIG. 6 .
Since the plate-like portion extends substantially over the entirety of the length of the toner bottle 1 A, and the plurality of inclined projections 3 a are provided in the manner described above, the toner is efficiently fed while being sufficiently stirred.
The inclined projections are partly overlapped as seen in the direction perpendicular to the rotation axis, that is, when they are projected onto the rotation axis. By doing so, the toner advanced toward the opening by an inclined projection is then further advanced by an inclined projection disposed immediately in front of the inclined projection. Thus, the toner is efficiently stirred and fed.
Using this embodiment, by properly selecting the configurations, dimensions, arrangement and structures of the inclined projection 3 a provided on the feeding member 3 , various toner discharging property can be provided.
(Feeding Member)
The feeding member 3 will be described in detail. The feeding member 3 is extended substantially the entire length of the main body 1 A of the container and partition the inside space of the main body 1 A. In this embodiment, the feeding member 3 divides the main body 1 A of the container into two parts, but it may divide the space into three or four parts.
The feeding member 3 preferably extends across the opening 1 a or an extension of the opening 1 a in the direction of the axis. The reason is as follows. The toner is finally discharged through the opening 1 a by the toner feeding function of the inclined projection 3 a as described hereinbefore. Therefore, the feeding member 3 preferably extends across the opening 1 a adjacent to the flange portion (end wall surface) 3 b of the main body.
The feeding member 3 rotates integrally with the main body 1 A of the container, and extends over the entire length of the main body 1 A of the container. Thus, it functions as if it is reinforcing ribs for the main body 1 A.
Since the feeding member 3 rotates integrally with the main body 1 A of the container, it can be avoided that toner is rubbed between the feeding member 3 and main body 1 A with the result of solidification.
The toner supply container may have an elongated configuration, since the strength can be assure by the reinforcing function of the feeding member 3 (like a framework maintaining the shape of the hollow body). For the same reason, the thickness of the wall of the main body 1 A may be reduced, which leads to cost reduction of the main body 1 A and greater choice of materials of the main body 1 A.
Referring to FIG. 7 , the toner stirring effect will be described.
FIG. 7 shows a perspective view of a feeding member 3 according to an embodiment of the present invention (A), and a front view thereof and a left-hand side view thereof (B).
The feeding member 3 is provided with a plurality of through-hole portions 3 c in the flat plate portion. By the hole portions 3 c , the toner in the toner bottle 1 A are substantially freely movable between the spaces defined by the feeding member 3 .
Therefore, a certain amount of the toner lifted by the rotation of the toner bottle is guided and fed by the inclined projection 3 a toward the opening, and the other amount of the lifted toner drops through the hole portions 3 c . Thus, there occurs various motions of the toner within the bottle.
The dropping of the toner through the hole portions 3 c is effective to loosen the coagulated toner by the impact resulting from the dropping, thus improving the flowability of the toner in the bottle. The hole portions 3 c are provided substantially over the entire length of the toner bottle, and therefore, the flowability of the toner is enhanced at any part of the inside of the bottle very quickly, so that satisfactorily discharging performance can be provided at the initial stage after the exchange of the toner containers. For this reason, the preliminary rotation for the standardization of the discharging performance is not necessary, thus minimizing the down time (the time period in which the image formation is impossible) of the image forming apparatus.
In the case of the conventional toner supply container in which a helical projection is formed on the inside surface of the bottle, there is no positive means to loosen the coagulated toner, and therefore, it has been necessary to rotate until the toner is predicted to have been loosened to such an extent that toner is dischargeable.
According to this embodiment, however, on the feeding member 3 positively moves the toner and enhances the flowability. The toner can be discharged without problem even if the toner is bridged and therefore caked.
The feeding member 3 is preferably manufactured through an injection molding of a plastic resin material, but may be manufactured through another method and/or from a different material.
The material thereof is preferably the same as the main body 1 A of the container from the standpoint of recycling the container. More particularly, ABS, PP, POM, HI-PS are preferable materials. In this embodiment, HHI-PS was used.
(Inclined Projection)
Referring to FIG. 8 , the description will be made as to the inclined projection 3 a which is significantly influential to the stirring and feeding performance of the toner. In FIG. 8 , Θ is an inclination angle of the inclined projection 3 a relative to the bottle rotation axis a—a, and dimension p is an interval between adjacent inclined projections 3 a . In addition, s is a distance through which the toner is fed by the inclined projection 3 a, b is a width of the inclined projection 3 a.
The inclined projection 3 a is in the form of a projection from the flat plate portion of the feeding member 3 , and therefore, the inclined projection 3 a has a function as if it cuts into the toner powder in the toner bottle when the toner bottle 1 A is rotated. In addition, the toner is fed toward the opening by the inclination of the inclined projection 3 a , thus performing the dual functions.
By changing the inclination angle Θ of the inclined projections 3 a , the toner feeding power is selectively determined. For example, when the inclination angle Θ is changed to provide a steep inclination, the toner slides on the inclined projection 3 a in a fashion close to the vertical dropping. In this case, the toner sliding action is enhanced so that toner feeding amount is larger, but the toner feeding distance s per inclined projection is short, and therefore, the feeding speed is lower. When the inclination angle Θ is changed to provide less steep arrangement, the toner feeding distance s per inclined projection 3 a is long, so that feeding speed is higher. However, if inclination angle Θ is too small, the toner does not easily slides down on the inclined projection 3 a . An optimum design of the toner feeding power is accomplished by properly selecting the inclination angle Θ. The inclination angle Θ was preferably 30°–80° and further preferably 45°–70°, from experiments.
In the foregoing analysis, the toner feeding distance s by the inclined projection is assumed as a length thereof projected on the rotation axis. The lower side of the inclined projection (when the feeding member guides the toner downwardly toward the opening ((B) of FIG. 7 , for example)) is away from the inside the surface of the bottle. The structure is advantageous.
By doing so, it can be avoided the toner lifted by the inclined projection overtakes the immediately front side inclined projection due to the inertia of the toner sliding down on the inclined projection. Thus, the toner feeding distance per inclined projection can be increased.
On the other hand, as shown in (B) of FIG. 7 , it is preferable that upper side of the inclined projection ((B) of FIG. 7 , for example) is as close as possible to the inner surface of the bottle, and further preferably it is contacted into the inner surface of the bottle.
By doing so, substantially all of the toner lifted by the lifting portion can be guided and fed on the inclined projection.
Thus, the toner can be efficiently fed.
(Inclination Angle and Intervals of the Projections)
It is not necessary that all of the inclined projections 3 a are inclined to the same inclination angle Θ. As shown in FIG. 9 , (A), the inclined projections 3 a may be set differently for the inclined projections 3 a (inclination angle Θ 1 , Θ 2 , Θs 3 ). Similarly, the intervals p are not necessary regular, but may be set for the inclined projections 3 a (intervals p 1 , p 2 , p 3 ).
By the settings, the toner discharging property can be controlled.
In a conventional toner supply container which is rotated as a whole, the toner discharge amount changes in accordance with the amount of the toner remaining in the toner bottle, and therefore, it is very difficult to maintain a constant discharge amount. This is because at the initial stage in which the toner is filled in the bottle and therefore the powder pressure of the toner is high, the toner discharging amount is necessarily large, and at the last stage with the small amount of the toner contained in the bottle, the toner discharging amount is extremely small as compared with the discharge amount at the initial stage.
However, according to the structure of this embodiment, by properly setting the inclination angle Gs and the intervals p thereof, the toner discharging amount can be made constant.
For example, the interval p is set at a large distance adjacent the opening 1 a so as to provide a relatively low toner discharging speed, and inclination angle Θ is set at a small angle so as to provide a higher toner discharging speed in the portions away from the opening 1 a . In this manner, for example, the feeding power can be changed in the longitudinal direction of the toner bottle. By doing so, at the initial stage, the tendency of large toner discharging amount can be suppressed, and on the contrary at the last stage, the toner feeding speed is higher. Thus, substantially constant toner discharge amount can be assured.
(Width)
As shown in FIG. 9 , (B), the width of the inclined projection 3 a is selectable to adjust the toner feeding force, similarly to the inclination angles Θ and the intervals p.
For example, the larger the width b, the larger the amount of lifted toner. However, if it is too large, the filling of the toner at the time of manufacturing of the toner supply container is influenced. Therefore, it is set to be a preferable dimension.
The experiments and investigations by the inventors have revealed that the width of the inclined projection 3 a is preferably approx. 5–20% the inner diameter d of the toner bottle. Further preferably, it is 10–15%.
The width b finally continues to the opening 1 a of the discharge opening and may be larger than the width of the opening 1 a.
If it is smaller than the width of the opening 1 a , the toner feeding efficiency may be lower. A sufficiently practical feeding performance can be provided if it is not less than one half the opening 1 a.
In this embodiment, it is substantially the same as the width of the opening 1 a.
(Assembling Method of the Toner Supply Container)
An assembling method of the toner supply container 1 according to an embodiment of the present invention will be described.
FIG. 10 is a perspective view illustrating the assembling of the toner supply container 1 according to Embodiment 1. The structure of the toner supply container 1 according to this embodiment is very simple, and can be assembled by coupling five parts, as shown in FIG. 10 . The main body 1 A of the container can be easily produced by injection molding or blow molding, and the sealing member 2 , the feeding member 3 , the flange member 4 , the filling port and the capping member 5 can be easily produced by injection molding. In this embodiment, all the parts are manufactured through injection molding.
As for the method for coupling the main body 1 A of the container and the flange member 4 , an ultrasonic welding or vibration welding method is usable, or they may be bonded by hot melt adhesive material or another adhesive material, by which the sealing property is assured.
Or, a lightly press-fitted engagement between the outer periphery portion of the flange portion and the cylindrical end is usable. In this case, the outer periphery of the engaging portion is wound with an adhesive tape or the like. Then, the toner bottle is easily disassembled, and therefore, the recycling of the toner supply container is easy.
The steps of assembling is as follows. First, the feeding member 3 is inserted to the flange 4 such that end of the feeding member 3 is sandwiched between the projections 4 a provided on the inner surface of the flange 4 . Then, the flange member 4 is coupled with the main body 1 A flange member 4 of the container, and the sealing member 2 is engaged with the drive transmitting shaft portion 3 d of the feeding member 3 .
Thereafter, the toner is filled into the main body through the toner filling opening 4 b , and a filling cap 5 is press-fitted into the filling port 4 b , by which the assembling of the toner supply container is accomplished.
Using such an assembling method, attention is to be paid to the portion where the feeding member 3 is contacted to the inner surface of the main body 1 A of the container. As described hereinbefore, if there is a gap between the feeding member 3 and the inner surface of the main body, the toner passes through the gap with the result of reduction of the feeding efficiency, and the amount of the remaining toner which cannot be discharged at the last stage, increases. This is not preferable. FIG. 11 shows examples of the structures which prevents the reduction of the toner feeding efficiency or the increase of the amount of remaining toner.
In example (a) of FIG. 11 , the main body of the container has two parallel projection 1 e in the form of ribs extending in parallel to the direction of the axis, and the feeding member 3 is inserted into the gap provided between the projections 1 e . This structure is suitable for the manufacturing of the main body 1 A through the injection molding. The free end surface of the feeding member 3 is not contacted to the main body 1 A of the container, but the toner does not pass through, and therefore, no decrease of feeding efficiency or the increase of remaining toner can be effectively prevented. The projections 1 e in the form of the ribs may be provided only at a downstream side of the feeding member 3 with respect to the rotational direction of the container.
FIG. 11 , (b) shows another example, wherein a recess 1 f is provided extended in the axial direction, and the feeding member 3 is placed in the recess 1 f . This example is suitable for the main body 1 A manufactured through the blow molding. The toner feeding efficiency and the remaining toner are the same as with example (a).
FIG. 12 illustrates another embodiment of assembling step. In this example, the feeding member 3 and the flange member 4 are integrally injection-molded, and then the integral member is inserted into the main body 1 A. By doing so, the number of parts can be reduced to four.
Thus, according to the embodiments of the present invention, various manufacturing method and assembling method are usable. In addition, since the stirring member is not rotated in the toner container unlike a type of a conventional toner supply container, there is no problem of increase of the required torque for stirring.
Bearing members or the like are not used for receiving t stirring shaft, the part cost is reduced and the coagulation of the toner particles due to the sliding actions at the bearing portions, can be avoided.
(Recycling of Toner Supply Container)
Recycling of the used toner supply container 1 will be described. For the purpose of easy disassembling, the main body 1 A and the flange member 4 are united by an adhesive tape. The disassembling operation is opposite from the assembling operation. More particularly, the sealing member 2 is first removed, and the adhesive tape is removed, and the main body 1 A is separated into four parts as shown in FIG. 12 . The main body 1 A, the feeding member 3 with the projections 3 a , the flange member 4 , the sealing member 2 and the filling cap 5 are cleaned using air blow. Subsequently, they are reassembled into a container, and the predetermined amount of the toner is filled, by which the recycling is completed.
There is no part that is worn, and the reuse ratio is high. In normal cases, there is no part to be replaced. The structures are suitable for air cleaning, because there is no complicated structure part or no part involving a portion to which the air does not easy reach. Therefore, the cleaning can be simply and assuredly carried out. The toner supply property is the same as with the new toner bottle.
On the other hand, it is possible that used toner supply container 1 may be crushed, and the materials are reduced. Even if the main body 1 A, the feeding member 3 , the flange member 4 , the sealing member 2 and the filling cap 5 are made of different materials, they are very easily separated into the respective parts. This is convenient for such a case of recycling. In addition, the toner supply container 1 of the embodiments of the present invention gives great choice of material of the feeding member 3 . It is possible to make all the parts from the same material. In that case, the main body 1 A of the container is constructed by ultrasonic welding, so that when the main body of the container is reused, it is crushed without disassembling and reused. The material is preferably polypropylene or polyethylene, since then the material is common including the sealing member 2 .
(Structure for the Rotational Driving)
The description will be made as to the means for transmitting the driving force for rotating the main body 1 A of the container. For this mean, various known mechanism is usable. FIGS. 13 and 14 shows an example.
In FIG. 13 , a projection 3 f is provided on the outer surface of the flange portion 3 b , and it is engaged with a drive transmitting portion provided in the main assembly of image forming apparatus to receive the rotational driving force. FIG. 14 shows another example in which a gear portion 1 d is formed around a circumference of the main body 1 A, as shown in this Figure, by which the gear portion 1 d is in meshing engagement with a driving gear provided in the main assembly of the image forming apparatus to receive the rotational driving force.
In the example shown in FIG. 15 , the sealing member 2 functions also has a rotation driving force transmission member. The sealing member 2 comprises a sealing portion 2 c , a flange portion 2 d , a driving force receiving portion 2 e and a locking portion 2 f.
The outer diameter of the sealing portion 2 c is slightly larger than the inner diameter of the opening 1 a , and is press-fitted into the opening 1 a until it is stopped by the flange portion 2 d.
After the toner supply container 1 is loaded into the main assembly 100 of the image forming apparatus, in the locking part 11 is moved toward the center of the sealing member 2 by the opening and closing of the front door or the lever manipulation. The main body 1 A of the container is moved to the left in the Figure, while the locking part 11 is engaged with the groove of the locking portion 2 f of the sealing member 2 , by which the sealing member 2 is automatically unplugged. When the toner is to be discharged from the container thus loaded in the main assembly, the rotational driving force is transmitted to the driving force receiving portion 2 e of the sealing member 2 from the driving means 12 of the main assembly of the image forming apparatus. The sealing member 2 further comprises a non-circular shape shaft portion 3 d integrally extended from the feeding member 3 , and a corresponding rectangular hole 2 g which is slidable in the direction of the axis for engagement with the shaft portion 3 d . Even after the opening is unsealed, they are kept engaged with each other.
The toner is fed and discharged by transmitting the rotational driving force to the feeding member 3 and the main body 1 A through the sealing member 2 , the shaft portion 3 d by which they are all together rotated.
When the toner supply container 1 is to be taken out, the operation is reverse. More particularly, the main body 1 A of the container advances in response to opening of the front door or by manipulating the lever, by which the sealing member 2 is press-fitted into the opening 1 a to reseal the opening 1 a.
The sealing member 2 is preferably made by injection molding of plastic resin material, but may be produced through another method and/or from another material, or may be manufactured by assembling separate parts. The sealing member 2 is press-fitted into the toner supply opening 1 a to seal it, and therefore, a proper degree of elasticity is required. The material is preferably polypropylene, Nylon, high density polyethylene or the like, and further preferably low density polyethylene.
Embodiment 2
Referring to FIG. 16 , the second embodiment will be described.
In FIG. 16 , the inclined projections 3 a on the opposite sides of the plate-like portions are in a mirror symmetry relationship with respect to a rotation axis a—a of the toner bottle 1 A.
In a conventional example in which the toner is discharged by rotating the toner bottle 1 A, the rotational direction of the toner bottle 1 A is determined as being one direction, for discharging the toner (supply).
In the case of the conventional toner bottle having the helical rib on the inner surface of the toner bottle, the toner can be supplied only when the bottle is rotated in one predetermined direction.
However, in the case of the toner supply container 1 of this invention, the structure shown in FIG. 16 is possible in which the inclined projections 3 a are arranged in a mirror symmetrical fashion. With this arrangement, the toner can be discharged by rotation in either direction.
FIG. 17 shows a case of clockwise rotation of the toner bottle 1 A, and FIG. 18 shows a case of counterclockwise rotation of the toner bottle 1 A.
In FIGS. 17 , 18 , the toner is scooped by the scooping or lift portion of the feeding member 3 through the steps shown by (a) and (b) of these Figures. The toner then slides down on the inclined projection 3 a toward the opening (c).
As shown in these Figures, the inclined projections 3 a are arranged in the mirror symmetrical fashion, the toner can be discharged with the rotational direction in either direction. However, the toner discharging operation occurs only once in one full rotation in either direction, as is different from first embodiment.
Using this arrangement, the following advantageous effects are provided.
By intermittently changing the rotational direction of the bottle and the feeding member, the impact (acceleration) upon the exchange is effective to drastically enhance the stirring effect for the toner in the container. Simultaneously, it is possible to drop the toner particles deposited on the inner surface of the bottle, and therefore, the amount of the unusably remaining toner can be drastically reduced.
Other Embodiments
The present invention is not limited to the above-described Embodiments, and various modifications are possible.
In the foregoing Embodiments, the inclined projection is extended substantially perpendicularly from the plate-like region, bought the inclined projection 3 a may be modified as shown in FIG. 19 through FIG. 23 .
In FIG. 19 , the lateral end portion of the projection 3 a is bent to “L” shape to fence the toner, by which the amount of the toner sliding on the inclined projection 3 a is larger as compared with the foregoing embodiments.
FIGS. 20 , 21 show other examples in which in the inclined projection 3 a has a semicircular, elliptical or the like cross-section, that is, smoothly curved cross-section, by which the toner is assuredly held, therefore, the toner feeding force is enhanced. In addition, the amount of the toner deposited on the surface of the inclined projection 3 a is reduced, by which the unusably remaining amount of the toner is reduced.
As shown in FIGS. 22 and 23 , in the width b of the inclined projection 3 a is gradually changed (reduced or increased), by which the toner feeding amount can be adjusted. In the case of FIG. 22 , in the upper part of the inclined projection is able to guide and feed a large amount of the toner, that in the lower part, a part of the toner is left fall rather than guided or fed. This is effective to enhance the toner stirring effect, and the amount of the toner feeding can be adjusted.
Because of the wide latitude in the design of the shape of the inclined projection 3 a , the toner feeding amount can be properly set to provide a desire toner discharging property force.
The position of the opening 1 a through which the toner is discharged is not limited to the longitudinal end surface of the main body 1 A of the container, but, as shown in FIG. 24 , it may be disposed in the cylindrical surface of the main body.
In this case, the sealing member 2 considering the opening 1 a comprises an arcuate shutter 2 a conforming with the outer configuration of the main body 1 A and a gasket 2 b bonded to the inner surface of the shutter 2 a.
The sealing member 2 is mounted on the main body 1 A for reciprocation between a position for closing the opening 1 a and a position for opening in the opening 1 a . The mounting method may be such that rails parallel with the shutter 2 a are provided, and correspondingly, parallel rail guide portions are provided around the opening 1 a of the main body 1 A so as to be engageable with the rails.
The directions of the reciprocation of the sealing member 2 may be of the peripheral surface of the main body 1 A or color the rotation axis of the main body 1 A. The latter is preferable because the sealing member 2 can be moved between the opening and closing directions using the motion of the sealing member 2 when the toner supply container 1 is mounted to or demounted from the main assembly along the rotation axis. For example, a hooking portion is provided below a mounting portion of the image forming apparatus so as to be engageable with the shutter. In interrelation with the mounting operation of the toner supply container, the shutter is automatically moved from the closing position to the opening position.
The gasket 2 b is preferably made of polyurethane foam, and is fixed on the shutter 2 a by a both sided adhesive tape. The gasket may be made of another material such as another foam material, rubber or another elastic member. It may be fixed by another known method. When the sealing member 2 is mounted to the main body of the container, the gasket 2 b is compressed by a predetermined decree to hermetically seal the opening 1 a.
The description will be made as to results of experiments on the toner discharging property of the toner supply container in the foregoing Embodiments.
(Test 1)
Into the toner supply container of the first embodiment ( FIGS. 4–7 ), 2000 g of toner is filled, and the toner supply container was left placed vertically with the opening 1 a at the bottom side for 40 days under a high temperature and high humidity ambience (temperature 40° C. and humidity 80%).
Then, the toner powder in the toner bottle has a very poor flowability because of moisture absorbed.
Because of the positioning under which the container is left, that is, the opening 1 a at the bottom side, the toner is compressed at the bottom side due to the gravity. After placing under the harsh condition, the toner bottle was slowly loaded into the main assembly of the apparatus without shaking, and then was rotated at a predetermined rotational frequency (30 rpm). The toner bottle was rotated until all the toner is discharged, while the toner discharge was being measured at all times.
FIG. 27 shows the results of the measured toner discharging amount. The ordinate is the cumulative toner discharging amount (g), and the abscissa is elapse of the time of toner discharging time (sec), that is, the time of bottle rotation (sec).
(Test 2)
As shown in FIG. 25 , all of the hole portions 3 c of the feeding member 3 is closed, so that inside of the bottle is substantially completely partitioned into to chambers. The same test was carried out under the same conditions. FIG. 27 shows the results of the measured toner discharging amount.
(Structure of a Comparison Example 1)
The same test was carried out under the same condition with respect to a toner bottle having a helical rib on the inside surface.
FIG. 27 also shows the results of the measured toner discharging amount.
As will be understood from FIG. 27 , there is no problem from the initial stage of the rotation with respect to the toner bottle of test 1 in which the feeding member 3 is provided with hole portions 3 c . Without the hole portions (test 2), the discharging property is slightly poor. More particularly, until about 150 sec, the discharging amount is slightly poor.
In the case of test 2, the inside of the bottle is completely partitioned, and therefore, the toner is unable to move across the feeding member. This significantly increase is the starting torque of the driving motor. There is a liability that driving motor may fail and may be required to exchange. To avoid this, it is necessary to use an extensive driving motor, which will lead to cost increase.
On the other hand, in the case of the comprising example, hardly any toner is discharged until about 200 sec at the initial stage, and of the toner is rotating together with the bottle. With continued rotation of the bottle, the toner starts to discharge at 200 sec elapse from the start.
It has been confirmed that in the tests 1 and 2 , the collection be discharged from the beginning (initial stage of the rotation) even if the bottle is left under a harsh conditions and the toner in the bottle is bridged (the performance is poorer in test 2 than in test 2, though).
As described in the foregoing, according to the embodiments of the present invention, the following advantageous effects are provided.
(1) Since the number of parts constituting the toner bottle is small, and the number of assembling steps required a small, the manufacturing cost can be reduced. (2) No bearing sealing mechanism is used unlike the conventional structure, the required rotational torque is small. (3) No bearing sealing mechanism is used unlike the conventional structure, the liability of toner leakage can be reduced correspondingly. (4) By selecting the configuration and arrangements of the projections from greater choice, the toner discharging amount and the discharging speed can be easily adjusted. (5) A modification is easy to provide a container which can be rotated in the directions to discharge the toner. (6) Since the feeding member is provided inside the main body of the container, the mechanical strength of the main body is reinforced, and the thickness of the main body of the container can be reduced. (7) Even when the toner in the bottle contains large cake of particles, the toner can be properly discharged from the initial stage of the rotation. (8) The constant amount discharging property can be provided. (9) The main assembly of image forming apparatus can be downsize, and the cost of the driving unit for the toner supply container can be reduced. (10) The used toner supply container can be easily recycled. (11) Since the toner stirring power is high, the toner bridge is not produced in the main body of the container. (12) Since the toner bottle does not have a helical rib on the inner side of the toner bottle, the manufacturing of the metal mold or molding using the metal mold are simple and easy.
While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth and this application is intended to cover such modifications or changes as may come within the purpose of the improvements or the scope of the following claims.
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A toner supply container detachably mountable to an image forming apparatus, includes a main body for accommodating toner; an opening for permitting discharge of the toner from the main body; a rotatable feeding member, provided in the main body, for feeding the toner by rotation thereof; wherein the feeding member including a lift portion for lifting the toner in the main body, a guiding portion for guiding the toner lifted by the collecting portion downwardly toward the opening, and a falling portion for letting the toner lifted by the lifting portion fall without feeding it toward the opening with rotation of the feeding member.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to the U.S. Provisional Patent Application entitled “Wine Decanting Device” filed on May 3, 2006 and assigned application Ser. No. 60/746,294, which is incorporated herein by reference.
BACKGROUND OF INVENTION
[0002] The present invention relates to a method and device for pouring and decanting wine and the aeration of grape must or fermenting grape must.
[0003] Wine is typically decanted from the bottle used for storage and aging to accomplish at least one of separating sediment deposited during aging from the wine and/or allowing the wine to “breath” before serving. Allowing wine to “breath” is generally understood to involve a slight but important interaction of oxygen with chemical compounds in the wine that improve the bouquet and/or flavor of the wine. Full-bodied red wines are well known to especially benefit from decanting. It is usually necessary to wait for sometimes upward of an hour for a decanted wine to achieve the benefits of decanting. Moreover, it is not a simple matter to predict when even the same wine will have reached the optimum benefit, as not only are wines very different form each other, but wines from a single lot will change in breathing characteristics as they age.
[0004] However, it is not always practical to decant wine. Wine service by the glass is more common in restaurants as well as by the consumer, when the do not intend to drink the entire bottle at one sitting or meal.
[0005] It is therefore a first object of the present invention to provide an improved method of decanting wine that results in an immediate olfactory and flavor improvement, yet that can be practiced repeated as wine is served by the glass, such as at a tasting bar or in a restaurant.
SUMMARY OF INVENTION
[0006] The inventors have discovered a process of decanting wine that is convenient for achieving the olfactory and flavor benefits of allowing wine to breath without decanting an entire bottle.
[0007] Moreover, it has been discovered that the inventive process and an associated device result in a far superior enhancement to the olfactory and flavor of wines than is achieved by decanting.
[0008] The inventive and novel process involves first pouring wine into a first funnel, the causing the wine exiting the first funnel as a stream to spread laterally over a preferably convex shape. The wine that spills over the edges of the convex shape is collected. Other aspects of the invention involve repeating the fundamental process multiple times as desired to immediate achieve the optimum level of improvement.
[0009] Other aspects of the invention involve providing an apparatus for the above process that comprises a fluid receiving upper portion having a lower opening with a smaller diameter than the fluid receiving opening. Disposed below the bottom of the lower opening is at least one preferably convex surface to laterally spread the wine as it flows downward. Surrounding the edges of this convex surface is at least one funnel disposed to collect the liquid as it flows downward off the edges of the convex surface. The fluid receiving upper portion, convex surface and funnel are connected by an enclosing wall that extends downward from the periphery of the fluid receiving upper portion.
[0010] The above and other objects, effects, features, and advantages of the present invention will become more apparent from the following description of the embodiments thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a cross-sectional elevation of a first embodiment of the invention.
[0012] FIG. 2 is a cross-sectional elevation of a second embodiment of the invention showing the path of wine as it flows downward.
[0013] FIG. 3 illustrates another embodiment of the invention in which the device in FIG. 2 is inverted to rest on a surface along with a receiving flask.
[0014] FIG. 4 is a perspective view of another and preferred embodiment of the invention.
[0015] FIG. 5 is a top plan view of the embodiment in FIG. 4 .
[0016] FIG. 6 is a bottom plan view of the embodiment in FIG. 4 .
[0017] FIG. 7 is a first elevation of the embodiment in FIG. 4 .
[0018] FIG. 8 is an elevation of the embodiment of FIG. 4 taken orthogonal to the elevation shown in FIG. 7 .
[0019] FIG. 9 is a cross-sectional elevation of another embodiment of the invention.
[0020] FIG. 10 is a cross-sectional elevation of another embodiment of the invention.
[0021] FIG. 11 is a cross-sectional elevation of another embodiment of the invention.
[0022] FIG. 12 is a cross-sectional elevation of another embodiment of the invention.
[0023] FIG. 13 is a cross-sectional elevation of another embodiment of the invention.
[0024] FIG. 14 is a cross-sectional elevation of another embodiment of the invention.
[0025] FIG. 15 is a cross-sectional elevation of another embodiment of the invention.
[0026] FIG. 16A-C illustrate another embodiment of the invention in which the device comprises multiple components that can be stacked to provide the operative state and capable of being disabled for cleaning and storage.
[0027] FIG. 17 is a cross-sectional elevation of another embodiment of the invention in which the device comprises multiple components having features of the embodiments of FIG. 11 that can be stacked to provide the operative state and disabled for cleaning and storage.
[0028] FIG. 18 is a cross-sectional elevation of another embodiment of the invention in which the device comprises multiple components having features of the embodiments of FIG. 16 that can be stacked to provide the operative state and disabled for cleaning and storage.
[0029] FIG. 19 is a cross-sectional elevation of another embodiment of the invention in which the embodiments of FIG. 17 are stacked for delivery of wine to a mating serving receptacle.
[0030] FIG. 20 is a cross-sectional elevation of another embodiment of the invention in which different embodiments of separate cylindrical chambers are stacked in an alternating configuration for delivery of wine to a mating serving receptacle.
[0031] FIG. 21 is a cross-sectional elevation of another embodiment of the invention with a single aerating flow chamber with a vertical extending dispersing surface.
DETAILED DESCRIPTION
[0032] Referring to FIGS. 1 through 2 , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved wine decanting device, generally denominated 100 herein.
[0033] In accordance with the present invention, FIG. 1 illustrates one embodiment 100 of a wine decanting device for performing one or more times the process described in the above summary. Device 100 is preferably circularly symmetric like a tube such that all elevational views and sections will be essentially the same. The device 100 deploys one or more aerating flow chambers 131 , such that device 100 comprises a fluid receiving upper portion 110 having a lower opening 111 with a smaller diameter than the fluid receiving opening 113 that extends to the rim 112 . Disposed below the bottom of the lower opening 111 is at least one disperser 130 , which is preferably a convex surface, to aerate the wine by forming the stream it receives into a thin radial spreading film layer as it flows downward. Surrounding the edges of this disperser 130 is at least one funnel portion 120 disposed to collect the liquid as it flows downward off the edges 130 a of said convex surface. In this embodiment the dispersing surface 130 has an upper conical portion 130 a and lower vertically descending skirt 130 b , terminating in lower rim 130 c.
[0034] Spacers 125 and 125 ″ connect two or more points on the periphery about skirt portion 130 b to the inner surface of aerating flow chamber 131 . Aerating flow chamber 131 comprises the bottom portion of lower opening 111 , funnel section 120 and preferably concave dispersing surface 130 . The fluid receiving upper portion 110 , at least one convex surface 130 and at least one funnel 120 are connected by an enclosing wall 180 that extends downward from rim 112 at the periphery of the opening 130 in the fluid receiving upper portion 110 . As shown in this preferred but non-limiting embodiment the enclosing wall 180 may be a continuation of the exterior of chamber 131 . In the embodiment of FIG. 1 , the wine exits device 100 via neck 170 . Neck 170 extends downward from the end of the funnel portion 130 of aerating chamber 131 . In the preferred version of this embodiment illustrated herein, neck 170 terminates in a truncated conical fitted section 172 that may accommodate a matching fitting in a liquid receiving vessel 190 that is shown and described further with respect to FIG. 3 . Like most fine serving ware for wine, device 100 in the most preferred embodiments is fabricated from glass so that the decanting process is easily observed. In such a case, if sediment does travel from the bottle of the bottle to the device 100 , it will be more readily visible on convex surface 120 as it deflects or distorts the stream of wine over the surface.
[0035] FIG. 2 illustrates another embodiment with multiple aerating flow chambers such that there is in effect a cascading flow from one aerating flow chamber to the next. Thus, first the wine spreads as thin film over a surface in the first chamber, is collected in the funnel portion such that it can then be dispensed to cascade into the next aerating flow chamber where the process is repeated until the wine exits the device. The device 100 also comprises a fluid receiving upper portion 110 having a lower opening 111 with a smaller diameter than the fluid receiving opening 113 . The lower opening 111 is also preferably the end of a funnel shaped wall leading to upper chamber 131 . Upper chamber 131 also includes at least one convex surface 120 to laterally spread the liquid wine as a radial film layer as it flows downward. Surrounding the edges 120 a of this convex surface is at least one funnel shaped surface 130 disposed to collect the liquid as it flows downward off the edge or lower rim 130 c of the dispersing surface 130 such that it exits through a lower opening 111 ′ between upper chamber 131 and middle chamber 141 . Thus, wine will flow over the dispersing surface 130 before it enters middle chamber 141 .
[0036] Middle chamber 141 also includes at least one preferably convex dispersing surface 130 ′ to laterally spread the liquid wine as a radial film layer as it flows downward. Surrounding the edges of this convex surface 130 ′ is at least one funnel shaped wall 120 ′ is disposed to collect the liquid as it flows downward off the edges 130 c of the dispersing surface 130 . The funnel shaped wall 120 ′ again collects and directs the wine such that it exits through a lower opening 111 ″ between middle chamber 141 and the lower chamber 151 .
[0037] Accordingly, as the wine 20 then flows into lower chamber 151 via opening 111 ″ it again encounters another convex surface 130 ″ that laterally spreads the wine as a radial film layer as it flows downward. Surrounding the edges of this convex surface 130 ″ is again a funnel shaped wall 120 ″ disposed to collect the liquid as it flows downward off the edges 130 c of the dispersing surface 120 such that it can finally exits device 100 . In this example, wine exits device 100 by entering and flowing through neck region 170 , which includes in more preferred embodiment a truncated conical fitted section 172 .
[0038] While the dispersing surface 130 in the various embodiments is preferably convex, is may also be flat or a tilted planar surface, as well as a porous surface for dispersing the wine over a large area before recollection and concentration in the funneling portion 120 . Further, non-limiting examples of convex dispersing surfaces are pyramids, cones and dome, the latter of which can have an elliptical, spherical or compound curvature, and the like.
[0039] Not wishing to be bound by theory, it is believed that the combined and repeated separation of the wine into a flowing film over the convex surface, with repeated recollection provides a beneficial form of aeration or breathing to wine by entrapping or absorbing oxygen from the surrounding air. This seems to occur in a manner that is also gentle in not bruising the wine and stripping important volatile olfactory substances that contribute greatly to the nose, taste and fullness. The effect, if not actually improving the wine over conventional decanting processes, has at least the benefit of being very rapid and suitable to aerate a single serving portion, rather than entire bottle.
[0040] The path of wine 20 as it flows downward from 110 to 170 is shown in FIG. 2 to further illustrate another beneficial aspect of the devices design with respect to pouring measured servings of wine, such as a tasting bar or for wine by the glass service at a restaurant, bar or café. Specifically, in other preferred embodiments, the sidewalls 110 a of fluid receiving upper portion 110 include vertical pouring marks 114 and 114 ′. As the flow constricting opening 111 in each funnel portion 120 limits the rate at which wine 20 poured into fluid receiving upper portion 110 can escape into each successive aerating flow chamber, the server can quickly pour up to vertical pouring mark 114 or 114 ′ before a major portion of the wine has exited the device 100 via neck 170 . Thus, vertical pouring mark 114 or 114 ′ represent different measured servings of wine that are controlled by the limited flow rate of wine through device 100 . Ultimately, the serving of wine 20 measured by pouring to mark 114 or 114 ′ eventually flows downward through each chamber 131 , 141 and 151 such that a glass or another receiving vessel will be filled with the desired unit serving.
[0041] It should be appreciated that the size of the fluid receiving upper portion 110 can be varied to be of a different scale and even shape than chamber 131 , 141 and 151 , as may be preferred to accommodate a larger or smaller quantity of wine. However, it should be understood that a wide range of device sizes and shapes could be deployed to successfully decant an entire bottle of wine by simply avoiding pouring wine 20 into fluid receiving upper portion 110 faster than the rate that the wine exits neck 170 . Further, it should be appreciated that the first opening 111 may have a small diameter, while other openings between aerating flow chamber may have a larger diameter.
[0042] It has been discovered by taste tests described below that multiple aerating flow chambers 131 , 141 and 151 in device 100 of FIG. 2 more preferably aerate the wine in each pass over the convex surfaces 120 , 120 ′ and 120 ″. While a comparable aeration is achievable using the device 100 shown in FIG. 1 multiple times, having the three chambers that combine a preferably convex dispersing surface and a collaborative collecting funnel is far simpler and faster for a server that must accommodate a larger number of clients.
[0043] In addition to the devices 100 of FIG. 1 providing an the immediate improvement in quality, the multiple cascade device 100 of FIG. 2 can provides uniform aeration of any volume of wine when multiple passes through the device of FIG. 1 are desired. Further, like the device 100 in FIG. 1 , the devise in FIG. 2 facilitates the aeration and breathing of a serving size portion of wine.
[0044] FIG. 3 illustrates another embodiment that includes a liquid receiving vessel 190 . Receiving vessel 190 has a wide resting base 193 at the bottom of intermediate fluid collecting portion 191 . The wide base 193 aids in supporting the taller device 100 in FIG. 2 when fitting male fitting 172 on neck 170 is inserted into the mating female fitting 192 at the top of flask 190 . The width, w, of base 193 is preferably at least the same, and more preferably larger than the height, H, of vessel 190 from bottom 193 to the bottom portion of female fitting 192 . Most preferably, the mating contact surfaces on male fitting 172 and female fitting 192 have a ground glass finish to facilitate removal after insertion.
[0045] It should be appreciated that as shown in FIG. 3 , the device 100 in addition to being inserted into vessel 190 by following the dashed line can also rest on a table or other lateral surface 10 on rim 113 when the wine in flask 190 is poured into serving glasses or other another vessel.
[0046] Thus, flask 190 may be large to store an entire bottle of wine that is decanted, or small, say for collecting a single glass serving of wine or merely catching drips from device 100 after it is used to directly direct wine into serving glasses or other another vessel.
[0047] It should be further appreciated that the device and method of use disclosed herein provide the benefit of avoiding the need to decanting an entire bottle when smaller portions are desired. It further provides the benefit of providing an optimum aeration of the wine minimizing the time a decanted bottle needs to breathe.
[0048] It should also be appreciated that device 100 of either FIG. 1 or FIG. 2 while preferably being an integrated glass assembly, can also be fabricated by assembled by stacking interlocking components, as will be described with respect to additional embodiments. Such stacked components can be permanently attached or fused together in the case of glass, or be intended to be de-interlocking for storage and cleaning. Further, it can be fabricating by first stacking individual glass components before welding or fusing them together to form an integrated device 100 of FIGS. 1 and 2 .
[0049] FIG. 4-8 shows more preferred embodiment. A typical 750 ml wine bottle 5 is shown in FIG. 4 so that the scale of device 100 is better appreciated. It should be apparent from these figures that only a single spacer 125 is used to support each disperser 130 . Funnel portion 120 ″ is dimpled at elongated depression 135 to provide an air vent when the neck 170 of device 100 is inserted into a larger wide necked decanter to allow air to escape Similarly, the truncated conical fitted section 172 has a longitudinal external slit 173 to vent air when the mating flask 190 is filled. Further, the truncated conical fitted section 172 has an internal narrowing taper 174 to better direct the wine as a stream into flask 190 or any other receiving vessel, such as a wine glass, carafe or larger decanter.
[0050] For single serving use it is desirable that the wine can be filled to the level of the fill marks before a significant portion escapes into the lower aerating flow chambers. This is achieved by restricting the opening 111 to a diameter less than about 7 mm, and more preferably less than about of 5 mm. In device 100 , the funnel portion 120 preferably has an upper diameter of about 6 cm, while disperser 130 has a diameter of about 5 cm. The dispenser 130 cone portion 130 a has a height of about 1.5 cm and the height of the descending vertical portion 130 b that terminates at lower rim 130 c is about 1.5 cm. Thus, with these preferred dimensions a serving portion of wine, filled to about a 3 cm height in the receiver (represents a volume of about 90 ml or 3 U.S. fluid oz.) completes the aeration process in 10-12 seconds cascade into the flask 190 or another receiver vessel
[0051] FIG. 9 is a cross-sectional elevation of another embodiment of the invention. Like the alternative embodiment 100 shown in FIG. 10-19 , a plurality of discrete aerating chambers of the geometry of FIG. 1-8 is not required, as a plurality of funnels 120 is attached to the a single internal and substantially upright surrounding wall 119 . In this embodiment a series of three dispersers 130 are solid inverted cones interspersed between funnels 120 and arranged with the apex pointing upward and disposed below the outlet of each funnel 130 . The dispersers 130 are optionally connected to either each other by vertical spacer rod 126 , the funnel 120 or the upright sidewall 119 by various alternative spaces 125 also shown in dashed lines in FIG. 13-14 . The combination of a funnel 120 and a disperser 130 define an effective aerating flow chamber 131 , 141 or 151 .
[0052] FIG. 10 is a cross-sectional elevation of another embodiment of the invention. In this embodiment, a series of three dispersers 130 are open inverted domes arranged with the apex pointing upward and disposed below the outlet of each funnel 120 . The dome can have an elliptical, spherical or compound curvature and are centered within single cylindrical wall 119 . The inverted domes are optionally connected to wall 119 by spacers 125 or to the bottom of each funnel 120 by vertical spacers 126 .
[0053] FIG. 11 is a cross-sectional elevation of another embodiment of the invention. In this embodiment a single disperser 130 is an open inverted domes centered within single cylindrical wall 119 and arranged with the apex pointing upward and disposed below the outlet of the first or upper funnel 130 . The dome can have an elliptical, spherical or compound curvature. Spacers 125 are shown in broken lines to indicate that they are optionally placed at different locations to connect the dome to the cylindrical wall 119 .
[0054] FIG. 12 is a cross-sectional elevation of another embodiment of the invention. In this embodiment a series of three dispersers 130 are flat plates disposed below the outlet of each funnel 120 and centered within single cylindrical wall 119 .
[0055] FIG. 13 is a cross-sectional elevation of another embodiment of the invention. In this embodiment a series of three dispersers 130 are flat porous plates disposed below the outlet of each funnel 120 and are centered within the single cylindrical wall 119 of device 100 .
[0056] FIG. 14 is a cross-sectional elevation of another embodiment of the invention. In this embodiment the funnels 120 are the off center portion of a downward facing cone attached to the side of cylindrical wall 119 such that the opening or hole 141 is adjacent wall 119 , rather than centered with respect to the central axis of device 100 . Below the outlet of each funnel 120 is disperser 130 . Each disperser 130 is the offset portion of an upward facing cone attached to the upright inner wall 119 such that the opening 141 ′ is at the opposite side of the wall 119 , rather than centered with respect to the central axis of device 100 so that the drain hole 141 or 141 ′ from the funnel 120 and disperser 130 respectively are also disposed adjacent wall 119 . FIG. 14B is a plan view illustrating the profile of the hole 141 ′ between the edge of the disperser 130 on the right side of the wall 119 and the 141 between the edge of the funnel 120 and the left side of the wall 119 to ensure a full cascade of wine over each disperser surface 130 . It is more preferred that each disperser 130 have an upward bulge 136 below the drain portal of the funnel 120 disposed above it. The bulge 136 is shaped to disperse the fluid over the majority of the disperse element 130 . It should be understood that none of the embodiments require that the draining or collecting surface be smooth, but may have bulges, ripples or ribbing and the like to increase or improve the dispersion of wine as well as the exposure to air.
[0057] FIG. 15 is a cross-sectional elevation of another embodiment of the invention, the funnels 120 and disperses 130 are arranged as in FIG. 9 , however now the disperser 130 is a portion of an off center a dome wherein the hypothetical apex is pointing upward outside the upright cylinder walls 119 . The dome can have an elliptical, spherical or compound curvature. Note that the drain hole 141 ′ from disperser 130 ( FIG. 15 b ) is shaped around a portion of the cylindrical wall 119 to collect wine flowing in the direct of the arrows and then drain in on the portion of the collecting funnels 120 ( FIG. 15C ) below representing the starting point of the arrows on the collecting funnel 120 .
[0058] FIG. 16A is a cross-sectional elevation of another embodiment of the invention in which a plurality of draining surfaces 140 and 141 ′ generally point downward and are attached to the side of the cylindrical wall 119 but are rotated by 180 degrees with respect to the central axis of device 100 to stagger the position of holes 141 and 141 ′ draining surfaces 140 and 140 ′ respectively. Each of the draining surfaces 140 and 140 ′ has a dispersing surface portion 130 ′ and a collecting or funnel like surface portion 120 ′ such that is acts likes an aerating flow chamber 131 , 41 and 151 , etc. in other embodiments. The dispersing surface portion 130 ′ is generally convex and the collecting surface portion 120 ′ is generally concave. Plan views, FIG. 16B and FIG. 16C of draining surfaces 140 and 140 ′ illustrate with arrows the direction of fluid flow across the adjacent draining and collecting surface. The staggered location of holes 141 in each draining surface provides that the hole or outlet 141 of the collecting surface 120 ′ of the upper draining surface 140 is oriented to drain onto dispersing surface portion 130 ′ of the lower draining surface 140 ′.
[0059] FIG. 17A-C illustrate another embodiment of the invention in which the device comprises multiple tubular components 117 that can be stacked to provide the operative state shown in other embodiments, yet be disassembled for cleaning and storage. Each funnel 120 is disposed with a generally cylindrical element 117 . Each cylinder 117 has at least a partially laterally extending upper rim 117 a for receiving the separate and detachable disperser 130 , as well as resting the lower rim 117 b of another funnel and cylinder component on it to ultimately provide multiple aerating flow chamber 131 of the most preferred embodiments. The disperser 130 may take any cross section shape previously described, as well as equivalents thereof, but preferable has 3 or more appendages 171 that extend from the edge to rest on the upper rim portion 117 a.
[0060] FIG. 18 AB are cross sectional elevations of an alternative embodiment where separable cylinder 118 are comparable to that shown in FIG. 16 , but have the off center single draining surface element 140 that operates as shown in FIG. 15 . In this embodiment, identical cylinders can be stacked, provides they are rotated by 180 degrees as shown to provide for the multiple cascade of wine over each draining surface 140 .
[0061] FIG. 19 is a is a cross-sectional elevation of another embodiment of the invention in which the cylinders 117 are stacked with disperser 130 as described with respect to FIG. 17 with the lower rim 117 b of the lowest cylinder 117 disposed on the upper rim of the wine receiving vessel 190 .
[0062] FIG. 20 is a cross-sectional elevation of another embodiment of the invention in which the cylinders 200 and 200 ′ are similarly alternatively stacked for delivery of wine to a mating serving receptacle 190 , to define aerating flow chamber 131 . Cylinder 200 has a centrally disposed funnel portion 120 , while cylinder 200 ′ has an inverted cone dispersing element 130 comparable to that shown in FIG. 1-8 .
[0063] Blind taste testing was used to evaluate select configuration of device 100 . The four participants were given five glasses filled with wine that had been marked: Bottle, 1, 2, 3, and 4. They were then asked to compare the taste of each marked glass to that of the glass marked “bottle”, representing un-decanted wine. They were then instructed to grade each marked glass, and record their grades on a questionnaire. The ordering of the samples was randomized for each participant to eliminate the potential for bias from discussions or observing the other participants reactions. There were crackers and water for pallet cleansing. Taster's were asked to differentiate any change from the un-decanted wine on a scale of 1 to 5, with 1 being no change, 2 slight improvement, 3 moderate improvement, 4 significant improvement and 5 greatly improved. Four alternative configurations of device 100 were evaluated, the single aerating flow chamber of FIG. 1 , a comparably dimensioned device with dual aerating flow chambers as well as the triple aerating flow chamber device 100 of FIG. 2 . Further, a device 100 shown in FIG. 21 with a single tall aerating flow chamber 130 was also evaluated. The disperser surface 130 has an upper cone portion 130 a with a height of about 1.5 cm and the height of the descending vertical portion 130 b that terminates at lower rim 130 c is about 15 cm.
[0064] As their where 4 individual tasters, the maximum raw score any configuration could achieve were 20 points. The results below are the sum of the raw scores of the four tasters, divided by 20 and expressed as a percentage. The lowest score, no change, in contrast would be 4/20 or 20%.
[0000]
Triple Chamber:
81%
Double Chamber:
64%
Single Chamber:
52%
Tall Chamber:
48%
[0065] As the results indicate, the triple aerating flow chamber device was judged as providing the most improvement with a significant margin between it and the alternative embodiments. thus, the use of multiple flow chambers that successively cause the wine to diffuse over a first surface and then collect it again in a funneling portion provide a surprising and unexpected advantage of quickly breathing and improving the taste and olfactory sensations of wine. It should be noted that all embodiments showed some improvement, as even the slightest improvement would result in an average score of 40%.
[0066] It should also be appreciated the device and methods of the invention are not limited to the aeration of wine, but may be deployed for the aeration of grape just or grape must to provide oxygen that is beneficial to the fermentation process.
[0067] While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be within the spirit and scope of the invention as defined by the appended claims.
[0068] For example it should be understood that the various embodiments of the device 100 need not be strictly limited to having a cylindrical cross-section but can be oblong, elliptical, rectangular and of any arbitrary shape so long as the function of one or more aerating flow chambers is preserved. Further, it is expected that any combination of the different aerating flow chambers disclosed herein, as would be readily apparent to one of ordinary skill in the art after disclosure of this application, can be mixed and interchanged to form a device with multiple aerating flow chambers.
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A device for decanting wine provides optimum aeration to readily measured minimum quantities by first causing the wine poured into the device to form a stream. The stream is then spread laterally over a convex shape before it is again collected. In various embodiments, the wine is collected by an internal funnel like structure within the device, being again spread over another convex surface. The multiple pairs of convex surfaces and associated collecting funnels are preferably housed in a generally tubular enclosure that terminates in a final spout that delivers wine to a storage flask type decanting vessel or wine glass.
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FIELD OF THE INVENTION
The present invention relates to a slider mechanism for moving a vehicle seat forwards or backwards, and more particularly, a slider mechanism which is disposed between a fixed rail and a movable rail arranged between a vehicle seat and a vehicle floor so as to allow the movable rail to be slidably engaged with the fixed rail.
BACKGROUND OF THE INVENTION
A conventional slider mechanism for a vehicle seat is constituted in such a manner that a synthetic resin slider is secured to a movable rail fixed to a seat and the slider is formed a groove for engaging with a fixed rail fixed to a vehicle floor so as to allow the movable rail to slide with respect to the fixed rail. This type of slider mechanism may generate rattling and other unpleasant noises on account of manufacturing errors in several dimensions, such as the clearance between the fixed rail and the movable rail, the thickness of the fixed rail and the width of the groove formed in the slider, the width of a groove-engaging portion of the fixed rail which engages with the groove and the depth of the groove, etc.
In addition, the groove-engaging portion of the fixed rail is usually composed of a flange which extends laterally from the fixed rail body. Thus, the flange will be exposed when the seat is moved so that this will not only possibly spoil the good appearance of passenger compartment interior but also damage the shoes or socks of the passenger.
Therefore, it is an object of the present invention to provide a slider mechanism which can overcome the above described conventional problems, does not require high-accuracy manufacture, and will not spoil the good appearance of the interior of the vehicle.
According to the present invention, the slider mechanism does not require high accuracy, can ensure the engagement between the fixed rail and the movable rail, and simplify the manufacturing process.
SUMMARY OF INVENTION
To accomplish the above object, a slider mechanism for a vehicle seat according to the present invention comprises a fixed rail which is fixed to a floor, a movable rail which is fixed to a seat and allowed to slidably engage with the fixed rail, and a synthetic resin slider block which is integrally molded to either the fixed rail or the movable rail and disposed between the fixed rail and the movable rail so as to slidably contact the other rail. The slider block includes an anchor member which secures the attachment to either the fixed rail or the movable rail so as to prevent the slider block from disengaging from the corresponding rail. In addition, it is preferable to form thin portions in the slider block so as to specify the location of cracks or breaks of the slider block which may be caused by the difference between the coefficients of thermal expansion of the slider block and the rail.
According to an embodiment of the present invention, a slider mechanism for a vehicle seat comprises;
a fixed rail which is fixed to a vehicle floor;
a movable rail which is fixed to a vehicle seat and engaged with the above-mentioned fixed rail; and
a synthetic resin slider block which is molded to one of the above mentioned rails so as to slidably contact the other rail.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be understood more fully from the detailed description given herebelow and from the accompanying drawings of the preferred embodiment of the present invention, which, however, should not be taken as limitative to the invention but for explanation or elucidation only.
In the drawings:
FIG. 1 is a perspective view of a vehicle seat which is equipped with a slider mechanism according to a preferred embodiment of the present invention;
FIG. 2 is an enlarged perspective view of the slider mechanism according to FIG. 1;
FIG. 3 is a side view of the slider mechanism according to FIG. 1;
FIG. 4 is an elevational view of the slider mechanism of FIG. 1;
FIG. 5 is a sectional view taken along the line V--V in FIG. 3;
FIG. 6 is an enlarged perspective view of a slider block for the slider mechanism according to FIG. 2;
FIG. 7 is a sectional view taken along the line VII--VII in FIG. 3;
FIG. 8 is a sectional view taken along the line VIII--VIII in FIG. 3; and
FIG. 9 is a sectional view of a movable rail of the slider mechanism in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will be explained with reference to the accompanying drawings. FIG. 1 shows a vehicle seat which is equipped with a slider mechanism according to a preferred embodiment of the present invention. The vehicle seat mainly consists of a seat back 9 and a seat cushion 4. The seat cushion 4 is supported by a cushion frame 4a, each of the two sides of which is fixedly provided with a movable rail 15 through a nut 18a secured by welding to the movable rail and a fixing bolt 18b as shown in FIG. 5. Each movable rail 15 is composed of a main body 15a with a channel-shaped cross-section, and flanges 15b and 15c formed by turning the free edges of the main body upwards and downwards respectively. The flanges 15b and 15c of the movable rail 15 are fixed to upper and lower edges 16a, 16b of a reinforcing member 16, respectively. Furthermore, synthetic resin slider blocks 14 are molded to the fixed edges of the flanges 15b, 15c and the upper and lower edges 16a and 16b of the reinforcing member. A movable rail assembly 1 consisting of the movable rail 15, the reinforcing member 16, and the slider blocks 14 slidably engages a fixed rail 2. The fixed rail 2 has a substantially C-shaped cross-section with a guide groove 13 in the bends at the upper and lower ends thereof so as to allow the slider block 14 to be slidably housed therein. The fixed rail 2 is fixed to a vehicle floor panel 3 by fixing bolts 21, 22 through brackets 19, 20.
FIGS. 2 to 8 show the above-mentioned slider mechanism in detail. As shown in FIGS. 2, 3 and 8, the upper and lower edges 16a, 16b of the reinforcing member 16 each include a cut-out 23. The cut-out 23 includes a substantially elliptical portion 23a and an open portion 23b which is narrower than the portion 23a and the end of which passes through the edge of the upper or lower edge 16a, 16b. In this cut-out 23, an anchor 14a is formed of the synthetic resin which is injected therein during molding and then cured therein.
The slider block 14 comprises, as shown in FIG. 6, a base portion 14b which engages the flange member 15b or 15c of the movable rail 15 and the upper edge 16a or lower edge 16b of the reinforcing member 16, a portion 14c extending upwards or downwards from the base portion, and a portion 14d extending laterally from both sides of the base portion. In addition, as shown in FIG. 2, the slider block 14 is provided with a thin portion 14e which does not include the portions 14c and 14d and which extends along the longitudinal direction of the block. The thin portion 14e can specify the part of the slider block to be broken on account of stretching forces generated in the slider block due to the difference between the coefficients of linear expansion of the metal material used for the movable rail, for example iron, and the synethetic resin material of the slider block. That is, when the ambient temperature changes from a normal temperature to a lower temperature, the resin slider block 14 which has a larger coefficient of linear expansion than the iron will contract remarkably in the longitudinal direction. However, since the slider block is fixed at both ends to the movable rail 15, the slider block is stretched towards the ends of the rail 15 so that only the thin portion 14e, being relatively weak, will be broken.
Nevertheless, since the anchors 14a arranged in suitable places securely engage with the movable rail assembly, the slider block 14 can not be torn off the movable assembly even if the thin portion 14e breaks.
On the other hand, when the ambient temperature varies from a normal temperature to a high temperature, the slider block 14 expands so that the slider block will be forcedly torn from the movable rail 15. However, since the slider block is securely held by the engagement between the anchors 14a and the cut-outs 23 in the reinforcing member, the slider block is maintained securely in position. Thus, even when the ambient temperature is relatively high or low, the external dimensions of each portion of the slider block 14 remain constant and dimensional accuracy is thus stable.
In accordance with the present invention as mentioned above, as shown in FIG. 9, the dimensional error between the movable rail and the reinforcing member constituting the movable assembly, i.e. errors in the thicknesses t 5 and t 4 of the movable rail and the reinforcing member, errors between the widths W 3 of the movable rail and the reinforcing member, errors g 3 and g 4 caused during assembly thereof, and so on, can be compensated for by forming the slider block in such manner that molten synthetic resin is injected and molded in a mold having fixed dimensions. Accordingly, the engagement between the movable rail assembly and the fixed rail will not rattle.
During molding of the slider block 14 to the movable rail 15 and the reinforcing member 16, both of longitudinal ends thereof are also provided with resin covers 24 as shown in FIG. 4 so that the movable rail and the reinforcing member will not be exposed even if the seat is moved to the rear-end position. Thus, the passenger's shoes or socks can be protected from damage.
Although the above mentioned embodiment shows an example in which the cut-out(s) for engaging the anchor(s) of the slider block is (are) formed in the reinforcing member, it is naturally possible to form the cut-out(s) in the movable rail. Furthermore, in the above-mentioned embodiment, the slider block is so formed as to slidably contact the guide groove 13 at three points. However, it is also possible to arrange four contact points or more.
Next, manufacture of the slider mechanism and assembly thereof onto a seat according to the above embodiment will be explained. The reinforcing member 16 has a rectangular shape including cut-out(s) 23. On the other hand, the movable rail 15 is formed with a mounting hole at the position corresponding to a mounting hole 4b formed in the cushion frame 4a and a nut 18a is welded to the external side of the hole. Then, the flange members 15a, 15c of the movable rail 15 and the upper and lower edges 16a, 16b of the reinforcing member 16 are welded together. The assembly composed of the movable rail and the reinforcing member is inserted into a mold and then synthetic resin is injected into the mold so that the resin slider block 14 with the anchor(s) 14a and the thin portion 14e is formed.
The movable rail assembly 1 formed in the manner described above is mounted onto the cushion frame by passing the fixing bolt 18b through the mounting hole 4b and engaging it with the nut 18a. The fixed rail 2 welded to the brackets 19, 20 is attached to the movable assembly 1 in this state and then stoppers for the movable rail assembly are provided in a well-known manner. Then, the fixed rail is fixed to the vehicle floor via the brackets 19 and 20 by means of fixing bolts.
In this manner, according to the embodiment disclosed above, the objects of the present invention can be achieved.
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In a slider mechanism for a vehicle seat, a synthetic resin slider block (14) is molded on a movable rail (15), and the slider block (14) slidably engages a guide groove (13) formed in a fixed rail (2). The slider block (14) is formed with an anchor (14e) which can engage a cut-out(s) (23) formed in the movable rail (1) so as to hold the slider block onto the movable rail, and a thin portion (14e) which is thinner than the other portions of the block. Thus, the inventive slider mechanism does not require highly accurate manufacture of the movable rail, and can prevent rattling of the seat in the assembled state.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to and claims priority from earlier filed U.S. Provisional Patent Application No. 60/545,400, filed Feb. 17, 2004, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to pneumatically operated projectile launchers. More specifically, the present invention relates to an electro-magnetically operated bolt configuration for use in firearms and other projectile launchers, such as pneumatically operated projectile launchers.
[0003] In general, in the prior art, it is well known to utilize a pneumatically operated projectile launcher to propel a projectile at a target. Further, such a device is typically referred to as either a paintball gun or a marker. Accordingly, for the purpose of this application, the term marker will be utilized throughout this application to define a paintball gun or a pneumatically operated projectile launcher. While the present invention is discussed in connection with paintball guns, it has application in any type of projectile launching device.
[0004] There are a wide variety of markers available in the prior art having different configurations and manners of operation. Regardless of the configuration or mode of operation utilized by any particular marker, the general purpose of the marker is to utilize pneumatic force to launch a fragile spherical projectile containing colored marker dye, known as a paintball, at a target. When the paintball impacts upon the target, the paintball bursts releasing the marker dye onto the target thereby providing visual feedback that the target was, in fact, hit by the paintball. In this regard, before the paintball can be launched by the marker, a paintball must be first loaded into the firing chamber or breech of the marker in preparation for the release of a burst of air that ultimately launches the paintball.
[0005] FIGS. 1-3 generally illustrate the paintball loading operation of a prior art marker 10 . The marker 10 can be seen to include a breech 14 , a barrel 16 extending from one side of the breech 14 , a reciprocating bolt 18 that is slidably received in the breech 14 in alignment with the barrel 16 and a feed port 20 to allow paintballs 12 to be loaded into the breech 14 of the marker 10 . In operation, paintballs 12 are loaded in to the barrel 16 of the marker 10 by means of the bolt 18 . The bolt 18 is arranged to move back and forth below the feed port 20 allowing paintballs 12 to pass, one at a time, through the feed port 20 and into the breech 14 . The bolt 18 then moves forward, pushing the paintball 12 into the barrel 16 opening. Generally, these prior art devices rely on either manual operation of the bolt, mechanical valves or electronic solenoid valves that alternately switch compressed gas back and forth between the two sides of a double-acting pneumatic cylinder to move the bolt 18 for loading the paintballs 12 . Such prior art pneumatic actuation of a bolt is well known in the art and need not be discussed in detail herein.
[0006] In order to illustrate the operation of the bolt 18 , FIGS. 1-3 show a cross-sectional view of the breech 14 of a prior art marker 10 that includes a reciprocating bolt mechanism 18 . In FIG. 1 the bolt 18 is show at rest in a position that would result immediately after firing a paintball 12 or prior to loading the initial paintball 12 . Turning now to FIG. 2 , the bolt 18 is shown after being moved in a rearward position. With the bolt 18 in this position, the feed port 20 is opened to allow a paintball 12 to drop into the breech 14 . FIG. 3 then shows the bolt 18 after it has returned to the forward position having pushed the paintball 12 into the opening of the barrel 16 , where it can be propelled by a pneumatic charge down the barrel 16 and launched out of the marker 10 .
[0007] The difficulty is that markers that rely on mechanically or pneumatically driven reciprocating bolts suffer from mechanical limitations that inherently limit the maximum rate of fire that the marker can achieve. Specifically, the ultimate cycle speed of a pneumatically operated bolt is limited by the speed at which the solenoids in the air system can be sequentially opened and closed.
[0008] There is therefore a need for a bolt mechanism that overcomes the inherent limitations found in the prior art, thereby allowing the bolt mechanism to cycle faster, ultimately resulting in a marker that has a higher firing rate. There is a further need for a bolt mechanism that can be more precisely controlled than prior art bolts.
BRIEF SUMMARY OF THE INVENTION
[0009] In this regard, the present invention provides for a novel bolt mechanism that overcomes many of the problems with the prior art bolts identified above. In particular, the present invention provides a bolt mechanism that is actuated by an electro-magnetic arrangement, which provides for rapid movement of the bolt as well as a high degree of control over the bolt. The use of electromagnetic force instead of electronic solenoids and a pneumatic piston to actuate the bolt in a marker is a departure from the known prior art and provides numerous advantages that result in a marker having higher reliability and improved performance.
[0010] As will be discussed in detail below, the base concept of the present invention is to utilize an arrangement of electromagnetic coils that exert a force on ferrous materials or permanent magnets thereby causing the bolt to reciprocate back and forth. In one embodiment, a piece of ferrous material or a permanent magnet is installed into the body of the bolt and at least one electro-magnetic coil is installed in the wall of the breach adjacent the bolt. Application of an electrical charge to the electromagnetic coil serves to attract or repel the magnet in the bolt, causing the bolt to be moved. In other embodiments, at least one coil is provided in the body of the bolt and at least one magnet or piece of ferrous material is installed in the wall of the breech, adjacent the bolt. In further embodiments, multiple electro-magnetic coils are utilized to increase the overall force exerted on the permanent magnet or ferrous material, thereby enhancing the speed at which the bolt can be moved. In another embodiment, the magnet or ferrous material is positioned adjacent the bolt in a chamber of its own with electro-magnetic coils placed within the walls of the chamber. The magnet or ferrous material is connected to the bolt by a linkage so that movement of the magnet or ferrous material results in movement of the bolt. In yet a further embodiment, the present invention provides for a rotary action bolt that includes at least one permanent magnet or piece of ferrous material mounted therein with an array of electromagnetic coils disposed around the wall of the breech surrounding the bolt. As each of the electromagnetic coils is activated by applying an electrical charge, the coils attract or repel the magnet or ferrous material, causing the rotary bolt to rotate.
[0011] In addition to the electromagnetic system as described above, various sensors may also be incorporated into the marker and electrically coupled to the control system within the marker thereby providing unprecedented control over the bolt that was not previously possible with known pneumatic systems. As a result, the electronic operating system of the marker can more precisely control the loading and launching of the projectile.
[0012] As can be seen in view of the above, a new and novel electro-magnet bolt control system is provided. Further, a new and novel method of actuating a bolt within a marker without the use of pneumatics or electronically operated solenoid valves is shown. The use of electromagnetic force as provided in the present invention allows for precise control of the travel of the bolt within a marker unlike the poor control capable of with a pneumatically piston-controlled bolt.
[0013] It is therefore an object of the present invention to provide an electro-magnetically operated bolt transport system for use in a pneumatic projectile launcher or marker. It is a further object of the present invention to provide an electro-magnetically operated bolt, wherein electromagnetic coils are utilized to attract and/or repel a piece of ferrous material or permanent magnet thereby causing movement of the bolt. It is yet a further object of the present invention to provide an electro-magnetically operated bolt, wherein multiple electromagnetic coils are utilized in conjunction to move a piece of ferrous material or permanent magnet thereby causing movement of the bolt. It is an even further object of the present invention to provide an electro-magnetic bolt control system that is equally applicable to both a slide bolt and a rotary bolt. It is still a further object of the present invention to provide sensors that are integrated with an electro-magnetically operated bolt system to facilitate a high degree of control over the movement of the bolt.
[0014] These together with other objects of the invention, along with various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed hereto and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:
[0016] FIG. 1 is a cross-sectional view of a prior art pneumatic projectile launcher with the bolt in a closed position;
[0017] FIG. 2 is a cross-sectional view of a prior art pneumatic projectile launcher with the bolt in an open position and a projectile dropping into the breech;
[0018] FIG. 3 is a cross-sectional view of a prior art pneumatic projectile launcher with the bolt returning to a closed position, pushing the projectile into the chamber for launching;
[0019] FIG. 4 is a cross-sectional view of a first embodiment of the pneumatic projectile launcher of the present invention with the bolt in an open position;
[0020] FIG. 5 is a cross-sectional view of the pneumatic projectile launcher of FIG. 4 with the bolt in a closed position;
[0021] FIG. 6 is a cross-sectional view of a second alternate embodiment of the pneumatic projectile launcher of the present invention with the bolt in an open position;
[0022] FIG. 7 is a cross-sectional view of a third alternate embodiment of the pneumatic projectile launcher of the present invention with the bolt in an open position;
[0023] FIG. 8 is a cross-sectional view of the pneumatic projectile launcher of FIG. 7 with the bolt in a closed position;
[0024] FIG. 9 is a cross-sectional view of a fourth alternate embodiment of the pneumatic projectile launcher of the present invention with the bolt in a closed position; and
[0025] FIG. 10 is a cross-sectional view of a fifth alternate embodiment of the pneumatic projectile launcher of the present invention showing a rotary bolt.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Now referring to the drawings, as was stated above, FIGS. 1-3 generally illustrate a pneumatic projectile launcher 10 of the prior art and the manner in which the bolt 18 is operated to load a projectile 12 in preparation for launch. As was stated above, the present invention is applicable to any projectile launcher and the disclosure of the present invention is intended to be applicable with regard to its use in any type of projectile launching device. However, for the purpose of this application, the common term marker will be used when referring to the general class of projectile launchers.
[0027] Turning to FIGS. 4 and 5 , a first preferred embodiment of the electro-magnetic bolt system of the present invention is shown and generally illustrated at 100 . The bolt system 118 is shown installed in the breech 114 of a representational marker 100 . The marker 100 generally includes a receiver body 113 , a breech 114 , a barrel 16 , a feed port 20 , an electro-magnetically actuated bolt 118 , an actuator 22 and a control system 115 for controlling the operation of the marker 100 . The control system 115 can be a control unit circuit board and operating system software, which are known structures for controlling the overall operation of the marker. Further, an LED or LCD display may be provided in conjunction with the control system 115 to monitor the operation of the marker 100 . Optional control elements that interface with the control system 115 may include buttons or levers to modify settings within the marker 100 or an interface means so that the marker can be monitored by a remote device. Finally, the interface means may be through a wired connection or other wireless means that allow both monitoring and control of the marker 100 as well as allowing control programs to be downloaded into the marker 100 as desired.
[0028] The receiver body 113 is the central structural element of the marker 100 to which all of the other elements are connected. The breech 114 is a chamber located within the receiver body 113 . The breech 114 serves as a guide within which the bolt assembly 118 operates to direct a projectile 12 from the feed port 20 to the barrel 16 as will be further described below. The barrel 16 is a hollow tubular member that extends from one end of the receiver body 113 and is in communication with the breech 114 . The feed port 20 extends from the exterior of the receiver body 113 and into the breech 114 , providing a path along which projectiles 12 are fed into the breech 114 . Adjacent the exterior of the feed port 20 a means for containing a plurality of projectiles (not shown) is provided that serves to distribute the projectiles 12 into the feed port 20 opening. The bolt 118 of the present invention is positioned within the breech 114 and operates in a manner that controls and directs the flow of projectiles 12 from the feed port 20 into the barrel 16 for subsequent launching as will be more fully described in detail below. Finally, a handle 24 and an actuator 22 , such as a trigger, are provided and attached to the receiver body 113 providing a means by which a user can hold and activate the marker 100 .
[0029] In contrast to prior art markers, the present invention provides for the bolt 118 to be operated using electro-magnetic principles. In the simplest form, a first preferred embodiment of the electro-magnetic bolt 118 of the present invention is illustrated in FIGS. 4 and 5 . In general, the principal upon which the present invention operates provides for the use of at least one magnetic coil 120 to attract or repel a permanent magnet 122 or other ferrous material. As can be seen in FIG. 4 , a permanent magnet 122 is provided within the bolt 118 and an electro-magnetic coil 120 is positioned in the wall of the breech 114 surrounding the bolt 118 . It should be noted that magnet 122 can be completely embedded within the bolt 118 , embedded in the surface thereof or simply encircling it. When current is applied to the coil 120 in one direction, the coil 120 is energized creating a magnetic field that attracts the permanent magnet 122 within the bolt 118 causing the bolt 118 to move rearwardly as illustrated by the arrow 124 . Once the bolt 118 clears the feed port 20 opening, a projectile 12 is then allowed to drop into the breech 114 . As is best illustrated in FIG. 5 , the control system 115 in the marker 100 , upon sensing the presence of a projectile 12 in the breech 114 , via sensors 126 within the marker 100 , reverses the polarity of the current applied to the coil 120 thereby reversing the magnetic field generated by the coil 120 . The reversed magnetic field generated by the coil 120 now serves to repel the magnet 120 within the bolt 118 , causing the bolt 118 to slide forward as is indicated by the arrow 128 , advancing the projectile 12 into the barrel 16 in preparation for launching the projectile 12 .
[0030] A second embodiment marker 200 that utilizes the principals of the present invention is shown in FIG. 6 . The bolt assembly 218 in this embodiment functions in the same manner as the one described above. In this embodiment however, the positioning of the electromagnetic coil 220 and permanent magnet 222 have been reversed. The permanent magnet 222 is installed in the sidewall of the breech 214 and the coil 220 is positioned in the bolt 218 . When electrical current is applied to the coil 220 in one direction, the coil 220 is energized causing a magnetic field that creates an attractive force between the permanent magnet 222 and the coil 220 . Since the permanent magnet 222 is in a fixed location and the bolt 218 can slide, the attractive force causes the bolt 218 to slide to an open position allowing a projectile 12 to drop from the feed port 20 into the breech 214 . As described above, when the polarity of the current applied to the coil 220 is reversed, the coil 220 repels the permanent magnet 222 , thereby causing the bolt 218 to be moved to a closed position.
[0031] It can be appreciated that in the configurations described above wherein a single coil is utilized, the coil must be used in conjunction with a permanent magnet so that the coil and magnet can interact to attract and/or repel one another. In other embodiments as will be described below, multiple coils may be utilized to attract and repel a permanent magnet. Further, should multiple coils be utilized, the magnet may be replaced with any ferrous material that is attracted by a magnetic field thereby allowing the coils to be operated in single direction to attract the ferrous material. For example, FIGS. 7 and 8 show a marker 300 in accordance with a third embodiment of the electro-magnetic bolt system 318 of the present invention where a front coil 320 b and rear coil 320 a have been installed in the wall of the breech 314 . If a permanent magnet 322 is installed into the bolt 318 , the front coil 320 b can be energized to repel the magnet 322 and the rear coil 320 a can be energized to attract the magnet 322 causing the bolt 318 to slide rearwardly to an open position allowing a projectile 12 to drop through the feed port 20 and into the breech 314 . By reversing the polarity of the current on the front coil 320 b and rear coil 320 a , the front coil 320 b now attracts the magnet 322 and the rear coil 320 a repels the magnet 322 causing the bolt 318 to move into a closed position where the projectile 12 is slid into the barrel 16 for launching. When constructed in this manner, the electro-magnetic force acting on the magnet 322 is doubled allowing faster and more reliable shuttling of the bolt 318 between the open and closed positions.
[0032] One skilled in the art should appreciate that the magnet 322 shown in FIGS. 7 and 8 above could be replaced with a ferrous material 322 . In this configuration, the front coil 320 b and rear coil 320 a would be energized sequentially. To open the bolt 318 , the rear coil 320 a is energized by the controller 115 causing the bolt 318 to slide rearwardly. To close the bolt 318 , the rear coil 320 a is de-energized and the front coil 320 b is energized causing the bolt 318 to slide forward. It should also be appreciated that while two coils 320 a , 320 b are shown herein, any possible combination of an array of a plurality of coils in combination with more than one magnet or ferrous material may be utilized to cause movement of the bolt 318 . In the broadest sense, the disclosure of the present invention is directed to moving the bolt 318 in a marker 300 utilizing electro-magnetic force. Therefore, while specific configurations are shown for the purpose of illustration the preferred embodiments of the invention, one skilled in the art can appreciated that there are literally dozens of other possible combinations wherein coils, magnets and ferrous materials are utilized to move or move a bolt mechanism in a marker, all of these combinations are intended to fall within the scope of the present disclosure.
[0033] By integrating sensors 126 into any of the markers illustrated herein, the controller 115 can monitor input from various points within the markers. For example, sensors 126 can be utilized to monitor the positioning of projectiles 12 within the markers or whether a projectile 12 is even present, or to monitor the position and speed at which the bolt is operating. This sensor feedback can be instantaneously processed by the controller 115 and used to quickly adjust the position of the bolt by simply energizing the coils and moving the bolt. This ability to precisely and quickly control the positioning of the bolt in response to sensor feedback was not previously available in the prior art.
[0034] Turning now to FIG. 9 , a marker 400 in accordance with a fourth embodiment of the present invention is shown wherein an actuator chamber 402 is provided in the receiver body 413 adjacent the breech 414 . A linkage 404 extends from the bolt 418 into the actuator chamber 402 and terminates in either a permanent magnet 422 or a piece of ferrous material. Electro-magnetic coils 420 are provided preferably at both ends of the actuator chamber 402 , although one coil 420 may be utilized. In the same manner as described in detail above, the coils 420 are used to either attract or repel the magnet 422 or ferrous material thereby causing the linkage 404 and the bolt 418 to be moved as desired by the controller 115 .
[0035] FIG. 10 illustrates a marker 500 in accordance with a fifth embodiment where the principles of the present invention are employed in the context of a rotary bolt 518 . The slidable bolt that was described above has now been replaced with a bolt 518 that is configured to rotate around an axis 519 that is aligned with the longitudinal axis of the marker 500 . Again, electromagnetics are used to move a bolt for loading and launching of a projectile. The bolt 518 includes at least one seat 502 and preferably a plurality of seats 502 therein. As the bolt 518 rotates as illustrated by arrow 504 , a projectile 12 drops through the feed port 20 into one of the seats 502 . As the bolt 518 continues to rotate, the bolt 518 ultimately places the projectile 12 in alignment with the breach for launching of the projectile 12 . In this embodiment, at least one permanent magnet 522 is provided in the rotary bolt 518 and a plurality of coils 520 is provided in the walls of the receiver body 513 around the bolt 518 . The controller (not shown in this figure) sequentially energizes the coils 520 thereby attracting the magnet 522 and causing the bolt 518 to rotate as the magnet 522 is drawn to the next coil 520 in the energization sequence. Clearly, the position of the coils 520 and magnet 522 can be reversed and still be within the scope of the disclosure. Similarly, multiple magnets 522 may be utilized or ferrous material may be used in place of the permanent magnet 522 to operate the rotary bolt 518 in this embodiment in accordance with the principals disclosed above.
[0036] It can therefore be seen that the present invention provides an improved system for actuating a bolt within a marker using electromagnetic forces in order to enhance the speed and reliability with which the bolt can be operated. Further by operating the bolt using electrically controlled coils in conjunction with sensors placed throughout the marker, a high degree of control over the operation of the bolt can be achieved. For these reasons, the instant invention is believed to represent a significant advancement in the art, which has substantial commercial merit.
[0037] While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.
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A bolt mechanism that is actuated by an electromagnetic arrangement is provided for use within a pneumatic projectile launcher or marker. The electro-magnetic arrangement provides for rapid movement and a high degree of control over the bolt. Generally, an arrangement of electro-magnetic coils is provided that exert a force on ferrous materials or permanent magnets thereby causing the bolt to reciprocate back and forth. Several embodiments are provided that disclose configurations having varied numbers of electromagnetic coils, ferrous materials and permanent magnets strategically placed within the breech and bolt of the marker, wherein energizing the coils produces movement of the bolt. Further, the electro-magnetic bolt system of the present invention is equally applicable to slide bolts as well as rotary bolts.
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TECHNICAL FIELD
This disclosure relates to devices which assist hearing, and more specifically to a battery door with an integrated switch for a hearing assistance devices.
BACKGROUND
The ability to adjust operational parameters of a hearing assistance device is a feature of the device that is both useful and desirable. For example, users have benefited from the ability to adjust the volume of a hearing assistance device.
Hearing assistance devices employ different types of switches to assist the user in making operational adjustments. Momentary switches are one type of switch commonly used on hearing assistance devices. However, momentary switches in small hearing assistance devices require costly and complex micro molded mechanical components. These components take up space within the housing of the hearing assistance device.
Thus, there is a need in the art for switches that provide economy in design, assembly, operation and space as to their use in hearing assistance devices.
SUMMARY
This application addresses the foregoing needs in the art and other needs not discussed herein. The various embodiments described herein relate to user controls incorporated into the battery door of a hearing assistance devices.
The present subject matter provides method and apparatus related to hearing assistance devices with at least one control disposed within a battery door. In one example, the control is electrically connected through the battery door hinge to hearing assistance electronics within the hearing assistance device housing. In various embodiments, the control includes an operator and a switch. In various examples, the battery door with an integrated control is provided for use with various hearing assistance device housings. Examples of connecting the switch to the electronics and providing for switch activation are provided in varying embodiments. The present subject matter also includes methods of using the battery door with an integrated control, for example, operating the control to adjust parameters affecting the operation of the hearing assistance electronics, such as volume.
This Summary is an overview of some of the teachings of the present application and not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details about the present subject matter are found in the detailed description and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates an example of the battery door in use with a in-the-ear (ITE) type housing.
FIG. 1B illustrates an example of the battery door in use with a behind-the-ear (BTE) type housing.
FIG. 1C illustrates the equivalent circuit diagram of a battery door with an integrated switch according to various embodiments.
FIG. 2 shows an exploded view of a integrated momentary switch according to the present subject matter.
FIG. 3 illustrates a cutaway view of an assembled battery door with the spring member insert molded into the battery door.
FIG. 4 is a cross-section of a portion of an assembled battery door installed in a hearing assistance device.
DETAILED DESCRIPTION
The following detailed description refers to subject matter in the accompanying drawings which show, by way of illustration, specific aspects and embodiments in which the present subject matter may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present subject matter. References to “an”, “one”, or “various” embodiments in this disclosure are not necessarily to the same embodiment, and such references contemplate more than one embodiment. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope is defined only by the appended claims, along with the full scope of legal equivalents to which such claims are entitled.
FIG. 1A shows a three dimensional example of one embodiment of the battery door 100 according to the present subject matter. The battery door 100 incorporates a switch 102 for assisting the user in modifying the operation of a hearing assistance device 103 . When the battery door 100 is properly installed in the hearing assistance device 103 , the switch 102 is electrically connected to the electronics of the hearing assistance device through a pre-wired hinge pin 104 . The battery door 100 is configured to make connections between the electronics of the hearing assistance device and the battery 105 when in a closed state.
FIG. 1A illustrates an embodiment of the battery door 100 adapted for use with an in-the-ear (ITE) type hearing assistance device 103 . FIG. 1B shows an embodiment of the battery door 100 B adapted for use with a behind-the-ear (BTE) type hearing assistance device 103 B. The embodiment of FIG. 1B includes an integrated switch 102 B, a battery 105 B and a pre-wired hinge pin 104 B. Various embodiments of the present subject matter are adapted for use with over-the-ear (OTE) and receiver-in-canal (RIC) housings. FIG. 1C illustrates the equivalent circuit diagram of a battery door with an integrated switch according to various embodiments. FIG. 1C includes a hearing assistance device 103 C, a battery door 100 C with an integrated switch 102 C, a battery 105 C and hearing assistance electronics 110 C. The integrated switch 102 C forms part of a circuit connected to the hearing assistance device 110 C. Generally, the illustrated circuit includes the battery 105 C and switch 102 C, wherein the switch includes a conductive hinge member 104 C pre-wired to the hearing assistance electronics 110 C.
FIG. 2 shows a three dimensional exploded view of an integrated switch 202 according to one embodiment of the present subject matter. The switch 102 includes an operator 207 , in the form of a button and a spring member 208 . The illustrated spring member 208 includes three tabs. The center tab 209 is made from electrically conductive material and forms a contact of the switch 202 . The two outside tabs of the spring member are insert molded into the battery door 200 . The switch 202 is assemble by snapping the operator 207 into the opening of the battery door 200 such that the spring member 208 is between the operator 207 and a subsequently installed battery. In various embodiments, operator 207 and battery door 200 are made of nonconductive material, for example, injection molded plastic. In various embodiments, the operator is in a form other than a button. For example, the operator may be a slide bar, a rotary operator, a toggle or other operator form. These switch operators allow switch functionality to be maintained or momentary, as well as, normally opened or normally closed.
FIG. 3 illustrates a cutaway view of an assembled battery door 300 with the spring member 308 insert molded into the battery door 300 . In the illustrated example, pressure applied to the operator 307 , in the direction of the battery 305 , causes the center tab 309 of the spring member 308 to contact the battery 305 .
FIG. 4 is a cross-section of a portion of the assembled battery door installed in a hearing assistance device. FIG. 4 includes the operator 407 , the contact portion 409 of spring member 408 , the battery 405 and the hinge pin 404 . The illustration shows a user 410 operating the momentary switch 402 such that the switch contact 409 closes on the battery 405 completing a circuit connected to the hearing assistance electronics. The pressure exerted on the operator 407 deforms the spring member 408 such that the contact tab 409 of the spring member contacts the battery 405 . Upon contact with the battery 405 , the switch 402 completes a circuit. In various embodiments, the circuit includes the hearing assistance electronics connected to the battery 405 , the battery connected to the contact tab 409 of the spring member 408 , and the spring member 408 in contact with the hinge pin 404 , the hinge pin being pre-wired to the hearing assistance electronics. Upon the user 410 releasing pressure from the switch 402 , the spring member 408 returns to an unbiased state such that the contact tab 409 withdraws from the battery 405 .
The present subject matter extends to various hearing aid designs including, but not limited to, in-the-ear, in-the-canal, completely-in-the-canal and behind-the-ear designs. The present subject matter provides an economical, reliable and robust solution to providing a switch in a battery door of a hearing assistance device.
This description has set forth numerous details and features of various embodiments, but is intended to be illustrative and not intended in an exclusive or exhaustive sense. Changes in detail, material, parts, order of process and design may occur without departing from the scope of the appended claims and their legal equivalents.
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The present subject matter includes a switch and an operator to interface with the switch, the operator in a battery door of a hearing assistance device. One embodiment includes a housing, hearing assistance electronics disposed in the housing, a hinge electrically connected to the hearing assistance electronics, and a battery door coupled to the hinge, the battery door includes a switch comprising an operator and at least one contact connected to the hinge.
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CROSS REFERENCE STATEMENT
This application claims benefit of U.S. Provisional Application No. 60/114,035, filed Dec. 29, 1998.
BACKGROUND OF THE INVENTION
This invention relates to polyurethane foams. This invention particularly relates to polyurethane foams prepared from aqueous polyurethane dispersions, and to a process for preparing same.
Polyurethane dispersions are known and can be useful for preparing polyurethane polymers that can themselves be useful in various applications. Polyurethane dispersions can be used, for example, to prepare coatings for leather; wood finishing; glass fiber sizing; textiles; adhesives; and automotive topcoats and primers. Polyurethane dispersions can be prepared by various processes, including, for example, those described in: U.S. Pat. No. 4,857,565; U.S. Pat. No. 4,742,095; U.S. Pat. No. 4,879,322; U.S. Pat. No. 3,437,624; U.S. Pat. No. 5,037,864; U.S. Pat. No. 5,221,710; U.S. Pat. No. 4,237,264; and, U.S. Pat. No. 4,092,286.
It is known that carpet backings can be prepared from polyurethane dispersions. For example, polyurethane dispersions prepared according to the process of U.S. application Ser. No. 09/039,978, filed Mar. 16, 1998, now abandoned, can be useful for preparing polyurethane carpet backings and polyurethane textile backings. Typically, mechanical froths of dispersions which are applied as a primary or secondary binder to a carpet backing are unstable due to high concentration of filler and the absence of foam stabilizers. Mechanical frothing to produce a stable froth requires that less filler and foam stabilizers be used, and is therefore a distinctly different process than that conventionally used to coat the back of a carpet for primary or laminate applications. Mechanical frothing of currently commercially available polyurethane dispersions using air, for example, can be carried out using additives such as, for example, stabilizing soap, inorganic filler, and wax dispersions. While foams, on casting and drying, having good physical properties and stable fine cell structure up to 10 mm thickness can be prepared, the foams so prepared are not resilient.
Resiliency is a desirable characteristic for foams used in applications such as carpet backings. Increasing the resilience of such a foam can increase both the durability and comfort of the foams. For example, a more resilient foam, or stated another way, a “springy” foam is commonly perceived as more comfortable than a non-resilient foam. A more resilient foam can also dissipate energy mechanically, by springing back, rather than as heat such as would a non-resilient foam. Dissipating energy as heat can eventually cause polymer degradation which in turn leads to the foam not returning to its original shape. When this occurs in a carpet application, the resulting pattern evident on the surface of the carpet in normal traffic areas can be perceived as premature wear.
It would be desirable, in the art of preparing polyurethane foams, to have a polyurethane dispersion composition that can be mechanically frothed such that a foam having suitable fine cell structure and good properties, including resilience, can be prepared. It would also be desirable in the art to have a process for preparing a polyurethane foam having good resilience from a polyurethane dispersions by mechanically frothing the polyurethane dispersions.
SUMMARY OF THE INVENTION
In one aspect, the present invention is a resilient polyurethane foam comprising a foam prepared by a process including the steps of frothing an aqueous polyurethane dispersion; applying the froth to a substrate; and drying the froth into a foam, wherein the polyurethane dispersion is prepared by admixing water, a chain extender, a surfactant, and a polyurethane prepolymer under mixing conditions sufficient to prepare a stable dispersion; the polyurethane is prepared from a formulation including a polyisocyanate and a polyol having a hydroxyl functionality of greater than about 2.2; and the polyurethane foam has a resiliency of from about 5 to about 80 percent.
In another aspect, the present invention is a foam backed substrate comprising a substrate and adherent thereto a resilient polyurethane foam prepared by a process including the steps of frothing an aqueous polyurethane dispersion; applying the froth to a substrate; and drying the froth into a foam, wherein the polyurethane dispersion is prepared by admixing water, a chain extender, a surfactant, and a polyurethane prepolymer under mixing conditions sufficient to prepare a stable dispersion; the polyurethane is prepared from a formulation including a polyisocyanate and a polyol having a hydroxyl functionality of greater than about 2.2; and the polyurethane foam has a resiliency of from about 5 to about 80 percent.
Frothed foams of the present invention can be useful in cushioned flooring applications such as attached cushion broadloom, carpet tiles, carpet underlay, or vinyl flooring. Frothed foams of the present invention could also be useful as cushion or absorbent layers for various textiles and disposable goods.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one embodiment, the present invention is a resilient polyurethane foam prepared using an aqueous polyurethane dispersion composition that can be mechanically frothed to yield a polyurethane foam having good resiliency. A polyurethane dispersion useful in the practice of the present invention includes water, and either: a polyurethane; a mixture capable of forming a polyurethane; or a mixture of both. Polyurethane-forming materials as used in the present invention are materials which can be used to prepare polyurethane polymers. Polyurethane-forming materials include, for example, polyurethane prepolymers. While polyurethane prepolymers may retain some isocyanate reactivity for some period of time after dispersion, for purposes of the present invention, a polyurethane prepolymer dispersion shall be considered as being a fully reacted polyurethane polymer dispersion. Also, for purposes of the present invention, a polyurethane prepolymer or polyurethane polymer can include other types of structures such as, for example, urea groups.
Polyurethane prepolymers useful in the practice of the present invention are prepared by the reaction of active hydrogen compounds with any amount of isocyanate in a stoichiometric excess relative to active hydrogen material. Isocyanate functionality in the prepolymers useful with the present invention can be present in an amount of from about 0.2 weight percent to about 20 weight percent. A suitable prepolymer can have a molecular weight in the range of from about 100 to about 10,000. Prepolymers useful in the practice of the present invention should be substantially liquid under the conditions of dispersal.
The prepolymer formulations of the present invention include a polyol component. Active hydrogen containing compounds most commonly used in polyurethane production are those compounds having at least two hydroxyl groups or amine groups. Those compounds are referred to herein as polyols. Representatives of suitable polyols are generally known and are described in such publications as High Polymers, Vol. XVI, “Polyurethanes, Chemistry and Technology” by Saunders and Frisch, Interscience Publishers, New York, Vol. I, pp. 32-42, 44-54 (1962) and Vol. II, pp. 5-6, 198-199 (1964); Organic Polymer Chemistry by K. J. Saunders, Chapman and Hall, London, pp. 323-325 (1973); and Developments in Polyurethanes, Vol. I, J. M. Burst, ed., Applied Science Publishers, pp. 1-76 (1978). However, any active hydrogen containing compound can be used with the present invention. Examples of such materials include those selected from the following classes of compositions, alone or in admixture: (a) alkylene oxide adducts of polyhydroxyalkanes; (b) alkylene oxide adducts of non-reducing sugars and sugar derivatives; (c) alkylene oxide adducts of phosphorus and polyphosphorus acids; and (d) alkylene oxide adducts of polyphenols. Polyols of these types are referred to herein as “base polyols”. Examples of alkylene oxide adducts of polyhydroxyalkanes useful herein are adducts of ethylene glycol, propylene glycol, 1,3-dihydroxypropane, 1,4-dihydroxybutane, and 1,6-dihydroxyhexane, glycerol, 1,2,4-trihydroxybutane, 1,2,6-trihydroxyhexane, 1,1,1-trimethylolethane, 1,1,1-trimethylolpropane, pentaerythritol, polycaprolactone, xylitol, arabitol, sorbitol, mannitol, and the like. Preferred herein as alkylene oxide adducts of polyhydroxyalkanes are the propylene oxide adducts and ethylene oxide capped propylene oxide adducts of dihydroxy- and trihydroxyalkanes. Other useful alkylene oxide adducts include adducts of ethylene diamine, glycerin, piperazine, water, ammonia, 1,2,3,4-tetrahydroxy butane, fructose, sucrose, and the like.
Also useful with the present invention are poly(oxypropylene) glycols, triols, tetrols and hexols and any of these that are capped with ethylene oxide. These polyols also include poly(oxypropyleneoxyethylene)polyols. The oxyethylene content should preferably comprise less than about 80 weight percent of the total polyol weight and more preferably less than about 40 weight percent. The ethylene oxide, when used, can be incorporated in any way along the polymer chain, for example, as internal blocks, terminal blocks, or randomly distributed blocks, or any combination thereof.
Another class of polyols which can be used with the present invention are “copolymer polyols”, which are base polyols containing dispersed polymers such as acrylonitrile-styrene copolymers. Production of these copolymer polyols can be from reaction mixtures comprising a variety of other materials, including, for example, catalysts such as azobisisobutyro-nitrile; copolymer polyol stabilizers; and chain transfer agents such as isopropanol.
Polyester polyols can be used to prepare the polyurethane dispersions of the present invention. Polyester polyols are generally characterized by repeating ester units which can be aromatic or aliphatic and by the presence of terminal primary or secondary hydroxyl groups, but any polyester terminating in at least 2 active hydrogen groups can be used with the present invention. For example, the reaction product of the transesterification of glycols with poly(ethylene terephthalate) can be used to prepare the dispersions of the present invention.
Polyamines, amine-terminated polyethers, polymercaptans and other isocyanate-reactive compounds are also suitable in the present invention. Polyisocyanate polyaddition active hydrogen containing compounds (PIPA) can be used with the present invention. PIPA compounds are typically the reaction products of TDI and triethanolamine. A process for preparing PIPA compounds can be found in, for example, U.S. Pat. No. 4,374,209, issued to Rowlands.
In the practice of the present invention, preferably at least 50 weight percent of the active hydrogen compounds used to prepare the polyurethane or polyurethane prepolymer is a polyether polyol a having molecular weight of from about 600 to about 20,000, preferably about 1,000 to about 10,000, most preferably about 3,000 to about 8,000. In the practice of the present invention, preferably this polyol has a hydroxyl functionality of at least 2.2. Preferably this polyol has a hydroxyl functionality of from 2.2 to about 5.0, more preferably from about 2.3 to about 4.0 and even more preferably from about 2.5 to about 3.8. Most preferably, the active hydrogen compounds used to prepare the polyurethane or polyurethane prepolymer is a polyether polyol having a hydroxyl functionality of from about 2.6 to about 3.5 and a molecular weight of from about 3,000 to about 8,000. For purposes of the present invention, functionality is defined to mean the average calculated functionality of all polyol initiators further adjusted for any known side reactions which affect functionality during polyol production.
The polyisocyanate component of the formulations of the present invention can be prepared using any organic polyisocyanates, modified polyisocyanates, isocyanate-based prepolymers, and mixtures thereof. These can include aliphatic and cycloaliphatic isocyanates, but aromatic and especially multifunctional aromatic isocyanates such as 2,4- and 2,6-toluenediisocyanate and the corresponding isomeric mixtures; 4,4′-, 2,4′- and 2,2′-diphenyl-methanediisocyanate (MDI) and the corresponding isomeric mixtures; mixtures of 4,4′-, 2,4′- and 2,2′-diphenylmethanediisocyanates and polyphenyl polymethylene polyisocyanates (PMDI); and mixtures of PMDI and toluene diisocyanates are preferred. Most preferably, the polyisocyanate used to prepare the prepolymer formulation of the present invention is MDI or PMDI.
The present invention includes a chain extender or crosslinker. A chain extender is used to build the molecular weight of the polyurethane prepolymer by reaction of the chain extender with the isocyanate functionality in the polyurethane prepolymer, i.e., chain extend the polyurethane prepolymer. A suitable chain extender or crosslinker is typically a low equivalent weight active hydrogen containing compound having about 2 or more active hydrogen groups per molecule. Chain extenders typically have 2 or more active hydrogen groups while crosslinkers have 3 or more active hydrogen groups. The active hydrogen groups can be hydroxyl, mercaptyl, or amino groups. An amine chain extender can be blocked, encapsulated, or otherwise rendered less reactive. Other materials, particularly water, can function to extend chain length and, therefore, can be chain extenders for purposes of the present invention.
Polyamines are preferred chain extenders. It is particularly preferred that the chain extender be selected from the group consisting of amine terminated polyethers such as, for example, JEFFAMINE D-400 from Huntsman Chemical Company, amino ethyl piperazine, 2-methyl piperazine, 1,5-diamino-3-methyl-pentane, isophorone diamine, ethylene diamine, diethylene triamine, aminoethyl ethanolamine, triethylene tetraamine, triethylene pentaamine, ethanol amine, lysine in any of its stereoisomeric forms and salts thereof, hexane diamine, hydrazine and piperazine. In the practice of the present invention, the chain extender can be used as an aqueous solution.
In the practice of a present invention, a chain extender is employed in an amount sufficient to react with from about zero (0) to about 100 percent of the isocyanate functionality present in the prepolymer, based on one equivalent of isocyanate reacting with one equivalent of chain extender. It can be desirable to allow water to act as a chain extender and react with some or all of the isocyanate functionality present. A catalyst can optionally be used to promote the reaction between a chain extender and an isocyanate. When chain extenders of the present invention have more than two active hydrogen groups, then they can also concurrently function as crosslinkers.
A polyurethane formulation suitable for preparing a foam of the present invention (hereinafter Compound) can be prepared from a polyurethane dispersion and a foam stabilizer. In addition to a polyurethane dispersion and a foam stabilizer, a Compound of the present invention can optionally include: cross-linkers; surfactants; fillers; dispersants; thickeners; fire retardants; absorbents; fragrances and/or other materials known in the art to be useful in the preparation of polymer foam products. The term “Compound” particularly means the material placed into a frother to produce a froth which can be dried to form a foam.
A Compound of the present invention optionally includes a filler material. The filler material can include conventional fillers such as milled glass, calcium carbonate, aluminum trihydrate, talc, bentonite, antimony trioxide, kaolin, fly ash, or other known fillers. In the practice of the present invention, a suitable filler loading in a polyurethane dispersion can be from about 0 to about 500 parts of filler per 100 parts of polyurethane. Preferably, filler can be loaded in an amount of less than about 250 pph, more preferably less than about 200 pph, most preferably less than about 150 pph.
The present invention optionally includes a filler wetting agent. A filler wetting agent generally can help make the filler and the polyurethane dispersion compatible. Useful wetting agents include phosphate salts such as sodium hexametaphosphate. A filler wetting agent can be included in a Compound of the present invention at a concentration of at least about 0.5 parts per 100 parts of filler, by weight.
The present invention optionally includes thickeners. Thickeners can be useful in the present invention to increase the viscosity of low viscosity polyurethane dispersions. Thickeners suitable for use in the practice of the present invention can be any known in the art. For example, suitable thickeners include ALCOGUM™ VEP-II (trade designation of Alco Chemical Corporation) and PARAGUM™ 241 (trade designation of Para-Chem Southern, Inc.). Thickeners can be used in any amount necessary to prepare a Compound of desired viscosity.
The present invention can include other optional components. For example, a formulation of the present invention can include surfactants, frothing agents, dispersants, thickeners, fire retardants, pigments, antistatic agents, reinforcing fibers, antioxidants, preservatives, biocides, acid scavengers, and the like. Examples of suitable frothing agents include: gases and/or mixtures of gases such as, for example, air, carbon dioxide, nitrogen, argon, helium, and the like. While optional for purposes of the present invention, some components can be highly advantageous for product stability during and after the manufacturing process. For example, inclusion of antioxidants, biocides, and preservatives can be highly advantageous in the practice of the present invention.
Preferred in the practice of this invention is the use of a gas as a frothing agent. Particularly preferable is the use of air as a frothing agent. Frothing agents are typically introduced by mechanical introduction of a gas into a liquid to form a froth, that is mechanical frothing. In preparing a frothed polyurethane backing, it is preferred to mix all components and then blend the gas into the mixture, using equipment such as an OAKES or FIRESTONE frother.
Surfactants can be useful for preparing a stable dispersion of the present invention, and/or a surfactant useful for preparing a stable froth. Surfactants useful for preparing a stable dispersion are optional in the practice of the present invention, and can be cationic surfactants, anionic surfactants, or a non-ionic surfactants. Examples of anionic surfactants include sulfonates, carboxylates, and phosphates. Examples of cationic surfactants include quaternary amines. Examples of non-ionic surfactants include block copolymers containing ethylene oxide and silicone surfactants. Surfactants useful in the practice of the present invention can be either external surfactants or internal surfactants. External surfactants are surfactants which do not become chemically reacted into the polymer during dispersion preparation. Examples of external surfactants useful herein include salts of dodecyl benzene sulfonic acid, and lauryl sulfonic acid salt. Internal surfactants are surfactants which do become chemically reacted into the polymer during dispersion preparation. An example of an internal surfactant useful herein includes 2,2-dimethylol propionic acid and its salts. A surfactant can be included in a formulation of the present invention in an amount ranging from about 0.01 to about 8 parts per 100 parts by weight of polyurethane component.
Surfactants useful for preparing a stable froth are referred to herein as foam stabilizers. Foam stabilizers are essential in the practice of the present invention. In addition to the surfactants described hereinabove, foam stabilizers can include, for example, sulfates, succinamates, and sulfosuccinamates. Any foam stabilizer known to useful by those of ordinary skill in the art of preparing polyurethane foams can be used with the present invention.
Catalysts are optional in the practice of the present invention. Catalysts suitable for use in preparing the polyurethanes and polyurethane prepolymers of the present invention include tertiary amines, and organometallic compounds, like compounds and mixtures thereof. For example, suitable catalysts include di-n-butyl tin bis(mercaptoacetic acid isooctyl ester), dimethyltin dilaurate, dibutyltin dilaurate, dibutyltin sulfide, stannous octoate, lead octoate, ferric acetylacetonate, bismuth carboxylates, triethylenediamine, N-methyl morpholine, like compounds and mixtures thereof. An amount of catalyst is advantageously employed such that a relatively rapid cure to a tack-free state can be obtained. If an organometallic catalyst is employed, such a cure can be obtained using from about 0.01 to about 0.5 parts per 100 parts of the polyurethane prepolymer, by weight. If a tertiary amine catalyst is employed, the catalyst preferably provides a suitable cure using from about 0.01 to about 3 parts of tertiary amine catalyst per 100 parts of the polyurethane-forming composition, by weight. Both an amine type catalyst and an organometallic catalyst can be employed in combination.
Generally, any method known to one skilled in the art of preparing polyurethane dispersions can be used in the practice of the present invention to prepare a polyurethane dispersions material suitable for preparing, for example, a carpet of the present invention. A suitable storage-stable polyurethane dispersions as defined herein is any polyurethane dispersions having a mean particle size of less than about 5 microns. A polyurethane dispersions that is not storage-stable can have a mean particle size of greater than 5 microns. For example, a suitable dispersion can be prepared by mixing a polyurethane prepolymer with water and dispersing the prepolymer in the water using a mixer. Alternatively, a suitable dispersion can be prepared by feeding a prepolymer into a static mixing device along with water, and dispersing the water and prepolymer in the static mixer. Continuous methods for preparing aqueous dispersions of polyurethane are known and can be used in the practice of the present invention. For example, U.S. Pat. Nos.: 4,857,565; 4,742,095; 4,879,322; 3,437,624; 5,037,864; 5,221,710; 4,237,264; and 4,092,286 all describe continuous processes useful for preparing polyurethane dispersions. In addition, a polyurethane dispersion having a high internal phase ratio can be prepared by a continuous process such as is described in U.S. Pat. No. 5,539,021.
Other types of aqueous dispersions can be used in combination with the polyurethane dispersions of the present invention. Suitable dispersions useful for blending with polyurethane dispersions of the present invention include: styrene-butadiene dispersions; styrene-butadiene-vinylidene chloride dispersions; styrene-alkyl acrylate dispersions; ethylene vinyl acetate dispersions; polychloropropylene latexes; polyethylene copolymer latexes; ethylene styrene copolymer latexes; polyvinyl chloride latexes; or acrylic dispersions, like compounds, and mixtures thereof.
The polyurethane foams of the present invention are resilient. For purposes of the present invention, a resilient foam is one which has a minimum resiliency of 5 percent when tested by the falling ball method. This method, ASTM D1564-64T, generally consists of dropping a ball of known weight from a standard height onto a sample of the foam and then measuring the rebound of the ball as a percentage of the height from which it was dropped. Preferably the foams of the present invention have a resiliency of from about 5 to about 80 percent, more preferably from about 10 to about 60 percent, and most preferably from about 15 to about 50 percent. The resiliency of foams of the present invention can impart longer wear and greater comfort to products including them than can conventional polyurethane foams prepared from aqueous polyurethane dispersions.
A polyurethane dispersion of the present invention can be stored for later application to the back of a substrate, such as, for example, a carpet. Storage for this purpose requires that the dispersion be storage-stable. Alternatively, the polyurethane dispersion can be applied in a continuous manner to the back of a carpet substrate, that is, the dispersion can be applied to the back of a carpet as the dispersion is prepared according to the practice of the present invention.
In the practice of the present invention, a frothed polyurethane layer is dried to prepare a foam. For the purposes of the present invention, this means that the froth is treated in any way such that the froth structural integrity is maintained and after the froth is substantially free of water, the resulting material is a resilient polyurethane cellular foam. Drying can be at ambient temperature but preferably is done in an oven at temperatures of from about 50 to about 200° C.
In preparing polymer backed carpets according to the present invention, a polyurethane dispersion is applied as a layer of preferably uniform thickness onto the non-pile surface of a suitably prepared carpet substrate. Polyurethane precoats, laminate coats, and foam coats can be prepared by methods known to those of ordinary skill in the art of preparing such backings. Precoats, laminate coats and foam coats prepared from dispersions are described in P. L. Fitzgerald, “Integral Dispersion Foam Carpet Cushioning”, J. Coat. Fab. 1977, Vol. 7 (pp. 107-120), and in R. P. Brentin, “Dispersion Coating Systems for Carpet Backing”, J. Coat. Fab. 1982, Vol. 12 (pp. 82-91).
A reactive polyurethane backing, also known as an A+B backing, such as is formed by the reaction of a polyisocyanate and a polyol in the presence of a catalyst and blowing agent, can be applied to one surface of a carpet substrate before it cures to a tack-free state to form a carpet. Alternatively, in the practice of the present invention, a polyurethane dispersion containing no unreacted isocyanate functionality can be advantageously applied to the surface of a carpet substrate, thereby removing the need to react the polyurethane precursors in situ to form the polyurethane polymer. Typically the polyurethane dispersion, usually in the form of a Compound, is applied as a stable froth to a carpet surface which has been coated with a primary backing or precoat. The polyurethane dispersion may be applied to a suitable substrate using equipment such as a doctor knife or roll, air knife, or extruder to apply and gauge the layer. The amount of polyurethane dispersion used to coat a textile can vary widely, ranging from about 1.5 to about 300 ounces per square yard (53 g/m 2 -10.7 kg/m 2 ) dry weight, depending on the characteristics of the textile. Preferably, the foams of the present invention are applied at a level of from about 5 to about 50 ounces per square yard (170 g/m 3 -1.8 kg/m 3 ) dry polymer weight. After the layer is applied and gauged, the layer can be dried using heat from any suitable heat source such as an infrared oven, a convection oven, or heating plates.
In preparing the polyurethane foam backed substrates of the present invention in general and the backed textiles in particular, it is advantageous to dry the polyurethane dispersion as quickly as possible after it is applied to the substrate. It has been observed that using a slow heating process can result in coarser cell structure in the center of the foam. It is particularly advantageous to do at least the initial drying of a polyurethane dispersion of the present invention using an infra-red heater as this practice can promote the formation of a smooth skin on the surface of the foam facing the heater which is both aesthetically desirable and may also be embossed or subjected to some other form of marking process.
One unique property of the polyurethane foams of the present invention is that they are resistant to yellowing. Conventional polyurethane foams, particularly those prepared with aromatic starting materials such as MDI or TDI, can yellow upon exposure to air and ultraviolet light. The foams of the present invention have a surprising ability to resist yellowing under conditions which would cause yellowing in a conventional polyurethane foam.
The following examples are provided to illustrate the present invention. The examples are not intended to limit the scope of the present invention and should not be so interpreted. All percentages are by weight unless otherwise noted.
EXAMPLES
Materials used in the examples:
VORANOL 4701*—A 4950 molecular weight triol having 15 percent EO capping (* Trade designation of The Dow Chemical Company).
ISONATE 125M*—4,4′-methylene diphenyl isocyanate having a functionality of 2.0 and an equivalent weight of 125 g/equivalent (* Trade designation of The Dow Chemical Company).
ISONATE 50 OP*—A 50 percent 4,4′-methylene diphenyl isocyanate, 50 percent 2,4′-methylene diphenyl isocyanate mixture having a functionality of 2.0 and an equivalent weight of 125 g/equivalent (* Trade designation of The Dow Chemical Company).
MPEG 950*—Monol produced by reacting ethylene oxide with methanol to an equivalent weight of 950 g/equivalent (* Trade designation of The Dow Chemical Company).
BIO-TERGE AS-40*—Mixed olefin (C14-16) sodium sulfonate (*Trade designation of Stepan Corporation).
EMPIMIN MK/B*—Di sodium N-tallow sulphosuccinamate available as a 35 percent active solution in water (* Trade designation of Albright & Wilson UK).
ACUSOL A810* Thickener—Acrylate thickener available as a 19 percent solution in water (* Trade designation of Rohm and Haas Co).
Antioxidant L: an emulsion of 54 parts β,β-ditrydecylthiodipropionate, 40 parts water, and 6 parts WINGSTAY L* which is a butylated reaction product of p-cresol and dicyclopentadiene (* Trade designation of Goodyear Rubber Company).
Example 1
Preparation of a Prepolymer
A prepolymer is prepared by adding 504 g of VORANOL 4701, 14 g MPEG 950, 9.1 g diethylene glycol, 86.45 g ISONATE 125 M, and 86.45 g ISONATE 50 OP into a glass bottle wherein the threads of the glass bottle are wrapped with TEFLON* tape to prevent the lid from adhering to the bottle (*A trade designation of DUPONT). The bottle is sealed, shaken vigorously until homogeneity of the components is achieved, and then rolled on a bottle roller for about 10 minutes. The bottle is then placed in an oven held at 70° C. for 15 hours, whereupon it was removed and allowed to cool to room temperature prior to use.
Preparation of an Aqueous Polyurethane Dispersion
75 g of prepolymer is weighed into an 8 oz glass bottle having an internal diameter of 5.6 cm. The bottle is clamped and an INDCO type A mixing blade (4.3 cm diameter from INDCO, INC.) is inserted into the prepolymer such that the blade is just covered by the liquid. Water is fed into the prepolymer at a rate of 14 g/min. for 2 minutes and 19 seconds while stirring is conducted at 3000 rpm. At 30 seconds into the water feed, 6.1 g of BIO-TERGE AS-40 is introduced over a period of no more than 5 seconds via syringe. After complete addition of the water, a solution of 10 percent piperazine in water (32.9 g, 80 percent stoichiometry based on prepolymer isocyanate equivalents) is added via syringe over a period of about 15 seconds. The resulting dispersion is then poured into a plastic tripour beaker, covered tightly with aluminum foil and allowed to stir gently overnight with a magnetic stirrer. The next day the 55 percent solids dispersion is filtered through a coarse paint filter.
Preparation of a Resilient Polyurethane Frothed Foam
200 g of the aqueous polyurethane dispersion is mixed with 4.7 g of a 25 percent aqueous sodium lauryl sulfate solution, 18.7 g of EMPIMIN MK/B, and 3.6 g ACUSOL A810 thickener using a blender until frothing is observed. The froth is poured onto a sheet of polyester film and heated in an oven at 150° C. for 20 minutes to yield a resilient, low density foam.
Example 2
Preparation of a Prepolymer
A polyurethane prepolymer is prepared using a formulation which consists of 2 parts of MPEG 950, 72 parts of VORANOL 4701, 1.3 parts of diethylene glycol, 12.35 part each ISONATE 50 OP and ISONATE 125M.
Preparation of a Polyurethane Dispersion
A polyurethane dispersion is prepared by chain extending the prepolymer of this example in water with piperazine to a stoichiometry of 0.75 to a solids content of 52.7 percent. The dispersion is prepared with 3% BIO-TERG AS-40 surfactant, based on prepolymer solids. The polyurethane dispersion has a volume average particle size of 0.229 micron.
Preparation of a Resilient Polyurethane Frothed Foam
A compound is prepared using 215 parts of the polyurethane dispersion of this Example, 2.1 part Antioxidant L, 10 parts of EMPIMIN MK/B, and 3.6 parts of a 25 percent aqueous solution of sodium lauryl sulfate. The Compound is frothed using a COWIE RIDING FOAM MACHINE* (*Trade designation of Cowie & Riding Ltd.), and cast onto a TEFLON sheet. The foam is dried for 30 seconds under infrared heat and then for 20 minutes in an oven at 150° C. The foam is tested and the results of the tests are listed below in the table.
Example 3
A foam is prepared and tested substantially identically to Example 2 except that the Compound also includes 180 parts of calcium carbonate.
TABLE
Example 2
Example 3
Density g/dm 3 *
127
237
Resilience - minimum (percent)
45
25
Resilience - maximum (percent)
50
26
Gauge Retention (percent) 1
109
130
Compression Set (percent) 2
48
PeakLoad 3
24.8
14.1
Elongation (percent) 4
325
225
1 Determined by measuring the thickness of the foam after dying and reported as a percentage of the original thickness of the foam as applied to the substrate.
2 ASTM D 1564B
3 DIN 53571 A
4 DIN 53571 A
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The present invention is polyurethane dispersion composition that can be mechanically frothed to yield a foam that has good resiliency. Frothed foams of the present invention can be useful in cushioned flooring applications such as attached cushion broadloom, carpet tiles, carpet underlay, or vinyl flooring. Frothed foams of the present invention can also be useful as coatings for various textiles and for diapers.
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CLAIM OF PRIORITY
[0001] The present application claims priority from Japanese patent application serial no. 2010-084772 filed on Apr. 1, 2010, the content of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an aluminum porous body and a method of fabricating the same.
[0004] 2. Description of Related Art
[0005] Aluminum porous bodies are used as heat-exchanger materials, filter materials, shock/vibration-absorbing materials, sound-insulating/absorbing materials, and the like. An aluminum porous body is fabricated usually by molding a base material (e.g., powder material, chip material, fibrous material) of pure aluminum or aluminum alloy into a desired shape and joining the contact points of the base material by sintering or brazing.
[0006] Meanwhile, a base material of pure aluminum or aluminum alloy is known as a sintering-resistant material since it generally forms a coating of alumina (Al 2 O 3 ), which is thermally very stable, on a surface thereof. Therefore, in order to obtain a sintered body of a pure aluminum base material or an aluminum alloy base material, it is necessary to subject the base material to high deformation at a molding stage to break the Al 2 O 3 coating on the surface and to promote contact between newly-formed surfaces before subjecting the base material to liquid-phase sintering in the solid-liquid coexistence region.
[0007] For example, JP-A 2004-285410 discloses an aluminum porous body having a bulk density of not less than 0.20 g/cm 3 and not more than 1.20 g/cm 3 . This aluminum porous body is obtained by cutting an aluminum clad material formed of an aluminum or aluminum alloy material clad with a brazing filler metal of aluminum alloy to form chips containing the brazing material, by molding the chips into a predetermined shape, and by subjecting the molded piece to brazing. The contact point joining percentage between the chips is not less than 25% and less than 50%.
[0008] Unfortunately, with conventional techniques such as the one described above, it is difficult to fabricate a porous body having a complex shape since conventional techniques inevitably involve molding a base material into a desired shape by metal stamping or the like as a preliminary step prior to the sintering or brazing process. Moreover, conventional techniques tend to be costly since each change in shape requires a new stamping die.
SUMMARY OF THE INVENTION
[0009] In view of the foregoing, it is an objective of the present invention to solve the above-described problems and to provide an aluminum porous body which is formed of a pure aluminum and/or aluminum alloy base material and has excellent sinterability and high dimensional accuracy without employing metal stamping. Furthermore, it is another objective of the invention to provide a method of fabricating such an aluminum porous body.
[0010] (I) According to one aspect of the present invention, there is provided an aluminum porous body having a relative density of from 5 to 80% with respect to the theoretical density of pure aluminum, in which the aluminum porous body contains 50 mass % or more of aluminum (Al) and from 0.001 to 5 mass % of at least one selected from chlorine (Cl), sodium (Na), potassium (K), fluorine (F), and barium (Ba).
[0011] In the above aspect (I) of the present invention, the following improvements and modifications can be made.
[0012] (i) The aluminum porous body further contains from 0.1 to 20 mass % of at least one selected from carbon (C), silicon carbide (SiC), iron (II) oxide (FeO), iron (III) oxide (Fe 2 O 3 ), and iron (II,III) oxide (Fe 3 O 4 ).
[0013] (II) According to another aspect of the present invention, there is provided a method of fabricating an aluminum porous body, in which the method comprises the steps of: mixing a raw material powder of pure aluminum and/or aluminum alloy with an aluminum brazing flux; shaping the raw material powder via the flux by irradiating the raw material powder mixed with the flux with a laser; and sintering the raw material powder by irradiating the shaped raw material powder with electromagnetic waves.
[0014] In the above aspect (II) of the present invention, the following improvements and modifications can be made.
[0015] (ii) The frequency of the electromagnetic waves ranges from 900 MHz to 30 GHz.
[0016] (iii) The aluminum brazing flux is a chloride-based flux or fluoride-based flux.
[0017] (iv) The chloride-based flux is mainly composed of barium chloride (BaCl 2 ), sodium chloride (NaCl), potassium chloride (KCl), or zinc chloride (ZnCl 2 ).
[0018] (v) The fluoride-based flux is mainly composed of aluminum fluoride (AlF 3 ), potassium tetrafluoroaluminate (KAlF 4 ), potassium pentafluoroaluminate (K 2 AlF 5 ), or potassium hexafluoroaluminate (K 3 AlF 6 ).
Advantages of the Invention
[0019] According to the present invention, it is possible to provide an aluminum porous body that is formed of a pure aluminum and/or aluminum alloy base material and has excellent sinterability and high dimensional accuracy without employing metal stamping. Also, it is possible to provide a method of fabricating such an aluminum porous body. As a result, a porous body having a complex shape can be easily provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic view of microwave heating of an aluminum porous body in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] In recent years, product development cycles have become shorter and there is a growing need for producing prototypes rapidly and easily (i.e. at low cost). One solution to meet the need is rapid prototyping (hereinafter referred to as RP), which is a 3D modeling method to create only the outside shape of an object rapidly. RP is widely used to produce machine parts having complex shapes, prototypes based on which the suitability of industrial products of high esthetic quality is checked, or the like.
[0022] A technique for RP is called additive manufacturing, with which a multiplicity of thin unit layers are stacked to form a shape. More specifically, layers of a powder material are laid down and irradiated with a laser so that the powder is directly sintered or its particles are joined via a binder. In the case of a metallic powder, the surfaces of its particles are coated with a binder, or the metallic powder is mixed with a binder powder, and the binder is melted by laser irradiation so that the powder particles are joined to form a shape (preform), and then the metallic powder is sintered. In this way, with RP, complex-shaped structures which are difficult to make by metal stamping can be produced rapidly.
[0023] The most important feature (advantage) of the present invention resides in the fact that an aluminum porous body that has excellent sinterability and high dimensional accuracy can be provided without employing metal stamping, even though it is formed of a pure aluminum- and/or aluminum alloy-based powder, which is a sintering-resistant material, and even if it has a complex shape. Therefore, the aluminum porous body and the method of fabricating the same in accordance with the present invention can be preferably applied to RP.
[0024] Here, there is no particular limitation on the particle shape of the pure aluminum- and/or aluminum alloy-based powder used in an embodiment of the present invention as long as the size specifications described below are met. Also, aluminum alloy is defined as alloy containing at least 50 mass % of aluminum.
[0025] An embodiment of the present invention will be described hereinafter with reference to the accompanying drawing. In this regard, however, the present invention is not limited to the embodiment disclosed herein, and combinations and improvements may be made as appropriate without departing from the spirit and scope of the present invention.
[0026] As described before, a coating of Al 2 O 3 , which is thermally very stable, is formed on the surface of each particle of pure aluminum or aluminum alloy powder (hereinafter referred to as Al-system metallic powder), inhibiting the sintering of the powder particles. The inventors devoted themselves to study the sintering behavior of Al-system metallic powder and thought that if a liquid phase was created in the surface region of Al-system metallic powder particles by selectively heating the surfaces of Al-system powder particles, the Al 2 O 3 coating would be pushed away to expose newly-formed surfaces (virgin surfaces) by the surface tension effect of the liquid phase, thus making it possible to sinter the particles.
[0027] Here, it is difficult to produce a liquid phase only in the surface region of each particle by typical electric-heater heating (radiation heating from outside). In the present invention, in contrast, the surface region of each particle is heated intensively by irradiation of electromagnetic waves at frequencies of 900 MHz to 30 GHz, making it possible to create a liquid phase in the surface region of each particle. However, in the case of heating metallic powder by electromagnetic irradiation, it is important to effectively insulate the metallic powder from the atmosphere since plasma otherwise would be generated and severe chemical reactions with the atmosphere would occur.
[0028] In the present invention, Al-system metallic powder is effectively insulated from the atmosphere by mixing an aluminum brazing flux in the Al-system metallic powder, thus making it possible to sinter the Al-system metallic powder by electromagnetic irradiation. In addition, since the aluminum brazing flux softens by laser irradiation, it also serves as an adhesive that bonds Al-system metallic powder particles, making it possible to produce a preform without employing metal stamping. In other words, the aluminum brazing flux also serves as a binder in additive manufacturing of RP, making it possible to fabricate a complex-shaped structure.
[0029] Although Al-system metallic powder can be induction-heated by electromagnetic irradiation, when the powder particle is small and the particle size becomes 1 mm or smaller, heating at frequencies of several kHz or so is difficult. In order to heat Al-system metallic powder with a particle size of 1 mm or smaller, the frequency range must be from 300 MHz to 300 GHz or so (the frequency range for the so-called microwaves). Meanwhile, the particle size is preferably 500 μm or smaller for improved sinterability of Al-system metallic powder. Also, in terms of workability, the particle size is preferably 0.5 μm or larger. As a result, in order to effectively heat Al-system metallic powder with a particle size of from 0.5 to 500 μm, it is preferred to use microwaves at frequencies ranging from 900 MHz to 30 GHz.
[0030] In general, when metal is heated by irradiating electromagnetic waves (microwaves), the electric current is concentrated on the surface of a target object by a skin effect. The degree of current concentration is referred to as current penetration depth. The current penetration depth depends on the frequency, and it becomes shallower as the frequency becomes higher. Therefore, by irradiating metallic powder with electromagnetic waves (microwaves), the surface region of each powder particle can be heated intensively.
[0031] In this regard, however, under microwave irradiation, chemical reactions between metallic powder and the atmosphere tend to become severe. For example, in the case of microwave-heating pure aluminum powder in nitrogen (N 2 ), Al combines with N 2 to generate aluminum nitride (AlN), making it difficult to sinter the aluminum powder particles. Meanwhile, inert gases such as argon (Ar) and helium (He) do not react with metal. However, they are easily brought into the state of plasma under microwave irradiation, often resulting in localized melting of metallic powder or hot spots. Therefore, they are ill suited as atmospheric gases. In addition, although plasma generation and chemical reactions between metallic powder and the atmosphere can be controlled under a high vacuum atmosphere of 1×10 −2 Pa or less, a costly vacuum pumping system is required and a lot of time is also required for vacuum pumping.
[0032] In the present invention, as described above, chemical reactions between Al-system metallic powder and the atmosphere, which tend to occur under microwave irradiation, can be prevented by effectively insulating the Al-system metallic powder from the atmosphere by mixing an aluminum brazing flux in the Al-system metallic powder. Preferable aluminum brazing fluxes include chloride-based fluxes (e.g., fluxes mainly composed of BaCl 2 , NaCl, KCl, or ZnCl 2 ) and fluoride-based fluxes (e.g., fluxes mainly composed of AlF 3 , KAlF 4 , K 2 AlF 5 , or K 3 AlF 6 ). Mixing these fluxes in Al-system metallic powder allows sintering by microwave irradiation even in the air atmosphere or N 2 .
[0033] The surface of each particle of Al-system metallic powder can be moistened by setting the content of the flux mixed with the Al-system metallic powder at from 0.01 to 20 mass % (not less than 0.01 mass % and not more than 20 mass %), more preferably 0.01 to 10 mass %, and as a result the above-described effect is produced. If the content is more than 20 mass %, excessive contraction occurs during sintering, which adversely affects the dimensional accuracy of the finished product.
[0034] Although it is preferred that the flux be removed by washing after the sintering process, it may not be fully removed and part of it may remain. If the content of the remaining flux is 5 mass % or less, the mechanical strength of the sintered porous body remains almost unaffected. When a chloride-based flux is used, the less content of residual chloride, the better. If the residual chloride content in the sintered porous body is around 0.01 mass %, more preferably around 0.001 mass %, effects on the base material (e.g. corrosion) can be virtually ignored. For these reasons, the sintered aluminum porous body contains from 0.001 to 5 mass % of at least one flux component selected from Na, Cl, K, F, and Ba.
[0035] In the case of sintering Al-system metallic powder by microwave irradiation, when the relative density of the porous body exceeds 80% with respect to the theoretical density of pure aluminum, microwaves are prevented from penetrating the porous body, which makes intensive heating in the surface region of each particle by a skin effect difficult. Therefore, the upper limit on the relative density of the porous body is set at 80%.
[0036] Meanwhile, effective methods for reducing the relative density of the porous body (i.e., increasing its porosity) include a spacer method. In the case of Al-system metallic powder, NaCl can be preferably used as a spacer material. The relative density of an aluminum porous body fabricated by means of a spacer method can be reduced down to around 5% (maximum porosity: around 95%). In other words, according to the present invention, the relative density of an aluminum porous body can be controlled from 5 to 80%.
[0037] In the case of heating metallic powder by microwave irradiation, the heating behavior is strongly affected by the output of microwaves, the method of irradiation, etc. Particularly when the so-called multimode oven is used as a microwave applicator, the heat produced in specimens to be heat-treated is small and may not reach the sintering temperature. In such a case, heat production can be promoted by mixing a powdered microwave absorber (e.g., C, SiC, FeO, Fe 2 O 3 , and Fe 3 O 4 ) in Al-system metallic powder. In this regard, however, adding too much of the microwave absorber rapidly increases the temperature and makes temperature control difficult. Therefore, it is preferred that the absorber content be 20 mass % or less.
[0038] On the other hand, when a single-mode oven is used as the microwave applicator, the specimens can be heated up to the sintering temperature without adding any powdered microwave absorber such as C, SiC, FeO, Fe 2 O 3 , and Fe 3 O 4 . However, adding around 0.1 mass % or more of a powdered microwave absorber increases the heating efficiency, and the Al-system metallic powder can be heated to the sintering temperature with less energy. Therefore, an aluminum porous body in accordance with the present invention preferably contains from 0.1 to 20 mass % of a microwave absorber such as C, SiC, FeO, Fe 2 O 3 , and Fe 3 O 4 .
[0039] FIG. 1 is a schematic view of microwave heating of an aluminum porous body in accordance with an embodiment of the present invention. The flux irradiated with a laser in RP partly melts and bonds the Al-system metallic powder particles. Then, as shown in FIG. 1 , while being heated to the sintering temperature by microwave irradiation, the flux melts and moistens the surfaces of the Al-system metallic powder particles, thereby effectively insulating the Al-system metallic powder particles from the atmosphere and preventing chemical reactions between them. As a result, the Al-system metallic powder particles can be sintered effectively.
[0040] As described above, according to the present invention, the mixture of Al-system metallic powder, an aluminum brazing flux powder, a powdered microwave absorber, and a spacer material as needed is irradiated with a laser so that the flux is melted and these powders can be provisionally shaped without pressure. In other words, they can be shaped by RP. This process is followed by a sintering process by the irradiation of electromagnetic waves (microwaves), thereby making it possible to fabricate an aluminum porous body having high dimensional accuracy and/or a complex structure in a short period of time.
[0041] Moreover, the aluminum porous body in accordance with the present invention can be used as an ultra-lightweight material, high-specific-rigidity material, energy-absorbing material, vibration-absorbing material, electromagnetic wave-absorbing material, sound-insulating material, sound-absorbing material, heat-insulating material, electrode material, filter material, heat-exchanger material, biomedical material, oil-impregnated bearing material, etc.
Examples
[0042] An embodiment of the present invention will be described hereinafter on the basis of an example. However, the present invention is not to be considered limited to this.
[0043] In the example, the inventors used pure Al powder and AC4B (Al—Si—Cu casting alloy) powder (each 150 μm or smaller in particle size) as Al-system metallic powder, AlF 3 (50 μm or smaller in particle size) as a fluoride-based flux, NaCl (500 μm or smaller in particle size) as a spacer material, and SiC (5 μm or smaller in particle size) as a microwave absorber. A powdered pure Al base material and a powdered AC4B base material were prepared by mixing these powders using a V-mixer such that each mixture contains 25 mass % of Al-system metallic powder, 3 mass % of the flux, 2 mass % of the microwave absorber, and 70 mass % of the spacer material.
[0044] Each powder mix was provisionally formed into a circular cylindrical shape having 10 mm of diameter and 10 mm of height (φ10×10) by RP. RP was performed under conditions that the laser power was 15 W (beam diameter: 0.4 mm), the laser scanning speed was 7.6 m/sec., and the stack pitch was 0.1 mm.
[0045] Next, each sample of φ10×10 provisionally formed by RP was irradiated with microwaves at a frequency of 2.45 GHz in a single-mode microwave oven. The sintering process was carried out in a nitrogen atmosphere while applying a magnetic field. The microwave output was controlled such that the sintering temperature for the powdered pure Al base material was 645° C. and the sintering temperature for the powdered AC4B base material was 570° C. The times to reach the sintering temperatures were measured. The holding times at the sintering temperatures were changed in the range of 5 to 30 minutes. For comparison, specimens were also fabricated by sintering preforms shaped in a similar way by electric-heater heating using a typical heating oven under the same conditions of sintering temperature and time. Each of the specimens was subjected to ultrasonic cleaning in water to remove the spacer material after the sintering process.
[0046] Relative density measurement and appearance inspection were conducted on each sample. The relative density of each sample was calculated with respect to the theoretical density of pure aluminum (2.7 g/cm 3 ) from the bulk density of the specimen measured on the basis of its size and weight. The added spacer material (NaCl) was assumed to have been eluted entirely by the ultrasonic cleaning. Also, the appearance of each specimen was evaluated visually. Table 1 shows the results of the experiment in which specimens provisionally shaped by RP were sintered by microwave heating and electric-heater heating.
[0000]
TABLE 1
Experimental Results
Time to Reach
Sintering
Holding
Relative
Temperature
Time
Density
Appear-
Preform
(min)
(min)
(%)
ance
Microwave
Powdered Pure
8
5
21
G
Heating
Al Base Material
10
22
G
30
23
R
Powdered AC4B
5
5
24
G
Base Material
10
24
G
30
23
R
Electric-
Powdered Pure
35
5
—
D
heater
Al Base Material
10
—
D
Heating
30
—
D
Powdered AC4B
27
5
17
R
Base Material
10
19
R
30
24
R
Evaluation of Appearance
G: Good,
R: Roughness or Shape Change, and
D: Degradation.
[0047] In the case of microwave heating, the time required for heating was short, and both of the powdered pure Al base material and the powdered AC4B base material could be heated to the target sintering temperature in 5 to 8 minutes. As a result of sintering the powder particles, porous bodies were fabricated. With either of the base materials, minor roughness (asperities) was observed partially on the surfaces of the specimens sintered for 30 minutes. However, there was little variation in relative density for different sintering times, and even with a short sintering time of 5 minutes, a nearly ideal relative density was obtained corresponding to the amount of the added NaCl spacer material.
[0048] In contrast, in the case of electric-heater heating, the time required to reach the target sintering temperature varied from 27 to 35 minutes, roughly 5 times the time of microwave heating. With the powdered pure Al base material, sintering was partly insufficient for either sintering time. Because the specimens degraded at the time of ultrasonic cleaning, relative densities could not be evaluated. With the powdered AC4B base material, significant roughness was observed for all the sintering times, and the shape itself changed when the sintering time is long. In the case of electric-heater heating, because temperature rising and cooling slow down due to the heat capacity of each specimen as a whole, the residence time at temperatures around the sintering temperature becomes long, and the surface of each specimen is heated most due to radiation heating, which was considered to have adversely affected the appearance and dimensional accuracy of the specimen.
[0049] These experimental results have demonstrated that an aluminum porous body having a high dimensional accuracy can be fabricated by heat treatment in a shorter time than ever.
[0050] Although the invention has been described with respect to the specific embodiments for complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art which fairly fall within the basic teaching herein set forth.
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It is an objective of the present invention to provide an aluminum porous body which is formed of a pure aluminum and/or aluminum alloy base material and has excellent sinterability and high dimensional accuracy without employing metal stamping. There is provided an aluminum porous body having a relative density of from 5 to 80% with respect to the theoretical density of pure aluminum, in which the aluminum porous body contains 50 mass % or more of aluminum (Al) and from 0.001 to 5 mass % of at least one selected from chlorine (Cl), sodium (Na), potassium (K), fluorine (F), and barium (Ba). It is preferred that the aluminum porous body further contains from 0.1 to 20 mass % of at least one selected from carbon (C), silicon carbide (SiC), iron (II) oxide (FeO), iron (III) oxide (Fe 2 O 3 ), and iron (II,III) oxide (Fe 3 O 4 ).
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[0001] “This application claims priority from copending provisional application Serial No. 60/314,584 filed on Aug. 24, 2001 the entire disclosure of which is hereby incorporated by reference.”
FIELD OF THE INVENTION
[0002] The present invention relates to a novel series of 5-(substituted)-5-(substitutedsulfonyl or sulfanyl)thiazolidine-2,4-diones, to pharmaceutical compositions containing them, to their use in cancer therapy and to a process for their preparation. The compounds inhibit Ras FPTase, and may be used as an alternative to, or in conjunction with, traditional cancer therapy for treating ras oncogene-dependent tumors, such as cancers of the pancreas, colon, bladder, and thyroid. Compounds in the invention may also be useful for controlling metastasis, suppressing angiogenesis, inducing apoptosis, and in treating Ras-associated proliferative diseases other than cancer, such as restenosis, neuro-fibromatosis, endometriosis, and psoriasis. These compounds may also inhibit prenylation of proteins other than Ras, and thus be effective in the treatment of diseases associated with other prenyl modifications of proteins.
BACKGROUND OF THE INVENTION
[0003] Mammalian H-, K-, and N-Ras proteins, encoded by H-, K-, and N-ras proto-oncogenes, respectively, are 21 kD GTP-binding proteins which possess intrinsic GTPase activity and play a fundamental role in cell proliferation and differentiation (G. L. Bolton, J. S. Sebolt-Leopold, and J. C. Hodges, Annu. Rep. Med. Chem., 1994, 29, 165; R. J. A. Grand in “New Molecular Targets in Cancer Chemotherapy” J. D. Kerr, and P. Workman, Eds., CRC Press, Boca Raton, Fla., 1994, p. 97). Specific mutations in the ras gene impair GTPase activity of Ras, leading to uninterrupted growth signals and to the transformation of normal cells into malignant phenotypes. Mutant ras oncogenes are found in approximately 25% of all human cancers, including 90% of pancreatic, 50% of colon, and 50% of thyroid tumors (J. L. Bos, Cancer Res., 1989, 49, 4682). It has been shown that normal cells transfected with mutant ras gene become cancerous and that unfarnesylated, cytosolic mutant Ras protein does not anchor in cell membranes and cannot induce this transformation (J. F. Hancock, H. Paterson, and C. J. Marshall, Cell, 1990, 63, 133). Posttranslational modification and plasma membrane association of mutant Ras is essential for this transforming activity. The first and required step in the processing of Ras is farnesylation at the cysteine residue of its carboxyl terminal motif, CAAX (C=Cys-186, A=aliphatic amino acid, X=usually methionine, serine or glutamine). Since its identification, the enzyme farnesyl-protein transferase (FPTase) that catalyzes this first processing step has emerged as a promising target for therapeutic intervention (H.-W. Park, S. R. Boduluri, J. F. Moomaw, P. J. Casey, and L. S. Beese, Science, 1997, 275,1800; P. J. Casey, P. A. Solski, C. J. Der, and J. E. Buss, Proc. Natl. Acad. Sci. U.S.A., 1989, 86, 8323; S. Ayral-Kaloustian and J. S. Skotnicki, Annu. Rep. Med. Chem., 1996, 31,165, and references therein). Major milestones have been achieved with small molecules, such as mimics of the tetrapeptide CAAX and analogs of farnesyl pyrophosphate, that show efficacy without toxicity in vitro as well as in mouse models bearing ras-dependent tumors or human xenografts with H-, N-, or K-ras mutations (S. Ayral-Kaloustian and J. S. Skotniciki, Annu. Rep. Med. Chem., 1996, 31,165, and references therein; T. M. Williams, Exp. Opin. Ther. Patents, 1998, 8, 553, and references therein). Several low-molecular weight compounds that inhibit FPTase have entered Phase I trials in humans (SCH-66336, Pharmaprojects, 1998, No. 5128; R-115777, Pharmaprojects, 1998, No. 5532).
[0004] 5-[3-aryl-prop-2-ynyl]-5-(arylsulfonyl)thiazolidine-2,4-diones and 5-[3-aryl-prop-2-ynyl]-5-(arylsulfanyl)thiazolidine-2,4-diones which possess antihyperglycemic activity, are reported in U.S. Pat. Nos. 5,574,051 and 5,605,918.
[0005] Accordingly, there is still a need for drugs for treating and preventing cancer. In particular, there is a need for drugs which inhibit or treat the growth of tumors expressing an activated Ras oncogene and which include cancers of the pancreas, colon, bladder and thyroid.
[0006] The present invention further provides a method of treatment of ras oncogene-dependent tumors, such as cancers of the pancreas, colon, bladder, and thyroid; a method of controlling metastasis, suppressing angiogenesis, and inducing apoptosis; a method of treating Ras-associated proliferative diseases other than cancer, such as restenosis, neuro-fibromatosis, endometriosis, and psoriasis. The compounds of the present invention may also inhibit prenylation of proteins other than Ras, and thus provide a method of treatment of diseases associated with other prenyl modifications of proteins.
SUMMARY OF THE INVENTION
[0007] The present invention discloses compounds represented by Formula (I):
[0008] wherein:
[0009] R 1 is hydrogen, —CH 2 —CO 2 R 9 , or —CH 2 —C(O)NHOR 10 ;
[0010] n is an integer of 0 or 2;
[0011] v is an integer of 1 to 3;
[0012] each R 2 is independently hydrogen, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkyl(1 to 12 carbon atoms)amino, di(alkyl of 1 to 12 carbon atoms)amino, monoaryl(6 to 12 carbon atoms)amino, alkyl(1 to 12 carbon atoms)aryl(6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkyl(3 to 7 carbon atoms)amino, di(cycloalkyl of 3 to 7 carbon atoms)amino, alkyl(1 to 12 carbon atoms)cycloalkyl(3 to 7 carbon atoms)amino, aryl(6 to 12 carbon atoms)cycloalkyl(3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl(1 to 12 carbon atoms), carboxyaryl(6 to 12 carbon atoms), carboxycycloalkyl(3 to 7 carbon atoms), formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino, cycloalkyl(3 to 7 carbon atoms)acylamino, aryl(6 to 12 carbon atoms)acylamino, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aminocarbonyloxy, aminocarbonylamino, or optionally when v is an integer of 1, the moiety
[0013] wherein the moiety
[0014] is aryl of 6 to 12 carbon atoms optionally substituted with 1 to 3 groups independently selected from alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aryloxy of 6 to 12 carbon atoms, perhaloaryl of 6 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms;
[0015] heteroaryl of 5 to 12 ring atoms optionally-substituted with 1 to 3 groups independently selected from alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino, cycloalkyl(3 to 7 carbon atoms)acylamino, aryl(6 to 12 carbon atoms)acylamino, nitro, perhaloalkyl of 1 to 12 carbon atoms, perhaloalkoxy of 1 to 12 carbon atoms, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, perhaloaryl(6 to 12 carbon atoms), perhaloaryl(6 to 12 carbon atoms)oxy and a moiety of the formula:
[0016] G is a single covalent bond, —O—, —S—, —SO—, —SO 2 —, —N—R 4 , —CH 2 —, —CHOR 4 , —CR 8 OR 4 , —C(OR 5 ) 2 , —CO—, —CS—, —C═N—R 6 or moieties of the formulae:
[0017] m is an integer of 2 to 4;
[0018] R 3 is aryl of 6 to 12 carbon atoms optionally substituted with 1 to 3 groups independently selected from alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aryloxy of 6 to 12 carbon atoms, perhaloaryl of 6 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms;
[0019] or heteroaryl of 5 to 12 ring atoms optionally substituted with 1 to 3 groups independently selected from alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino, cycloalkyl(3 to 7 carbon atoms)acylamino, aryl(6 to 12 carbon atoms)acylamino, nitro, perhaloalkyl of 1 to 12 carbon atoms, perhaloalkoxy of 1 to 12 carbon atoms, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, perhaloaryl(6 to 12 carbon atoms), perhaloaryl(6 to 12 carbon atoms)oxy;
[0020] R 4 is hydrogen, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms optionally substituted with 1 to 3 groups independently selected from substitutions include: alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aryloxy of 6 to 12 carbon atoms, perhaloaryl of 6 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms;
[0021] acyl of 1 to 12 carbon atoms, carboxyalkyl of 1 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, carboxyaryl of 6 to 12 carbon atoms wherein the aryl is optionally substituted with 1 to 3 groups independently selected from substitutions include: alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aryloxy of 6 to 12 carbon atoms, perhaloaryl of 6 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms; formyl, carbamyl, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)carboxyl, di(alkyl of 1 to 12 carbon atoms)carboxyl, monoaryl(6 to 12 carbon atoms)carboxyl, di(aryl 6 to 12 carbon atoms)carboxyl, monocycloalkyl(3 to 7 carbon atoms)carboxyl, di(cycloalkyl 3 to 7 carbon atoms)carboxyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carboxyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carboxyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms) carboxylperfluoroaryl, monoalkyl(1 to 12 carbon atoms)thiocarbamyl, di(alkyl of 1 to 12 carbon atoms)thiocarbamyl, monoaryl(6 to 12 carbon atoms)thiocarbamyl, di(aryl 6 to 12 carbon atoms)thiocarbamyl, monocycloalkyl(3 to 7 carbon atoms)thiocarbamyl, di(cycloalkyl 3 to 7 carbon atoms)thiocarbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)thiocarbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms) thiocarbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)thiocarbamyl; heteroaryl of 5 to 12 ring atoms optionally substituted with 1 to 3 groups independently selected alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino, cycloalkyl(3 to 7 carbon atoms)acylamino, aryl(6 to 12 carbon atoms)acylamino, nitro, perhaloalkyl of 1 to 12 carbon atoms, perhaloalkoxy of 1 to 12 carbon atoms, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, perhaloaryl(6 to 12 carbon atoms), perhaloaryl(6 to 12 carbon atoms)oxy;
[0022] R 5 is alkyl of 1 to 12 carbon atoms;
[0023] R 6 is alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, di(alkyl of 1 to 12 carbon atoms)amino, monoarylamino of 6 to 12 carbon atoms, alkyl(of 1 to 12 carbon atoms)aryl(of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, alkyl(of 1 to 12 carbon atoms)cycloalkyl(of 3 to 7 carbon atoms)amino, aryl(of 6 to 12 carbon atoms)cycloalkyl(of 3 to 7 carbon atoms)amino, arylsulfamoyl of 6 to 12 carbon atoms;
[0024] R 7 is alkyl of 1 to 12 carbon atoms;
[0025] R 8 is alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 atoms and phenyl;
[0026] R 9 is hydrogen or alkyl of 1 to 6 carbon atoms;
[0027] R 10 is hydrogen or benzyl optionally substituted with nitro; and
[0028] the pharmacologically acceptable salts thereof.
[0029] Among the preferred compounds of Formula (I) of this invention are those in the subgroups, and pharmaceutically acceptable salts thereof:
[0030] a. R 3 is aryl; R 1 is H; and v is an integer of 1;
[0031] b. R 3 is aryl; R 1 is H; v is an integer of 1 and R 2 is a moiety
[0032] d. R 3 is aryl; v is an integer of 1; R 2 is the moiety
[0033] is heteroaryl optionally substituted with 1 to 3 groups independently selected.
[0034] e. R 3 is aryl; v is an integer of 1; R 2 is the moiety
[0035] is aryl optionally substituted with 1 to 3 groups independently selected.
[0036] Among the most particularly preferred compounds of this invention according to general Formula (I) are the following compounds or pharmaceutically acceptable salts thereof for treating or controlling ras oncogene-dependent tumors and associated proliferative diseases in warm-blooded animals preferably mammals, most preferably humans in need thereof are the following compounds or a pharmaceutically acceptable salt thereof:
[0037] 5-(4-[2-(5-Methyl-2-phenyloxazol-4-yl)ethoxy]benzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione,
[0038] 5-(4-Bromo-2-fluorobenzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione,
[0039] 5-(3,4-Dichlorobenzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione,
[0040] 5-(4-Bromo-2-fluorobenzyl)-5-(naphthalene-2-sulfonyl)thiazolidine-2,4-dione,
[0041] 5-(4-[2-(5-Methyl-2-phenyloxazol-4-yl)ethoxy]benzyl)-5-(naphthalene-2-sulfonyl)thiazolidine-2,4-dione,
[0042] 5-Benzyl-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione,
[0043] 2-[5-Benzyl-5-(4-methoxybenzenesulfonyl)-2,4-dioxothiazolidin-3-yl]-N-hydroxyacetamide,
[0044] 5-(3-[2-(4-Methoxyphenyl)[1,3]dioxolan-2-yl]benzyl)-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione,
[0045] 5-(3-[2-(4-Methoxyphenyl)[1,3]dioxolan-2-yl]benzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione,
[0046] 5-(3-(4-methoxybenzoyl)benzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione,
[0047] 5-(3-(4-methoxybenzoyl)benzyl)-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione,
[0048] 5-(3-[Hydroxy(4-methoxyphenyl)methyl]-benzyl)-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione,
[0049] 5-(4-Bromobenzyl-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione,
[0050] 5-[2′-cyanobiphen-4-ylmethyl]-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione,
[0051] 5-[2′-(1H-Tetrazol-5-yl)biphen-4-ylmethyl]-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione,
[0052] 5-[2′-cyanobiphen-4-ylmethyl]-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione,
[0053] 5-[3-(4-Methoxybenzyl)benzyl]-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione,
[0054] 5-[3-(2-Thiophen-2-yl[1,3]dioxolan-2-yl)benzyl]-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione,
[0055] 5-[3-(Thiophene-2-carbonyl)benzyl]-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione,
[0056] 5-Biphen-4-ylmethyl-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione,
[0057] 5-(4′-Chlorobiphen-4-ylmethyl)-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione,
[0058] 5-(4-Methoxybenzenesulfonyl)-5-(3′-(trifluoromethyl)biphen-4-ylmethyl)thiazolidine-2,4-dione,
[0059] 5-(3′,5′-Bis(trifluoromethyl)biphen-4-ylmethyl)-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione,
[0060] 5-(2′,4′-Dichlorobiphen-4-ylmethyl)-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione,
[0061] 5-[3-(3-Chlorophenoxy)benzyl]-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione,
[0062] 5-[3-(2-thiophen-2-yl[1,3]dioxolan-2-yl)benzyl]-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione and
[0063] 2-[5-Benzyl-5-(4-methoxybenzenesulfonyl)2,4-dioxothiazolidin-3-yl]-acetic acid.
[0064] For the compounds defined above and referred to herein, unless otherwise noted, the following terms are explained.
[0065] “Halogen”, as used herein means chloro, fluoro, bromo and iodo.
[0066] “Acyl” is the moiety —C(O)-alkyl of 1 to 12 carbon atoms.
[0067] “Alkyl” as used herein means a branched or straight chain having from 1 to 12 carbon atoms and more preferably from 1 to 6 carbon atoms. One or more of the carbon atoms may optionally be independently substituted with halogen optionally forming perfluoroalkyl. Exemplary alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, pentyl and hexyl. Exemplary groups include trifluoromethyl.
[0068] “Alkenyl” as used herein means a branched or straight chain having from 2 to 12 carbon atoms and more preferably from 2 to 6 carbon atoms, the chain containing at least one carbon-carbon double bond. Alkenyl, may be used synonymously with the term olefin and includes alkylidenes. Exemplary alkenyl groups include ethylene, propylene and isobutylene.
[0069] “Alkoxy” as used herein means an alkyl-O group in which the alkyl group is as previously described. Exemplary alkoxy groups include methoxy, ethoxy, n-propoxy, i-propoxy, n-butoxy, and t-butoxy.
[0070] “Aryloxy” as used herein means an aryl-O group in which the aryl group is as previously described.
[0071] “Cycloalkyl” as used herein means a saturated ring having from 3 to 7 carbon atoms and more preferably from 3 to 6 carbon atoms. One or more of the carbon atoms may optionally be independently substituted with halogen optionally forming perfluorocycloalkyl. Exemplary cycloalkyl rings include cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl.
[0072] “Cycloalkoxy” as used herein means a cycloalkyl-O-group in which the cycloalkyl group is as previously defined.
[0073] “Carbamyl” is the moiety —C(O)NH 2 .
[0074] “Aminocarbonyloxy” as used herein means the groups —N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms)C(O)O-alkyl of 1 to 12 carbon atoms, —N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms)C(O)O-cycloalkyl of 3 to 7 carbon atoms, or —N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms)C(O)O-aryl of 6 to 12 carbon atoms.
[0075] “Aminocarbonylamino” as used herein means the groups —N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms)C(O)N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms) (H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms), —N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms)C(O)N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms) alkyl of 1 to 12 carbon atoms, —N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms)C(O)N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms) aryl of 6 to 12 carbon atoms, or —N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms)C(O)N(H, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms or aryl of 6 to 12 carbon atoms)cycloalkyl.
[0076] Aryl is defined as an optionally mono, di or tri-substituted aromatic hydrocarbon moiety having 6 to 12 ring atoms. Exemplary aryl groups include: phenyl, α-naphthyl, β-naphthyl, biphenyl, anthryl, tetrahydronaphthyl, phenanthryl, fluorenyl, and indanyl. Arylalkyl is an aryl substituted alkyl moiety wherein the alkyl chain is 1-6 carbon atoms (straight or branched). Arylalkyl moieties include benzyl, 1-phenylethyl, 2-phenylethyl, 3-phenylpropyl, 2-phenylpropyl and the like. Optional independently selected mono, di or tri-substitutions include: alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aryloxy of 6 to 12 carbon atoms, perhaloaryl of 6 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms.
[0077] Heteroaryl is defined as an optionally independently selected mono, di or tri-substituted aromatic heterocyclic ring system (monocyclic or bicyclic) having 5 to 12 ring atoms and from 1 to 4 heteroatoms independently selected from nitrogen, oxygen and sulfur. Preferred heteroaryl moieties are elected from: (1) furan, thiophene, indole, azaindole, oxazole, thiazole, isoxazole, isothiazole, imidazole, N-alkylimidazole, pyridine, pyrimidine, pyrazine, pyrrole, N-alkylpyrrole, pyrazole, N-alkylpyrazole, benzoxazole, benzothiazole, benzofuran, benzisoxazole, benzisothiazole, benzimidazole, N-alkylbenzimidazole, indazole, quinazoline, quinoline, and isoquinoline; (2) a bicyclic aromatic heterocycle where a phenyl, pyridine, pyrimidine or pyridizine ring is: (1) fused to a 6-membered aromatic (unsaturated) heterocyclic ring having one nitrogen atom; (2) fused to a 5 or 6-membered aromatic (unsaturated) heterocyclic ring having two nitrogen atoms; (3) fused to a 5-membered aromatic (unsaturated) heterocyclic ring having one nitrogen atom together with either one oxygen or one sulfur atom; or (4) fused to a 5-membered aromatic (unsaturated) heterocyclic ring having one heteroatom selected from O, N or S. Optional independently selected mono, di or tri-substitutions include: alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino, cycloalkyl(3 to 7 carbon atoms)acylamino, aryl(6 to 12 carbon atoms)acylamino, nitro, perhaloalkyl of 1 to 12 carbon atoms, perhaloalkoxy of 1 to 12 carbon atoms, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7-carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, perhaloaryl(6 to 12 carbon atoms), perhaloaryl(6 to 12 carbon atoms)oxy.
[0078] “Phenyl” as used herein refers to a 6-membered aromatic ring.
[0079] “Sulfamoyl” as used herein refers to —SONH 2 .
[0080] “sulfo” as used herein refers to —SO 3 H.
[0081] Carbon number refers to the number of carbons in the carbon backbone and does not include carbon atoms occurring in substituents.
[0082] Where terms are used in combination, the definition for each individual part of the combination applies unless defined otherwise. For instance, perhaloalkoxy refers to an alkoxy group, as defined above, in which each hydrogen atom of the alkyl group has been replaced by a halogen. Further, perfluoroaryl refers to an aryl group as defined above in which each hydrogen of the aryl group has been replaced by a halogen.
[0083] It is understood by those practicing the art that the definition of compounds of Formula (I) when R 1 , R 2 , R 3 , R 4 , R 5 , R 6 and R 7 contain asymmetric carbons, encompass all possible stereoisomers, mixtures and regioisomers thereof which possess the activity discussed below. Such regioisomers may be obtained pure by standard separation methods known to those skilled in the art. In particular, the definition encompasses any optical isomers and diastereomers as well as the racemic and resolved enantiomerically pure R and S stereoisomers as well as other mixtures of the R and S stereoisomers and pharmaceutically acceptable salts thereof, which possess the activity discussed below. Optical isomers may be obtained in pure form by standard separation techniques or enantiomer specific synthesis. It is understood that this invention encompasses all crystalline forms of compounds of Formula (I). The compounds of the present invention can be used in the form of salts derived from pharmaceutically or physiologically acceptable acids or bases. These salts include, but are not limited to, the following: salts with inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid and, as the case may be, such organic acids as acetic acid, oxalic acid, succinic acid, and maleic acid. Other salts include salts with alkali metals or alkaline earth metals, such as sodium, potassium, calcium or magnesium or with organic bases. The compounds can also be used in the form of esters, carbamates and other conventional pro-drug forms, which, when administered in such form, convert to the active moiety in vivo.
[0084] The present invention accordingly provides a pharmaceutical composition which comprises a compound of Formula (I) of this invention in combination or association with a pharmaceutically acceptable carrier. In particular, the present invention provides a pharmaceutical composition which comprises an effective amount of a compound of this invention and a pharmaceutically acceptable carrier.
[0085] Additionally, this invention provides a method of treatment, by administration of an effective amount of compounds of Formula (I), of ras oncogene-dependent tumors, which include cancers of the pancreas, colon, bladder, and thyroid; a method of controlling metastasis, suppressing angiogenesis, and inducing apoptosis; a method of treating Ras-associated proliferative diseases other than cancer, which include restenosis, neuro-fibromatosis, endometriosis, and psoriasis The compounds of Formula (I) may also inhibit prenylation of proteins other than Ras, and thus provide a method of treatment of diseases associated with other prenyl modifications of proteins.
[0086] The compounds of Formula (I) inhibit farnesyl-protein transferase and the farnesylation of the oncogene protein Ras. Thus, this invention further provides a method of inhibiting farnesyl protein transferase, (e.g., Ras farnesyl protein transferase) in mammals, especially humans, by the administration of an effective amount of the compounds of Formula (I). The administration of the compounds of this invention to patients, to inhibit farnesyl protein transferase, is useful in the treatment of the cancers and other diseases described below.
[0087] This invention provides a method for inhibiting or treating the abnormal growth of cells, including transformed cells by administering an effective amount of a compound of Formula (I). Abnormal growth of cells refers to cell growth independent of normal regulatory mechanisms (e.g., loss of contact inhibition). This includes abnormal growth of tumor cells (tumors) expressing an activated Ras oncogene; tumor cells in which the Ras protein is activated as a result of oncogenic mutation in another gene; and benign and malignant cells of other proliferative diseases in which aberrant Ras activation occurs.
[0088] This invention also provides a method for inhibiting or treating tumor growth by administering an effective amount of a compound of Formula (I), described herein, to a mammal (e.g., a human) in need of such treatment. In particular, this invention provides a method for inhibiting or treating the growth of tumors expressing an activated Ras oncogene by administration of an effective amount of a compound of Formula (I). Examples of tumors which may be inhibited or treated include, but are not limited to, lung cancer (e.g., lung adenocarcinoma), pancreatic cancers (e.g., pancreatic carcinoma such as, for example, exocrine pancreatic carcinoma), colon cancers (e.g., colorectal carcinomas, such as, for example, colon adenocarcinoma and colon adenoma), myeloid leukemias (for example, acute myelogenous leukemia (AML)), thyroid follicular cancer, myelodysplastic syndrome (MDS), bladder carcinoma, epidermal carcinoma, breast cancer and prostate cancer.
[0089] This invention also provides a method for inhibiting or treating proliferative diseases, both benign and malignant, wherein Ras proteins are aberrantly activated as a result of oncogenic mutation in other genes-i.e., the Ras gene itself is not activated by mutation to an oncogenic form-with said inhibition or treatment being accomplished by the administration of an effective amount of a compound of Formula (I), to a mammal (e.g., a human) in need of such treatment. For example, the benign proliferative disorder neurofibromatosis, or tumors in which Ras is activated due to mutation or overexpression of tyrosine kinase oncogenes (e.g., neu, src, abl, Ick, and fyn), may be inhibited or treated by the compounds of Formula (I).
[0090] Additionally, this invention provides a method of inhibition or treating the abnormal growth of cells, by administration of an effective amount of compounds of Formula (I), of ras-oncogene-dependent tumors, which tumors include cancers of the pancreas, colon, bladder, and thyroid. Without wishing to be bound by theory, these compounds may function through the inhibition of G-protein function, such as ras p21, by blocking G-protein isoprenylation, thus making them useful in the treatment of proliferative diseases such as tumor growth and cancer. Without wishing to be bound by theory, the compounds of Formula (I) inhibit Ras farnesyl-protein transferase, and thus antiproliferative activity of ras-transformed cells and other prenyl modifications of proteins.
[0091] In another aspect, the invention provides a process for the preparation of a compound of Formula (I):
[0092] wherein:
[0093] R 1 is hydrogen;
[0094] n is an integer of 0 or 2;
[0095] v is an integer of 1 to 3; each R 2 is independently hydrogen, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkyl(1 to 12 carbon atoms)amino, di(alkyl of 1 to 12 carbon atoms)amino, monoaryl(6 to 12 carbon atoms)amino, alkyl(1 to 12 carbon atoms)aryl(6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkyl(3 to 7 carbon atoms)amino, di(cycloalkyl of 3 to 7 carbon atoms)amino, alkyl(1 to 12 carbon atoms)cycloalkyl(3 to 7 carbon atoms)amino, aryl(6 to 12 carbon atoms)cycloalkyl(3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl(1 to 12 carbon atoms), carboxyaryl(6 to 12 carbon atoms), carboxycycloalkyl(3 to 7 carbon atoms), formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino, cycloalkyl(3 to 7 carbon atoms)acylamino, aryl(6 to 12 carbon atoms)acylamino, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aminocarbonyloxy, aminocarbonylamino, or optionally when v is an integer of 1, the moiety
[0096] wherein the moiety
[0097] is aryl of 6 to 12 carbon atoms optionally substituted with 1 to 3 groups independently selected from alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aryloxy of 6 to 12 carbon atoms, perhaloaryl of 6 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms;
[0098] heteroaryl of 5 to 12 ring atoms optionally substituted with 1 to 3 groups independently selected from alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino, cycloalkyl(3 to 7 carbon atoms)acylamino, aryl(6 to 12 carbon atoms)acylamino, nitro, perhaloalkyl of 1 to 12 carbon atoms, perhaloalkoxy of 1 to 12 carbon atoms, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon-atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, perhaloaryl(6 to 12 carbon atoms), perhaloaryl(6 to 12 carbon atoms)oxy and a moiety of the formula:
[0099] G is a single covalent bond, —O—, —S—, —SO—, —SO 2 —, —N—R 4 , —CH 2 —, —CHOR 4 , —CR 8 OR 4 , —C(OR 5 ) 2 , —CO—, —CS—, —C═N—R 6 or moieties of the formulae:
[0100] m is an integer of 2 to 4;
[0101] R 3 is aryl of 6 to 12 carbon atoms optionally substituted with 1 to 3 groups independently selected from alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aryloxy of 6 to 12 carbon atoms, perhaloaryl of 6 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms;
[0102] or heteroaryl of 5 to 12 ring atoms optionally substituted with 1 to 3 groups independently selected from alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino, cycloalkyl(3 to 7 carbon atoms)acylamino, aryl(6 to 12 carbon atoms)acylamino, nitro, perhaloalkyl of 1 to 12 carbon atoms, perhaloalkoxy of 1 to 12 carbon atoms, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, perhaloaryl(6 to 12 carbon atoms), perhaloaryl(6 to 12 carbon atoms)oxy;
[0103] R 4 is hydrogen, alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms optionally substituted with 1 to 3 groups independently selected from substitutions include: alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon-atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aryloxy of 6 to 12 carbon atoms, perhaloaryl of 6 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms;
[0104] acyl of 1 to 12 carbon atoms, carboxyalkyl of 1 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, carboxyaryl of 6 to 12 carbon atoms wherein the aryl is optionally substituted with 1 to 3 groups independently selected from substitutions include: alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, sulfo, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3-to 7 carbon atoms)aryl(6 to 12 carbon-atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, aryloxy of 6 to 12 carbon atoms, perhaloaryl of 6 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms; formyl, carbamyl, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)carboxyl, di(alkyl of 1 to 12 carbon atoms)carboxyl, monoaryl(6 to 12 carbon atoms)carboxyl, di(aryl 6 to 12 carbon atoms)carboxyl, monocycloalkyl(3 to 7 carbon atoms)carboxyl, di(cycloalkyl 3 to 7 carbon atoms)carboxyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carboxyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carboxyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms) carboxylperfluoroaryl, monoalkyl(1 to 12 carbon atoms)thiocarbamyl, di(alkyl of 1 to 12 carbon atoms)thiocarbamyl, monoaryl(6 to 12 carbon atoms)thiocarbamyl, di(aryl 6 to 12 carbon atoms)thiocarbamyl, monocycloalkyl(3 to 7 carbon atoms)thiocarbamyl, di(cycloalkyl 3 to 7 carbon atoms)thiocarbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)thiocarbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms) thiocarbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)thiocarbamyl; heteroaryl of 5 to 12 ring atoms optionally substituted with 1 to 3 groups independently selected alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, dialkylamino of 1 to 12 carbon atoms, monoarylamino of 6 to 12 carbon atoms, (alkyl of 1 to 12 carbon atoms)(aryl of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, (alkyl of 1 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, (aryl of 6 to 12 carbon atoms)(cycloalkyl of 3 to 7 carbon atoms)amino, mercapto, alkylthio of 1 to 12 carbon atoms, cycloalkylthio of 3 to 7 carbon atoms, arylthio of 6 to 12 carbon atoms, acyl of 1 to 12 carbon atoms, carboxyl, carboxyalkyl of 1 to 12 carbon atoms, carboxyaryl of 6 to 12 carbon atoms, carboxycycloalkyl of 3 to 7 carbon atoms, formyl, acyloxy of 1 to 12 carbon atoms, cyano, alkyl(1 to 12 carbon atoms)carbonyldioxy, aryl(6 to 12 carbon atoms)carbonyldioxy, cycloalkyl(3 to 7 carbon atoms)carbonyldioxy, carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino, cycloalkyl(3 to 7 carbon atoms)acylamino, aryl(6 to 12 carbon atoms)acylamino, nitro, perhaloalkyl of 1 to 12 carbon atoms, perhaloalkoxy of 1 to 12 carbon atoms, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, acylamino of 1 to 12 carbon atoms, alkyl(1 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, cycloalkyl(3 to 7 carbon atoms)acylamino of 1 to 12 carbon atoms, aryl(6 to 12 carbon atoms)acylamino of 1 to 12 carbon atoms, nitro, monoalkyl(1 to 12 carbon atoms)carbamyl, di(alkyl of 1 to 12 carbon atoms)carbamyl, monoaryl(6 to 12 carbon atoms)carbamyl, di(aryl of 6 to 12 carbon atoms)carbamyl, monocycloalkyl(3 to 7 carbon atoms)carbamyl, di(cycloalkyl of 3 to 7 carbon atoms)carbamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)carbamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)carbamyl, monoalkyl(1 to 12 carbon atoms)sulfamyl, di(alkyl of 1 to 12 carbon atoms)sulfamyl, monoaryl(6 to 12 carbon atoms)sulfamyl, di(aryl of 6 to 12 carbon atoms)sulfamyl, monocycloalkyl(3 to 7 carbon atoms)sulfamyl, di(cycloalkyl of 3 to 7 carbon atoms)sulfamyl, aryl(6 to 12 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, cycloalkyl(3 to 7 carbon atoms)alkyl(1 to 12 carbon atoms)sulfamyl, or cycloalkyl(3 to 7 carbon atoms)aryl(6 to 12 carbon atoms)sulfamyl, perhaloaryl(6 to 12 carbon atoms), perhaloaryl(6 to 12 carbon atoms)oxy;
[0105] R 5 is alkyl of 1 to −12 carbon atoms;
[0106] R 6 is alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 carbon atoms, aryl of 6 to 12 carbon atoms, alkoxy of 1 to 12 carbon atoms, cycloalkoxy of 3 to 7 carbon atoms, aryloxy of 6 to 12 carbon atoms, hydroxy, halo, amino, monoalkylamino of 1 to 12 carbon atoms, di(alkyl of 1 to 12 carbon atoms)amino, monoarylamino of 6 to 12 carbon atoms, alkyl(of 1 to 12 carbon atoms)aryl(of 6 to 12 carbon atoms)amino, di(aryl of 6 to 12 carbon atoms)amino, monocycloalkylamino of 3 to 7 carbon atoms, di(cycloalkyl of 3 to 7 carbon atoms)amino, alkyl(of 1 to 12 carbon atoms)cycloalkyl(of 3 to 7 carbon atoms)amino, aryl(of 6 to 12 carbon atoms)cycloalkyl(of 3 to 7 carbon atoms)amino, arylsulfamoyl of 6 to 12 carbon atoms;
[0107] R 7 is alkyl of 1 to 12 carbon atoms;
[0108] R 8 is alkyl of 1 to 12 carbon atoms, cycloalkyl of 3 to 7 atoms and phenyl; and
[0109] the pharmacologically acceptable salts thereof,
[0110] comprising:
[0111] a) reacting a compound of the formula
[0112] wherein R 3 and n are as defined above with a compound of formula
[0113] wherein R 2 and v are as defined above, and Z is a leaving group, preferably chloro, bromo, iodo, alkylsulfonyloxy of 1 to 10 carbon atoms, perfluoroalkylsulfonyloxy of 1 to 10 carbon atoms and phenylsulfonyloxy optionally substituted with from 1 to 3 substituents independently selected from halogen, alkyl of 1 to 10 carbon atoms, alkoxy of 1 to 10 carbon atoms, nitro and cyano in the presence of a base in an aprotic solvent to give a compound of Formula (I) and
[0114] b) optionally converting a compound of formula (I) to a pharmaceutically acceptable salt.
DETAILED DESCRIPTION OF THE INVENTION
[0115] Synthesis:
[0116] Compounds of this invention are prepared according to the procedures described in the schemes below:
[0117] Refering to Scheme I, 5-bromothiazolidine-2,4-dione 1 (Zask, A., Jirkovsky, I., Nowicki, J. W., McCaleb, M. L. J. Med. Chem. 1990, 33,1418-1423) is allowed to react with an alkali metal anion of a thiol 2 where M is an alkali metal to give a 5-substituted-sulfanylthiazolidine-2,4-dione 3. Deprotonation of 5-substituted-sulfanylthiazolidine-2,4-dione 3 with two or more equivalents of a strong base such as lithium hexamethyldisilazide in an aprotic solvent such as N,N-dimethylformamide or tetrahydrofuran followed by the addition of an appropriate benzylic halide or sulfonate ester 4 where LG is a leaving group which includes halogen and p-toluenesulfonate provides the 5-substituted-sulfanyl-5-phenylmethylthiazolidine-2,4-diones 5. Selective oxidation of 5-substituted-sulfanyl-5-phenylmethylthiazolidine-2,4-diones 5 with a 2:1:1 mixture of potassium peroxymonosulfate (KHSO 5 ), potassium hydrogen sulfate (KHSO 4 ), and potassium sulfate K 2 SO 4 in a low molecular weight alcohol solvent such as methanol provides the corresponding 5-substituted-sulfonyl-5 phenylmethylthiazolidine-2,4-diones 6.
[0118] Refering to Scheme II, 5-bromothiazolidine-2,4-dione 1 is combined with one or more equivalents of an alkali metal arylsulfinate salt 7 where M is an alkali metal, in a polar, aprotic solvent such as tetrahydrofuran or N,N-dimethylformamide or a protic solvent such as a low molecular weight alcohol or water to provide the 5-substituted-sulfonylthiazolidine-2,4-diones 8. Deprotonation of 5-substituted-sulfonylthiazolidine-2,4-diones 8 with two or more equivalents of a strong base such as lithium hexamethyldisilazide in an aprotic solvent such as N,N-dimethylformamide (DMF)or tetrahydrofuran (THF) followed by the addition of an appropriate benzylic halide 4 where the leaving group (LG) is halo provides the 5-substituted-sulfonyl-5-phenylmethylthiazolidine-2,4-diones 6. Alkali metal arylsulfinate salts such as 7 where R 3 is hereinbefore defined, may be prepared for example from the corresponding readily available arylsulfonyl chlorides by treatment with sodium iodide in acetone (Harwood, L. M., Julia, M., Le Thuillier, G. Tetrahedron 1980, 36, 2483-2487).
[0119] Refering to Scheme III, benzylic halides 4 where LG is a halide leaving group and which are not commercially available may be synthesized by benzylic halogenation of the corresponding toluene derivative 9 where v is an integer of 1 to 3 and R 2 is hereinbefore defined. For example, treatment of toluene derivative 9 with one or more equivalents of N-bromosuccinimide, a catalytic amount of benzoyl peroxide and light in an inert solvent such as carbon tetrachloride provides the benzylic bromide 4 (LG=Br). Alternatively an oxygenated derivative 10 in which A is an aldehyde, carboxylic acid or carboxylic ester can be reduced to the corresponding benzylic alcohol 11 by methods standard in the art which include but not limited to sodium borohydride in ethanol, lithium aluminum hydride in THF or dioxane, and borane in tetrahydrofuran. Commercially available or synthesized benzylic alcohol 11 can be converted to an appropriate sulfonate ester 4 where LG=—OSO 2 alkyl of 1 to 12 carbon atoms or methyl substituted phenyl, by treatment with the corresponding sulfonyl chloride and a tertiary amine base such as triethylamine in a nonprotic solvent such as dichloromethane. The benzylic alcohols 11 can also be converted to the corresponding benzylic halides 4 (LG=Br) by treatment with carbon tetrabromide and triphenylphosphine in a nonreactive solvent such as tetrahydrofuran.
[0120] The preparation of benzylic halides 17 where G is
[0121] and (R 2 ) v with v=1 is
[0122] is shown in Scheme IV. Reaction of starting reagents 12 which are commercially available or readily available through literature synthesis and which include but are not limited to substituted and unsubstituted benzene, pyridine, thiophene, furan, quinoline and benzoxazole with metharylcarboxylic acid chloride 13 where G is —CO— in the presence of a Lewis acid catalyst such as aluminum chloride in an unreactive solvent such as dichloromethane or 1,2-dichloromethane to provide ketone 14. Reaction of ketone 14 with a 1,2-diol 15 where R 5 is hereinbefore defined by methods standard in the art provides ketal 16 which may be further brominated to give benzylic halide 17 which may then be added to 5-substituted-sulfanylthiazolidine-2,4-dione 3 using methods described in Scheme i.
[0123] The preparation of analogs of ketone 14, not accessible via the Friedel-Crafts chemistry of Scheme IV are prepared using an alternative approach as shown in Scheme V. N-methoxy-N-methyl amides 19 of methylarylcarboxylic acids 18 are prepared by treating an appropriate activated derivative of the acid such as an acid chloride with N,O-dimethylhydroxylamine. Aryl or heteroaryl halides 20 (X′=Br, I) can be converted into an aryl or heteroarylmetal derivative 21 (M=Li, Mg) by metallation or halogen-metal exchange. Reaction of aryl or heteroarylmetal derivative 21 with N-methoxy-N-methyl amides 19 in an etherial solvent such as tetrahydrofuran affords, after acidification, ketones 14 (Nahm, S., Weinreb, S. M. Tetrahedron Lett., 1981, 22, 3815-3818). Ketone 14 may be brominated to afford benzylic halides 22 using methods as described in Scheme III and then may be added to 5-substituted-sulfanylthiazolidine-2,4-dione 3 using the methods described in Scheme I.
[0124] It will be appreciated that -G- as defined herein may undergo further chemical transformations. It will be further understood by those skilled in the art of organic synthesis that the various functionalities present on the molecule must be consistent with the chemical transformations proposed. This will frequently necessitate judgement as to the order of synthetic steps, protecting groups, if required, and deprotection conditions. Substituents which are compatible with the reaction conditions will be apparent to one skilled in the art. Additionally it will be further understood that chemical manipulations of -G- may best be performed on intermediates which include 14, rather than on the compounds of Formula (I). However, those skilled in the art may determine that a particular chemical transformation may best be performed on compounds of Formula (I). Specific non-limiting chemical transformations include:
[0125] a. when -G- is a carbonyl group (—C(O)—): reduction with NaBH 4 to an alcohol; reductive amination (for example NHC 2 H 5 /Na(CN)BH 3 ) to give a primary, secondary or tertiary amine; conversion to a thiocarbonyl with P 2 S 5 ; conversion to an imine (for example butylNH 2 /p-toluenesulfonic acid/molecular sieves); nucleophilic addition of an organometallic reagent (for example CH 3 MgBr, butylLi, phenylMgBr, or phenylLi); and conversion to an acetal (for example CH 3 OH/p-toluenesulfonic acid/molecular sieves); further chemical manipulations include:
[0126] b. when -G- is for example —C(H)(OH)— or —C(butyl)(OH): alkylation or acylation of the oxygen (for example butylBr or CH 3 COCl); reduction to a methylene group
[0127] c. —CH 2 — (for example trifluroacetic acid/triethylsilane); and when -G- is
[0128] d. —C(H)(NHbutyl): alkylation or acylation of the nitrogen (for example butylBr or CH 3 COCl), and conversion of the amine to a carbamate, urea, or thiourea (for example C 2 H 5 OCOCl. C 2 H 5 NCO, or C 2 H 5 NCS).
[0129] As shown in Scheme VI, 5-substituted-sulfonyl-5-phenylmethylthiazolidine-2,4-diones 6 may be alkylated with R 1 Br where R 1 is hereinbefore defined provided R 1 is not H using bases such as potassium carbonate, sodium hydride in acetone, THF or DMF affords N-substituted derivative 23. For example, in the case where R 1 is —CH 2 —C(O)—OR 9 and R 9 is alkyl of 1 to 6 carbon atoms, base hydrolysis affords acid 24. Reaction of acid 24 with 1-hydroxybenzotriazole (HOBT) and 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (DAEC) affords benzyl substituted 25 which may be reduced with H 2 , Pd/C to afford hydroxyl amine 26.
Standard Pharmacological Test Procedures
[0130] The ability of the compounds of this invention to inhibit FPTase was evaluated in the standard pharmacological in vitro test procedures described below. Data for representative examples is summarized in Table I.
[0131] Enzyme assay: FPTase inhibition in vitro assay was performed according to James, G. L., Brown, M. S., and Goldstein, J. L., Methods in Enzymology, 1995, 255, 38-46; and Garcia, M. A., et al., J. Biol. Chem., 1993, 268,18415-18420.
[0132] Materials—Purified FPTase (Moomaw, J. F. and Casey, P. J., J. Biol. Chem., 1992, 267, 17438-17443), purified His 6 -Ras, inhibitor compounds at 10 mg/ml or 10 mM in 100% DMSO, 3 H-FPP (50,000 dpm/pmol) Amersham, TCA/SDS (6%/2%), TCA (6%), Glass fiber filters (0.22-0.45 m), vacuum manifold or 96 well filtration plates.
[0133] Methods—1. Dilute FPTase inhibitors from stock solutions to 2.5×in 2.5% DMSO, 10 mM DTT, 0.5% octyl-B-glucoside. 2. Solution #1 is added to FPTase reaction in a volume of 20 ml. 3. Standard reaction mix, 50 ml, contains 50 mM Tris (7.5),10 mM ZnCl2, 3 mM MgCl2, 20 mM KCl, 5 mM DTT, 0.2% octyl-B-glucoside, 1% DMSO, 40 mM His 6 -Ras, 10 ng FPTase, and various concentrations of FPTase inhibitors. 4. Incubate for 30-90 min at 25° C. 5. Stop reactions with TCA/SDS (6%/2%), hold at 4° C. for 45-60 min. 6. Filter by manifold or 96 well plate, wash filter 3-5×with TCA (6%). 7. Add scintillant to filters, measure 3 H-FPP incorporation into Ras protein.
[0134] Analysis of Results—Percent inhibition by test compounds is determined by the following:
(cpm from precipitated Ras with test compounds)−(background cpm)×100=% inhibition.
(cpm from precipitated Ras without test compounds)−(background cpm)
[0135] Cell-based assays: Tumor inhibition in vitro assay was performed according to P. Skehan, R. Storeng, D. Scudiero, A. Monks, J. McMohan, D. Vistica, J. Warren, H. Bokesh, S. Kenney, and M. R. Boyd, J. Natl. Cancer Instit., 1990, 82 (13), 1107-1112; L. V. Rubinstein, R. H. Shoemaker, K. D. Paull, R. M. Simon, S. Tosini, P. Skehan, D. A. Scudiero, A. Monks, and M. R. Boyd, J. Natl. Cancer Instit., 1990, 82 (13), 1113-1118; A. Monks, et al., J. Natl. Cancer Instit., 1991, 83, 757-766; M. R. Boyd and K. D. Paull, Drug Development Res., 1995, 34, 91-109; and S. P. Fricker and R. G. Buckley, Anticancer Research, 1996, 16, 3755-3760.
[0136] Materials—Cell Lines: Human tumor cell lines DLD-1 and LoVo; ras-transformed rat fibroblast cell lines, RAT-H-ras and RAT-K-ras (growth inhibited by standard FPTase inhibitors), and the parent cell line RAT-2 (resistant to standard FPTase inhibitors). Cell Media: RPMI 1640 (or DMEM medium and McCoy's medium) with 10% Fetal Bovine Serum supplemented with L-glutamine and Pennicilin/Streptomycin. Compounds: Supplied usually as a 10 mM stock in 100% DMSO. Normal Saline: 150 mM NaCl Trichloroacetic Acid (TCA): 50% (w/v) in water. Sulforhodamine (SRB): 0.4% (w/v) in 1% Acetic Acid. Tris Base: 10 mM in water.
[0137] Methods—Cells are plated at 2000 cells per well, per 200 ml media, and allowed to adhere overnight at 37° C. At 24 h post plating, compounds are added directly at a volume of 0.5 ml. Compound is first diluted in DMSO to generate concentrations of compound or reference standard of: 1, 5, 10 and 25 mM. Dilutions can be made in an identical 96 well plate so that compounds can be added using a multichannel micropipettor set at 0.5 ml. The cells are then incubated for four days after which the media is removed using a 12 well manifold by first tipping the plate forward at a 45 degree angle and then inserting the manifold in an upright orientation to prevent the tips of the manifold from disturbing cells at the bottom of the plate. 200 ml of normal saline is then added to each well using an 8 well multichannel pipettor, followed by the careful addition of 50 ml of 50% TCA. The plates are then incubated for 2 h at 4° C., after which the supernatant is removed using the same technique as above and the plates washed twice with 200 ml water. The plates are then air dried and 50 ml of SRB stock solution is carefully added so that the entire bottom of each well is covered. This again can be used using an 8 well multichannel pipettor. The SRB is incubated with fixed cells for 15 min at room temperature, after which the SRB is removed with the manifold as described above and the plates washed twice with 350 ml of 1% acetic acid per well each time. The plates are then air dried after which the bound SRB is released from protein by the addition of 200 ml of Tris base. Resolubilizing the SRB is aided by placing the plates on a rotator for 15-30 min. The absorbance of each well is determined at 550 or 562 nm using a microtiter plate reader.
[0138] Analysis of Results—Each compound or dilution thereof is performed in triplicate. Outliers are identified by visual inspection of the data. Each plate should have a control (vehicle only). A standard curve is constructed by plotting the concentration of compound against the average absorbance calculated at that concentration. A curve is plotted and the concentration at which the curve passes through the 50% absorbance mark seen in the control well is the IC 50 calculated for that compound.
TABLE I in vitro FTase Inhibition Assay Activity* Example # μM 1 2.25 2 6.5 3 (1%) 4 (1%) 5 (−2%) 6 (21%) 7 2.5 8 1.3 9 1.2 10 4.25 11 2.5 12 3.7 13 (28%) 14 0.077 15 (4%) 16 0.35 17 2.9 18 4.5 19 2.8 20 1.7 21 1 22 2.5 23 >10 24 0.74 25 3.5 26 6
[0139] Compounds of this invention were also tested with K-Ras as the substrate for farnesylation with observed activities of 2.5 μM to >10 μM. Compounds were additionally tested in cell-based assays against human tumor cell lines DLD-1 and LoVo and ras-transformed rat fibroblast cell lines, RAT-H-ras and RAT-K-ras, and the parent cell line RAT-2, as described under Assays. The range observed for inhibition of cell growth was IC 50 =9 to >40 μM.
[0140] Based on the results of these standard pharmacological test procedures, the compounds of this invention are useful as agents for treating, inhibiting or controlling ras-associated diseases by inhibiting farnesyl-protein transferase enzyme, when administered in amounts ranging from about 10 to about 200 mg/kg of body weight per day. A preferred regimen for optimum results would be from about 10 mg to about 100 mg/kg of body weight per day and such dosage units are employed that a total of from about 100 mg to about 1000 mg of the active compound for a subject of about 70 kg of body weight are administered in a 24 hour period.
[0141] The dosage regimen for treating mammals may be adjusted to provide the optimum therapeutic response. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation. A decidedly practical advantage is that these active compounds may be administered in any convenient manner such as by the oral, intravenous, intramuscular or subcutaneous routes.
[0142] The active compounds may be orally administered, for example, with an inert diluent or with an assimilable edible carrier, or they may be enclosed in hard or soft shell gelatin capsules, or they may be compressed into tablets or they may be incorporated directly with the food of the diet. For oral therapeutic administration, these active compounds may be incorporated with excipients and used in the form of ingestible tablets, buccal tablets, troches, capsules, elixirs, suspensions, syrups, wafers and the like. Such compositions and preparations should contain at least 0.1% of active compound. The percentage of the compositions and preparations may, of course, be varied and may conveniently be between about 2% to about 60% of the weight of the unit. The amount of active compound in such therapeutically useful compositions is such that a suitable dosage will be obtained. Preferred compositions or preparations according to the present invention are prepared so that an oral dosage unit form contains between 10 and 1000 mg of active compound. The tablets, troches, pills, capsules and the like may also contain the following: a binder such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, lactose, or saccharin may be added or a flavoring agnet such as peppermint, oil of wintergreen or cherry flavoring. When the dosage unit form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier. Various other materials may be present as coatings or to otherwise modify the physical form of the dosage unit. For instance, tablets, pills or capsules may be coated with shellac, sugar or both. A syrup or elixir may contain the active compound, sucrose, as a sweetening agent, methyl and propylparabens as preservatives, a dye and flavoring such as cherry or orange flavor. Of course, any material used in preparing any dosage unit form should be pharmaceutically pure and substantially non-toxic in the amounts used. In addition, these active compounds may be incorporated into sustained-release preparations and formulations.
[0143] These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxypropylcellulose. Dispersions can also be prepared in glycerol, liquid polyethylene glycols, and mixtures therof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth or microorganisms.
[0144] The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and starage and must be prepared against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (e.g., glycerol, propylene glycol and liquid poly-ethylene glycol), suitable mixtures thereof, and vegetable oils.
[0145] The present invention accordingly provides a pharmaceutical composition which comprises a compound of Formula (I) of this invention in combination or association with a pharmaceutically acceptable carrier. In particular, the present invention provides a pharmaceutical composition which comprises an effective amount of a compound of this invention and a pharmaceutically acceptable carrier.
[0146] As used in accordance with this invention, the term providing an effective amount of a compound means either directly administering such compound, or administering a prodrug, derivative, or analog which will form an effective amount of the compound within the body.
[0147] The invention will be more fully described in conjunction with the following specific examples which are not to be construed as limiting the scope of the invention.
EXAMPLE 1
5-(4-[2-(5-Methyl-2-phenyloxazol-4-yl)ethoxy]benzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione
[0148] Prepared analogously to Example 9. m.p. 202-204° C.
EXAMPLE 2
5-(4-Bromo-2-fluorobenzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione
[0149] Prepared analogously to Example 9. m.p. 236-237° C.
EXAMPLE 3
5-(3,4-Dichlorobenzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione
[0150] Prepared analogously to Example 9. m.p. 183-184° C.
EXAMPLE 4
5-(4-Bromo-2-fluorobenzyl)-5-(naphthalene-2-sulfonyl)thiazolidine-2,4-dione
[0151] Prepared analogously to Example 9. m.p. 195-197° C.
EXAMPLE 5
5-(4-[2-(5-Methyl-2-phenyloxazol-4-yl)ethoxy]benzyl)-5-(naphthalene-2-sulfonyl)thiazolidine-2,4-dione
[0152] Prepared analogously to Example 9. m.p. 133-136° C.
EXAMPLE 6
5-Benzyl-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione
[0153] Prepared analogously to Example 9. m.p. 146-152° C. 1 H NMR (DMSO): δ 12.70 (br s, 1H),
EXAMPLE 7
2-[5-Benzyl-5-(4-methoxybenzenesulfonyl)-2,4-dioxothiazolidin-3-yl]-N-hydroxyacetamide
[0154] To a solution of 2-[5-Benzyl-5-(4-methoxybenzenesulfonyl)-2,4-dioxothiazolidin-3-yl]-acetic acid (Example 27) (0.400 g, 0.92 mmol) in 13 mL of dichloromethane was added 1-hydroxybenzotriazole (0.126 g, 0.93 mmol), 4-methylmorpholine (0.506 g, 5.00 mmol), O-benzylhydroxylamine hydrochloride (0.440 g, 2.76 mmol), and 1-[3-(Dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (0.232 g, 1.21 mmol) and the mixture was stirred at room temperature for 24 hours under a nitrogen atmosphere. The mixture was diluted with 50 mL of dichloromethane and washed with 2×100 mL of water. The combined aqueous washings were back extracted with 100 mL of dichloromethane and the combined organic phases were washed with 100 mL of brine, dried over anhydrous Na 2 SO 4 and concentrated in vacuo. Column chromatography provided 0.280 g of 2-[5-Benzyl-5-(4-methoxybenzenesulfonyl)-2,4-dioxothiazolidin-3-yl]-N-benzyloxyacetamide as a colorless foam. This material was dissolved in 25 mL of dioxane and stirred at room temperature under a hydrogen atmosphere with an excess of 10% Pd on carbon for 2 days. The mixture was filtered through a celite pad washing with dioxane, followed by ethyl acetate, then methanol. The combined filtrates were concentrated in vacuo and column chromatography provided 0.050 g of the title compound as a white powder. m.p. 81-85° C.
EXAMPLE 8
5-(3-[2-(4-Methoxyphenyl)[1,3]dioxolan-2-yl]benzyl)-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione
[0155] A solution of 5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione (0.239 g, 1.00 mmol) (Wrobel, J., Zenan, L., Dietrich, A., McCaleb M., Mihan, B., Sredy J. Sullivan, D. J. Med. Chem. 1998, 41 1084-1091) in 3 mL of 1,2-dimethyoxyethane (DME) under an argon atmosphere was cooled to 0° C. and a 1.0 M solution of sodium hexamethyldisilylazide in tetrahydrofuran was added. The mixture was stirred 1 h at 0° C. and a solution of 2-[3-(bromomethyl)phenyl]-2-(4-methoxyphenyl)-1,3-dioxolane (0.528 g (75% pure) 1.13 mmol) in a small volume of DME was added. The mixture was stirred 1 h at 0° C. and then partitioned between diethyl ether (100 mL) and dilute HCl solution (100 mL). The organic phase was dried over anhydrous MgSO 4 , the solvent was removed in vacuo, and the residue was crystallized from petroleum ether/diethyl ether to give 0.221 g (44% yield) of the title compound as colorless prisms. 1 H NMR: δ 7.15-7.47 (m, 11H), 6.83 (dd, J=6.8, 1.9 Hz, 2H), 3.96-4.10 (m, 4H), 3.78 (s, 3H), 3.66 (A of AB, J=13.9 Hz, 1H), 3.32 (B of AB, J=13.9 Hz, 1H), 2.36 (s, 3H). 13 C NMR: δ 173.2, 167.0, 159.3, 142.6, 141.4, 137.3, 134.0, 133.5, 130.3,130.1, 128.7, 128.4, 127.6, 126.0, 124.8, 113.5, 109.1, 72.9, 64.9, 55.3, 43.3, 21.4. MS (m/e): 508.4 (M+H) + . Anal: Calc for C 27 H 25 NO 5 S 2 :63.89% C, 4.96%H, 2.76% N; Found: 63.67% C, 5.03% H, 2.53% N.
EXAMPLE 9
5-(3-[2-(4-Methoxyphenyl)[1,3]dioxolan-2-yl]benzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione
[0156] Prepared analogously to Example 8 from 5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione (Wrobel, J., Zenan, L., Dietrich, A., McCaleb M., Mihan, B., Sredy J. Sullivan, D. J. Med. Chem. 1998, 41 1084-1091). Column chromatography provided a light yellow foam. 1 H NMR: δ 7.85 (dd, J=6.8, 1.6 Hz, 2H), 7.61 (d, J=8.2 Hz, 1H), 7.22-7.45 (m, 7H), 7.08 (d, J=7.0 Hz, 1H), 6.82 (dd, J=6.8, 2.0 Hz, 2H), 3.96-4.08 (m, 4H), 3.90 (a of ab, J=13.6 Hz, 1H), 3.78 (s, 3H), 3.33 (b of ab, J=13.6 Hz, 1H), 2.49 (s, 3H). MS (m/e): 540.3 (M+H) + .
EXAMPLE 10
5-(3-(4-methoxybenzoyl)benzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione
[0157] During chromatographic purification of 5-(3-[2-(4-methoxyphenyl)[1,3]dioxolan-2-yl]benzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione (Example 9) the deketalized product was isolated as a yellow foam. 1 H NMR: δ 7.88 (br s), 1H, 7.87 (d, J=8.4 Hz, 2H), 7.74-7.79 (m, 2H), 7.67 (dt, J=6.9, 1.8 Hz, 1H), 7.53 (s, 1H), 7.36-7.44 (m, 4H), 6.92-6.99 (m, 2H), 3.99 (A of AB, J=13.8 Hz, 1H), 3.90 (s, 3H), 3.41 (B of AB, J=13.8 Hz, 1H), 2.50 (s, 3H). MS (m/e): 496.4 (M+H) + .
EXAMPLE 11
5-(3-(4-methoxybenzoyl)benzyl)-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione
[0158] Prepared analogously to example 19 from 5-(3-(4-methoxybenzoyl)benzyl)-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione (Example 10). Column chromatography provided a colorless foam. 1 H NMR: δ 7.78-7.82 (m, 2H), 7.72 (dt, J=7.2, 1.6 Hz, 1H), 7.65 (br s, 1H), 7.41-7.50 (m, 4H), 7.18 (d, J=7.9 Hz, 2H), 6.97 (dd, J=2.1, 6.9 Hz, 2H), 3.89 (s, 3H), 3.72 (A of AB, J=14.0 Hz, 1H), 3.39 (B of AB, J=14.0 Hz, 1H), 2.36 (s, 3H). MS (m/e): 464.4 (M+H) + .
EXAMPLE 12
5-(3-[Hydroxy(4-methoxyphenyl)methyl]-benzyl)-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione
[0159] To a solution of 5-(3-(4-methoxybenzoyl)benzyl)-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione (Example 11) (0.150 g, 0.32 mmol) in 1 mL of anhydrous ethanol was added NaBH 4 (0.015 g, 0.39 mmol) and the mixture was stirred 15 h at room temperature under an argon atmosphere. It was then partitioned between diethyl ether (50 mL) and dilute HCl solution (50 mL) with care to prevent excess foaming as residual NaBH 4 decomposed. The organic phase was dried over anhydrous MgSO 4 , and the solvent was removed in vacuo. Column chromatography provided 0.105 g (75% yield) of the title compound as a colorless foam. 1 H NMR: δ 7.46 (d, J=8.0 Hz, 2H), 7.45 (s, 1H), 7.15-7.33 (m, 7H), 6.84-6.88 (m, 2H), 5.78 (br s, 1H), 3.78 (s, 3H), 3.64 & 3.65 (diastereomeric pair, A of AB, J=13.9 Hz, 1H), 3.29 & 3.30 (diastereomeric pair, B of AB, J=13.9 Hz, 1H), 2.36 (s, 3H), 2.25 (br s, 1H). MS (m/e): 448.3 (M−OH) + .
EXAMPLE 13
5-(4-Bromobenzyl-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione
[0160] Prepared analogously to Example 9 from 4-bromobenzyl bromide. Column chromatography provided pale yellow microplates. 1 H NMR (DMSO): δ 12.70 (br s, 1H), 7.82 (d, J=8.4 Hz, 2H), 7.56 (d, J=8.4 Hz, 2H), 7.52 (d, J=8.4 Hz, 2H), 7.15 (d, J=8.4 Hz, 2H), 3.69 (A of AB, J=13.6 Hz, 1H), 3.48 (B of AB, J=13.6 Hz, 1H), 2.46 (s, 3H). 13 C NMR: δ 169.2, 167.6, 146.8, 132.9, 131.6, 131.3, 130.9, 129.9, 121.3, 85.3, 54.8, 21.2. MS (m/e): 438.2 and 440.3 (M−H) − Br isotopes. Anal: Calc for C 17 H 14 BrNO 4 S 2 : 46.37% C, 3.20% H, 3.18% N; Found: 45.98% C, 3.40% H, 3.28% N.
EXAMPLE 14
5-[2′-cyanobiphen-4-ylmethyl]-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione
[0161] Prepared analogously to Example 9 from from 4′-bromomethyl-2-cyanobiphenyl in N,N-dimethylformamide. Column chromatography provided a colorless glass. 1 H NMR: δ 8.06 (d, J=8.4 Hz, 2H), 7.82 (br s, 1H), 7.75 (dd, J=7.7, 1.0 Hz, 1H), 7.65 (dt, J=1.4, 7.7 Hz, 1H), 7.41-7.50 (m, 6H), 4.00 (A of AB, J=13.7 Hz, 1H), 3.42 (B of AB, J=13.7 Hz, 1H), 2.50 (s, 3H). MS (m/e): 463.1 (M+H) + .
EXAMPLE 15
5-[2′-(1H-Tetrazol-5-yl)biphen-4-ylmethyl]-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione
[0162] Prepared analogously to Example 9 using N-(Triphenylmethyl)-5-[2-[4′-(bromomethyl)biphenylyl]]tetrazole (Schoen, W. R.; Pisano, J. M.; Prendergast, K.; Wyvratt, M. J., Jr.; Fisher, M. H.; Cheng, K.; Chan, W.-S.; Butler, B.; Smith, R. G.; Ball, R. G. J. Med. Chem. 1994, 37, 897-906.)
[0163] [0163] 1 H NMR: δ 8.06 (d, J=7.3 Hz, 1H), 7.88 (d, 8.3 Hz, 2H), 7.52-7.63 (m, 2H), 7.41-7.46 (m, 3H), 7.23-7.26 (m, 2H), 7.12 (d, J=8.1 Hz, 2H), 3.94 (A of AB, J=13.6 Hz, 1H), 3.46 (B of AB, J=13.6 Hz,1H), 2.51 (s, 3H). MS (m/e): 506.2 (M+H) + .
EXAMPLE 16
5-[2′-cyanobiphen-4-ylmethyl]-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione
[0164] Prepared analogously to Example 9 from from 5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione and 4′-bromomethyl-2-cyanobiphenyl in N,N-dimethylformamide. Trituration with diethyl ether provided an off-white solid.
[0165] [0165] 1 H NMR: δ 7.93 (dd, J=7.0, 2.0 Hz, 2H), 7.75 (dd, J=7.7, 1.0 Hz, 1H), 7.64 (dt, J=1.3, 7.7 Hz, 1H), 7.42-7.50 (m, 4H), 7.31 (d, J=8.3 Hz, 2H), 7.07 (dd, J=7.1, 1.9 Hz, 2H), 4.00 (A of AB, J=13.7 Hz, 1H), 3.93 (s, 3H), 3.42 (B of AB, J=13.7 Hz, 1H). MS (m/e): 477.3 (M−H) + . Anal: Calc for C 24 H 18 N 2 O 5 S 2 .0.167 C 3 H 9 NO: 59.92% C, 4.00% H, 6.18% N; Found: 59.60% C, 4.04% H, 5.99% N.
EXAMPLE 17
5-[3-(4-Methoxybenzyl)benzyl]-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione
[0166] To a solution of 5-(3-(4-methoxybenzoyl)benzyl)-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione (0.100 g, 0.22 mmol) (Example 11) in 0.5 mL of trifluoroacetic acid under an argon atmosphere was added triethylsilane (0.055 g 0.47 mmol) and the solution was stirred 200 min at room temperature. An additional portion of triethylsilane (0.028 g, 0.24 mmol) was then added and the solution was stirred an additional 90 min at room temperature. The volatile materials were then removed in vacuo. Column chromatography provided, in addition to a like quantity of silane contaminated material, 0.041 g (42% yield) of pure title compound as a colorless foam. 1 H NMR: δ 7.48 (br s, 1H), 7.46 (d, J=8.4 Hz, 2H), 7.06-7.24 (m, 6H), 7.05 (d, J=8.4 Hz, 2H), 6.81-6.84 (m, 2H), 3.90 (s, 2H), 3.77 (s, 3H), 3.62 (A of AB, J=14.0 Hz, 1H), 3.27 (B of AB, J=14.0 Hz, 1H), 2.35 (s, 3H). 13 C NMR: δ 173.4, 167.4, 158.0, 141.9, 141.4, 137.3, 133.8, 131.2, 130.1, 129.8, 128.6, 128.5, 128.4,124.8,113.9, 72.8, 55.3, 43.2, 40.8,21.4. MS (m/e): 448.1 (M−H) − .
EXAMPLE 18
5-[3-(2-Thiophen-2-yl[1,3]dioxolan-2-yl)benzyl]-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione
[0167] Prepared analogously to Example 8 from 2-[3-(bromomethyl)phenyl]-2-(2-thienyl)-1,3-dioxolane. Column chromatography provided a colorless foam. 1 H NMR: δ 7.46-7.61 (m, 4H), 7.23-7.32 (m, 3H), 7.17 (d, J=8.0 Hz, 2H), 6.90 (dd, J=5.0, 3.6 Hz, 1H), 6.81 (dd, J=3.6, 1.2 Hz, 1H), 4.14-4.22 (m, 2H), 3.95-4.08 (m, 2H), 3.68 (A of AB, J=13.9 Hz, 1H), 3.34 (B of AB, J=13.9 Hz, 1H), 2.36 (s, 3H). 13 C NMR: δ 173.4, 167.3, 146.0, 141.7, 141.4, 137.3, 133.7, 130.7, 130.1, 128.7, 128.5, 126.6, 126.3,125.8,124.8, 107.4, 72.7, 65.2, 43.2, 21.4. MS (m/e): 483.9 (M+H) + .
EXAMPLE 19
5-[3-(Thiophene-2-carbonyl)benzyl]-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione
[0168] A solution of 5-[3-(2-thiophen-2-yl[1,3]dioxolan-2-yl)benzyl]-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione (Example 18) (0.593 g, 1.23 mmol) was dissolved in 15 mL of acetone under a nitrogen atmosphere and 0.064 g, 0.25 mmol) of pyridinium p-toluenesulfonate was added, followed by 1.5 mL of water. The mixture was warmed to reflux under a nitrogen atmosphere for 46 h then allowed to stir at room temperature for 24 h. The solvents were removed from the mixture by rotary evaporation and the residue was partitioned between diethyl ether (60 mL) and dilute HCl solution (50 mL). The organic phase was dried over anhydrous MgSO 4 , and the solvent was removed in vacuo. Column chromatography provided (0.375 g, 70% yield) of the title compound as a colorless foam. 1 H NMR: δ 7.81 (d, J=7.6 Hz, 1H), 7.78 (s, 1H), 7.73 (d, J=5.2 Hz, 1H), 7.70 (br s, 1H), 7.66 (d, J=3.6 Hz, 1H), 7.44-7.53 (m, 4H), 7.16-7.19 (m, 3H), 3.73 (A of AB, J=14.0 Hz, 1H), 3.42 (B of AB, J=14.0 Hz, 1H), 2.36 (s, 3H). 13 C NMR: δ 187.7, 173.2, 167.0, 143.4, 141.6, 138.4, 137.3, 135.0, 134.6, 134.5, 134.1, 131.6, 130.2, 128.8, 128.1, 124.5, 72.4, 42.9, 21.4. MS (m/e): 440.0 (M+H) + . Anal: Calc for C 22 H 17 NO 3 S 3 : 60.11% C, 3.90% H, 3.19% N; Found: 59.87% C, 3.96% H, 3.12% N.
EXAMPLE 20
5-Biphen-4-ylmethyl-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione
[0169] Prepared analogously to Example 9 from from 5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione and 4-(bromomethyl)biphenyl in N,N-dimethylformamide. Trituration with diethyl ether provided an off-white solid. 1 H NMR: δ 7.98 (s, 1H), 7.93, (dd, J=7.0, 2.0 Hz, 2H), 7.34-7.57 (m, 7H), 7.23-7.26 (m, 2H), 7.06 (dd, J=7.0, 2.0 Hz, 2H), 3.97 (A of AB, J=13.7 Hz, 1H), 3.92 (s, 3H), 3.39 (B of AB, J=13.7 Hz, 1H). MS (m/e): 452.1 (M−H) − . Anal: Calc for C 23 H 19 NO 5 S 2 .C 3 H 7 NO: 59.30% C, 4.98% H, 5.32% N; Found: 59.13% C, 4.89% H, 5.24%N. MP: 119-122° C.
EXAMPLE 21
5-(4′-Chlorobiphen-4-ylmethyl)-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione
[0170] Prepared analogously to Example 9 from from 5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione and 4′-bromomethyl-4-chlorobiphenyl in N,N-dimethylformamide. Trituration with diethyl ether provided an off-white solid. 1 H NMR: δ 7.99 (s, 1H), 7.93 (dm, J=9.0 Hz, 2H), 7.45-7.49 (m, 4H), 7.38-7.41 (m, 2H), 7.23-7.26 (m, 2H), 7.06 (dm, J=9.0 Hz, 2H), 3.97, (A of AB, J=13.7 Hz, 1H), 3.92 (s, 3H), 3.39 (B of AB, J=13.7 Hz, 1H). MS (m/e): 486.0 & 488.0 (M−H) − Cl isotopes. Anal: Calc for C 23 H 18 ClNO 5 S 2 .C 3 H 7 NO: 55.66% C, 4.49% H, 4.99% N; Found: 55.57% C, 4.41% H, 4.85% N. MP: 197-200° C.
EXAMPLE 22
5-(4-Methoxybenzenesulfonyl)-5-(3′-(trifluoromethyl)biphen-4-ylmethyl)thiazolidine-2,4-dione
[0171] Prepared analogously to Example 9 from from 5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione and 4′-bromomethyl-3-(trifluoromethyl)biphenyl in N,N-dimethylformamide. Column chromatography provided a light yellow glass. 1 H NMR: δ 7.93 (dm, J=9.0 Hz, 2H), 7.78 (br s, 2H), 7.72 (d, J=7.5 Hz, 1H), 7.49-7.62 (m, 4H), 7.28 (dm, J=8.7 Hz, 2H), 7.07 (dm, J=9.0 Hz, 2H), 3.98 A of AB, J=13.7 Hz, 1H), 3.92 (s, 3H), 3.40 (B of AB, J=13.7 Hz, 1H). MS (m/e): 520.0 (M−H) − . Anal: Calc for C 24 H 18 F 3 NO 5 S 2 : 55.27% C, 3.48% H, 2.69% N; Found: 55.23% C, 3.70% H, 2.69% N.
EXAMPLE 23
5-(3′,5′-Bis(trifluoromethyl)biphen-4-ylmethyl)-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione
[0172] Prepared analogously to Example 9 from from 5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione and 4′-bromomethyl-3,5-bis(trifluoromethyl)biphenyl in N,N-dimethylformamide. Trituration with diethyl ether provided a white solid. 1 H NMR: δ 8.43 (br s, 1H), 7.91-7.99 (m, 4H), 7.85 (s, 1H), 7.53 (dd, J=6.5, 1.8 Hz, 2H), 7.33 (d, J=8.3 Hz, 2H), 7.07 (dm, J=9.0 Hz, 2H), 4.00 (A of AB, J=13.7 Hz, 1H), 3.93 (s, 3H), 3.42 (B of AB), J=13.7 Hz, 1H). MS (m/e): 588.5 (M−H) − . Anal: Calc for C 25 H 17 F 6 NO 5 S 2 .C 3 H 7 NO: 50.75% C, 3.65% H, 4.23% N; Found: 50.70% C, 3.60% H, 4.01% N. MP: 122-125° C.
EXAMPLE 24
5-(2′,4′-Dichlorobiphen-4-ylmethyl)-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione
[0173] Prepared analogously to Example 9 from from 5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione and 4′-bromomethyl-2,4-dichlorobiphenyl in N,N-dimethylformamide. Column chromatography provided an off-white solid. 1 H NMR: δ 8.01 (v br s, 1H), 7.93 (dm, J=9.0 Hz, 2H), 7.47 (d, J=2.0 Hz, 1H), 7.22-7.35 (m, 6H), 7.07 (dm, J=9.0 Hz, 2H), 3.98 (a of ab, J=13.7 Hz, 1H), 3.93 (s, 3H), 3.40 (b of ab, J=13.7 Hz, 1H). MS (m/e): 519.9 (M−H) − . Anal: Calc for C 23 H 17 Cl 2 NO 5 S 2 .0.75 C 4 H 10 O: 54.03% C, 4.27% H, 2.42% N; Found: 53.63% C, 4.33% H, 2.23% N. MP: 104-107° C.
EXAMPLE 25
5-[3-(3-Chlorophenoxy)benzyl]-5-(4-methylbenzenesulfanyl)thiazolidine-2,4-dione
[0174] Prepared analogously to Example 8 from 3-(bromomethyl)phenyl 4-chlophenyl ether. Column chromatography provided an amorphous solid. 1 H NMR: δ 7.57 (br s, 1H), 7.46 (d, J=8.0 Hz, 2H), 7.27-7.30 (m, 3H), 7.17 (d, J=7.9 Hz, 2H), 7.02 (d, J=7.6 Hz, 1H), 6.88-6.95 (m, 4H), 3.64 (a of ab, J=13.9 Hz, 1H), 3.29 (b of ab, J=13.9 Hz, 1H), 2.36 (s, 3H). 13 C NMR: δ 182.3, 173.3, 167.2, 156.9, 155.6, 141.6, 137.3, 135.7, 130.1, 130.0, 129.8, 128.5, 125.8, 124.6, 121.1, 120.1, 118.5, 72.5, 43.0, 21.4. MS (m/e): 453.9 (M−H) − . Anal: Calc for C 23 H 18 NO 3 S 2 .0.5H 2 O: 59.41% C, 4.12% H, 3.01% N; Found: 59.73% C, 3.85% H, 2.82% N.
EXAMPLE 26
5-[3-(2-thiophen-2-yl[1,3]dioxolan-2-yl)benzyl]-5-(4-methylbenzenesulfonyl)thiazolidine-2,4-dione
[0175] Prepared analogously to Example 9 from 2-[(3-bromomethyl)phenyl]-2-(2-thienyl)-1,3-dioxolane in N,N-dimethylformamide as the solvent. Column chromatography provided an amorphous solid. 1 H NMR: δ 7.92 (br s, 1H), 7.85 (d, J=8.0 Hz, 2H), 7.52 (d, J=7.6 Hz, 1H), 7.38-7.40 (m, 3H), 7.25-7.30 (m, 2H), 7.13 (d, J=7.6 Hz, 1H), 6.88 (dd, J=4.8, 3.6 Hz, 1H), 6.76 (d, J=3.2 Hz, 1H), 4.12-4.18 (m, 2H), 3.93-3.99 (m, 2H), 3.91 (A of AB, J=13.6,1H), 3.34 (B of AB, J=13.6,1H), 2.48 (s, 3H). 13 C NMR: δ 168.0, 166.1, 147.1, 146.0, 142.0, 131.7, 131.4, 130.8, 130.4,129.9,128.7, 128.7, 126.6, 126.4, 126.4, 126.0, 107.4, 85.9, 65.2, 36.8, 21.8. MS (m/e): 516.0 (M+H) + . Anal: Calc for C 24 H 21 NO 6 S 3 .H 2 O: 54.02% C, 4.34% H, 2.62% N; Found: 54.22% C, 4.34% H, 2.62% N.
EXAMPLE 27
2-[5-Benzyl-5-(4-methoxybenzenesulfonyl)2,4-dioxothiazolidin-3-yl]-acetic Acid
[0176] To a solution of 5-Benzyl-5-(4-methoxybenzenesulfonyl)thiazolidine-2,4-dione (Example 6) (0.740 g, 1.96 mmol) in 34.5 mL of acetone was added t-butyl bromoacetate (4.227 g, 21.67 mmol) and potassium carbonate (2.75 g, 19.90 mmol) and the mixture was stirred for 16 h at room temperature under a nitrogen atmosphere. The mixture was filtered and concentrated in vacuo. Column chromatography provided the t-butyl ester of the title compound as a viscous yellow oil. This material was dissolved in 96 mL of dichloromethane and 17.8 mL of trifluroacetic acid was added and the mixture was stirred 2.5 h at room temperature under a nitrogen atmosphere. The mixture was concentrated in vacuo, triturated with hexane, and filtered. The solid was redissolved in dichloromethane and again concentrated in vacuo to give 0.720 g of the title compound as a beige solid.
[0177] MS (m/e): 436.0 (M+H) + .
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The invention relates to compounds of Formula (I) wherein R 1 , (R 2 ) v , R 3 and n are defined in the specification and pharmaceutical compositions thereof, that inhibit the Ras farnesyl-protein transferase enzyme (FPTase), and may be used as an alternative to, or in conjunction with, traditional cancer therapy for the treatment of ras oncogene-dependent tumors, such as cancers of the pancreas, colon, bladder, and thyroid.
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BACKGROUND OF THE INVENTION
This invention relates to certain imidazothiazines and to certain analogues and derivatives thereof which by virtue of their ability to inhibit indoleamine-N-methyl transferase are useful in the treatment of certain mental aberrations in man, such as schizophrenia. Such compounds will collectively hereinafter, for convenience, be referred to as "bicyclic amidines" because of the common structural unit which relates the compounds of the present invention. This invention also relates to processes for the preparation of such bicyclic amidines; to pharmaceutical compositions comprising such bicyclic amidines; and to methods of treatment comprising administering such compounds and compositions when indicated for the treatment of mental aberrations such as schizophrenia. The bicyclic amidines of the present invention may be depicted by the following generic structure (I): ##SPC1##
wherein:
A is S, O, or NR (R is selected from the group consisting of hydrogen, lower alkyl, or lower alkoxycarbonyl);
And R 1 and R 2 are independently selected from the group consisting of hydrogen, halogen such as chloro, lower alkyl, or lower alkoxycarbonyl.
N,N-dimethylindoleamines are generally psychotomimetic agents and some of these (e.g., dimethylserotonin and dimethyltryptamine) are reported to be produced in excessive amounts by individuals with certain mental aberrations, most commonly classified as schizophrenic. Indoleamino-N-methyl transferase catalyzes the methylation steps in the biosynthesis of these compounds. Accordingly, inhibitors of this enzyme are of therapeutic value in management of the body chemistry of patients having mental aberrations such as schizophrenia and thus are useful in alleviating some of the symptons of the disease. Thus it is an object of the present invention to provide the above-described bicyclic amidines and their pharmaceutically acceptable N-acid addition salts; to provide processes for the preparation of such compounds; pharmaceutical compositions comprising such compounds; and to provide methods of treatment comprising administering such compounds and compositions, when indicated for the treatment/management of mental aberrations such as schizophrenia.
DETAILED DESCRIPTION OF THE INVENTION
The preferred bicyclic amidines of the present invention are structurally depicted below: ##SPC2##
Wherein R 1 and R 2 are independently selected from the group consisting of hydrogen, chloro, lower alkyl having from 1 to about 6 carbon atoms, or lower alkoxycarbonyl having from 2 to about 7 carbon atoms; and R is selected from the group consisting of hydrogen, lower alkyl having from 1 to about 6 carbon atoms, or lower alkoxycarbonyl having from 2 to about 7 carbon atoms.
In general, the compounds of the present invention are prepared according to the following scheme: ##SPC3##
In words, relative to the above diagram, an appropriately substituted lactam is treated with an alkylating agent such as trialkyloxonium fluoroborate (e.g., trimethyl-, triethyl- or the like) in a solvent such as methylenechloride, chloroform and the like at 0° to about 25°C. for from 1 to about 6 hours. The resulting lactam ether is then reacted with a 2-haloethylamine hydrohalide such as 2-bromo-ethylamine hydrobromide in a solvent such as methanol, ethanol, DMF or the like at 25° to 75°C. for from 1 to 5 hours. The resulting amidine is then cyclized to the final product I by treatment with a strong base such as an alkali metal alkoxide, for example: sodium methoxide, sodium ethoxide, or hydrous oxide such as sodium hydroxide or the like in a solvent such as methanol, ethanol, DMF or the like.
Also contemplated within the scope of the present invention are pharmaceutically acceptable N-acid addition salts of the bycyclic amidines of the present invention represented by structural formula I. Such pharmaceutically acceptable forms, prepared by conventional means, include: the hydrochloride, hydrobromide, sulfate, phosphate, citrate, tartrate, succinate and the like. These pharmaceutically acceptable salts of I are generally equivalent in potency to the free amino form of I taking into consideration the stoichiometric quantities employed.
In the method of treatment and pharmaceutical composition aspects of the present invention, the daily dose can be from about 0.005 mg./kg. to about 300 mg./kg. per day and preferably from 0.05 mg./kg. to 100 mg./kg. per day, bearing in mind, of course, that in selecting the appropriate dosage in any specific case, consideration must be given to the individual's weight, general health, metabolism, age and other factors which influence response to the drug.
Another embodiment of this invention is the provision of pharmaceutical compositions in dosage unit form which comprise from about 1 mg. to 500 mg. of a compound of the above formula.
The pharmaceutical compositions may be in a form suitable for oral use, for example, as tablets, solutions, aqueous or oily suspension, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring agents and preserving agents in order to provide a pharmaceutically elegant and palatable preparation. Tablets contain the active ingredient in admixture with non-toxic pharmaceutically acceptable excipients which are suitable for manufacture of tablets. These excipients may be, for example, inert diluents, for example calcium carbonate, sodium carbonate, lactose, calcium phosphate or sodium phosphate; granulating and disintegrating agents, for example maize starch and alginic acid; binding agents, for example starch, gelatin or acacia, and lubricating agents, for example magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and adsorption in the gastro-intestinal tract and thereby provide a sustained action over a longer period.
Formulations for oral use may also be presented as hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example calcium carbonate, calcium phosphate or dalin, or as soft gelatin capsules wherein the active ingredient is dissolved or mixed with an oil or aqueous medium, for example arachis oil, liquid paraffin, olive oil or water by itself.
Aqueous suspensions or solutions containing the active compound in admixture with excipients are suitable for the manufacture of aqueous suspensions. Such excipients are suspending agents, for example sodium carboxymethylcellulose, methylcellulose, hydroxypropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia; dispersing or wetting agents may be a naturally-occurring phosphatide, for example lecithin, or condensation products of an alkylene oxide with fatty acids, for example polyoxyethylene stearate, or condensation products of ethylene oxide with long chain aliphatic alcohols, for example heptadecaethyleneoxy-cetanol, or condensation products of ethylene oxide with partial esters derived from fatty acids and a hexitol, for example polyoxyethylene sorbitol mon-oleate, or condensation products of ethylene oxide with partial esters derived from fatty acids and hexitol anhydrides, for example polyoxyethylene sorbitan mono-oleate. The aqueous suspensions may also contain one or more preservatives, for example ethyl or n-propyl, p-hydroxy benzoate, one or more coloring agents, one or more flavoring agents and one or more sweetening agents, such as sucrose, saccharin, or sodium or calcium cyclamate.
Oily suspensions may be formulated by suspending the active ingredient in a vegetable oil, for example arachis oil, olive oil, sesame oil or coconut oil, or in a mineral oil such as liquid paraffin. The oil suspensions may contain a thickening agent, for example beeswax, hard paraffin or cetyl alcohol. Sweetening agents, such as those set forth above, and flavoring agents may be added to provide a palatable oral preparation. These compositions may be preserved by the addition of an anti-oxidant such as ascorbic acid.
Dispersible powders and granules suitable for preparation of an aqueous suspension by the addition of water provide the active ingredient in admixture with a dispersing or wetting agent, suspending agent and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those already mentioned above. Additional excipients, for example sweetening, flavoring and coloring agents, may also be present.
The pharmaceutical compositions of the invention may also be in the form of oil-in-water emulsions. The oily phase may be a vegetable oil, for example olive oil or arachis oils, or a mineral oil, for example liquid parafin or mixtures of these. Suitable emulsifying agents may be naturally-occurring gums, for example gum acacia or gum tragacanth, naturally-occurring phosphatides, for example soya bean lecithin, and esters of partial esters derived from fatty acids and hexitol anhydrides, for example sorbitan mon-oleate, and condensation products of the said partial esters with ethylene oxide, for example polyoxyethylene sorbitan mon-oleate. The emulsions may also contain sweetening and flavoring agents.
Syrups and elixirs may be formulated with sweetening agents, for example glycerol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative and flavoring and coloring agents. The pharmaceutical compositions may be in the form of a sterile injectable preparation, for example as a sterile injectable aqueous solution or suspension. This aqueous medium may be formulated according to the known art using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example as a solution in 1,3-butanediol.
The pharmaceutical compositions may be tableted or otherwise formulated so that for every 100 parts by weight of the composition there are present between 5 and 95 parts by weight of the active ingredient. The dosage unit form will generally contain between about 0.05 mg. and about 500 mg. of the active ingredient of the formulae stated above.
From the foregoing formulation discussion it is apparent that the compositions of this invention can be administered orally or parenterally. The term parenteral as used herein includes subcutaneous injection, intravenous, intramuscular, or intrasternal injection or infusion techniques. In addition, the compounds can be given rectally as suppositories or topically with peneetrants.
The following examples further illustrate but do not limit the product, process, compositional or method of treatment aspects of the present invention.
EXAMPLE 1
Preparation of 2,3,5,6-tetrahydro-8H-imidazo[2,1-c] [1,4]-thiazine
A solution of 23.4 g. (0.20 moles) of 3-thiomorpholinone in 150 ml. dry CH 2 Cl 2 is added dropwise with stirring to a solution of 44 grams of triethyloxonium fluoroborate in 100 ml. of CH 2 Cl 2 maintained at 0°-5°C. Stirring is continued for six hours as temperature is allowed to come to 25°C; K 2 CO 3 (46 g.) is added and the methylene chloride solution is decanted and the residue of K 2 CO 3 is washed with CH 2 Cl 2 . The combined organic solutions are dried over anhydrous K 2 CO 3 , filtered and solvent evaporated. Distillation of the concentrate gives 17.9 g. of the lactam ether. The lactam ether is added to a solution of 24.6 grams (0.12 moles) of 2-bromo-ethylamine hydrobromide in 150 ml. absolute ethanol and the resulting solution heated on a steam bath for two hours. The solvent is evaporated and the residue washed with ether. The resulting crystalline material is washed with acetone and air dried under suction. The crude crystalline product (28.5 g.) is dissolved in 200 ml. ethanol and sodium methoxide (.07 mole in 50 ml. methanol is added; the resulting solution is heated under reflux with stirring for two hours prior to evaporation of the solvent under reduced pressure. To the residue is added 75 ml. water and the solution made basic with potassium carbonate; the basic solution is extracted with chloroform (3 × 100 ml.). The combined extracts are dried over anhydrous Na 2 SO 4 , filtered and the solvent evaporated. Distillation of the concentrate gives 2,3,5,6-tetrahydro-8H-imidazo[2,1-c] [1,4] thiazine (11.3 g.). The hydrochloride and oxalate salts are prepared, respectively, by dissolving 1 g. of the product in the minimum volume of absolute ethanol at 45°C. and adding dropwise an aqueous 1 molar solution of the respective acid; the resulting salts are collected by filtration, washed with ethanol and dried.
EXAMPLE 2
Preparation of 2,3,5,6-tetrahydro-8H-imidazo[2,1-c] [1,4]-oxazine hydrogen fumarate
A solution of 3-morpholinone (10.5 g.) in methylenechloride (100 ml.) is added dropwise with stirring at 0°C. to a solution of triethyloxonium fluoroborate (24 g.) in methylene chloride (200 ml.). The solution is stirred for 6 hours and then treated with 26 g. of 50% aqueous potassium carbonate solution. The organic solution is separated, dried over K 2 SO 3 , filtered and the filtrate concentrated under reduced pressure. Distillation of the residue gives the lactam ether, b.p. 68°/20 mm., 8.1 g. A solution of lactam ether and 2-bromo-ethylamine hydrobromide (12.7 g.) in ethanol (100 ml.) is heated under reflux for one hours, treated with sodium methoxide (3.2 g.) and heated under reflux for one additional hour. The solvent is evaporated, the residue treated with aqueous sodium hydroxide solution and them extracted with chloroform. The chloroform extract is dried over Na 2 SO 4 , filtered and the filtrate concentrated under reduced pressure. The concentrate on distillation yields 5.2 g. of product, b.p. 107°-9°C. 18 mm. which is added to fumaric acid in hot isopropanol to yield on cooling the hydrogen fumarate, m.p. 179°-182°C.
Analysis Calc. for: C 10 H 14 N 2 O 5;
Calc.: C, 49.58; H, 5.83; N, 11.57.
Found: C, 49.10; H, 6.04; N, 11.40.
EXAMPLE 3
Preparation of ethyl 2,3,5,6,7,8-hexahydroimidazao[1,2-a]-pyrazine-7-carboxylate ##SPC4##
A solution of ethyl 3-ketopiperazin-1-yl carbamate (25 g., .15 moles) in 100 ml. of methylene chloride is added dropwise with stirring at 0°C. to a solution of triethyloxonium fluoroborate (32 g.) in 200 ml. of methylenechloride. After six hours of stirring, the solution is treated with 36 g. of 50% aqueous potassium carbonate solution. The organic solution is separated, dried over anhydrous K 2 CO 3 , filtered and the filtrate concentrated under reduced pressure. The concentrate is distilled to yield 6 g. of lactam ether b.p. 80°-85°/0.2 mm. A solution of the lactam ether and 2-bromoethylamine hydrobromide (6.1 g.) in ethanol (150 ml.) is allowed to stand for 2 days. This solution is heated under reflux for one hour after adding 1.8 g. of sodium methoxide. The solvent is evaporated, the residue treated with aqueous sodium hydroxide solution and then extracted with chloroform. The chloroform solution is dried over Na 2 SO 4 , filtered and the filtrate contrated under reduced pressure. Distillation of the concentrate gives the product, b.p. 166°-168°/4 mm.
Analysis Calc. for: C 9 H 15 N 3 O 2 :
Calc.: C, 54.81; H, 7.66; N, 21.29.
Found: C, 54,40; H, 7.75; N, 21,51.
EXAMPLE 4
Following the procedure of Example 1, the following compounds of the present invention, given in the table below, are prepared when the appropriate substitution (in equivalent amount) for the 3-thiomorpholinone of Example 1 is made:
TABLE I______________________________________COMPOUND A R.sup.1 R.sup.2 REAGENT, USED IN PLACE OF LACTAM OF EXAMPLE 1______________________________________1.) S CH.sub.3 H2.) S H CH.sub.33.) O CH.sub.3 H4.) O H CH.sub.35.) S C.sub.6 H.sub.5 H______________________________________
EXAMPLE 5
Pharmaceutical compositions
A typical tablet containing 5 mg. of 2,3,5,6-tetrahydro-8H-imidazo[2,1-c] [1,4]-thiazine per tablet is prepared by mixing together with the active ingredient calcium phosphate, lactose and starch in the amounts shown in the tables below. After these ingredients are thoroughly mixed, the dry mixture blended for an additional three minutes. This mixture is then compressed into tablets weighing approximately 129 mg. each. Similarly prepared are tablets containing 2,3,5,6-tetrahydro-8H-imidazo[2,1-c] [1,4]-oxazine and ethyl 2,3,5,6,7,8-hexahydroimidazo[1,2-a]-pyrazine-7-carboxylate.
______________________________________TABLET FORMULAINGREDIENT MG. PER TABLET______________________________________2,3,5,6-Tetrahydro-8H-imidazo-[2,1-c][1,4]-thiazine 5 mg.Calcium phosphate 52 mg.Lactose 60 mg.Starch 10 mg.Magnesium stearate 1 mg.TABLET FORMULAINGREDIENT MG. PER TABLET______________________________________2,3,5,6-Tetrahydro-8H-imidazo-[2,1-c][1,4]-oxazine 5 mg.Calcium phosphate 52 mg.Lactose 60 mg.Starch 10 mg.Magnesium stearate 1 mg.TABLET FORMULAINGREDIENT MG. PER TABLET______________________________________Ethyl 2,3,5,6,7,8-hexahydroimidazo-[1,2-a]-pyrazine-7-carboxylate 5 mg.Calcium phosphate 52 mg.Lactose 60 mg.Starch 10 mg.Magnesium stearate 1 mg.______________________________________
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Disclosed are 2,3,5,6-tetrahydro-8H-imidazo-[2,1-c][1,4]thiazines, analogues and derivatives thereof which are effective in inhibiting indoleamine-N-methyl transferase and thus useful in the treatment of mental aberrations, such as schizophrenia. Also disclosed are processes for the preparation of such imidazothiazines; pharmaceutical compositions comprising such compounds; and methods of treatment comprising administering such compounds and compositions.
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BACKGROUND AND DISCUSSION OF THE INVENTION
The present invention relates to devices for interconnecting fluid carrying tubing utilized with life-support and/or monitoring systems for the patient or for experimental laboratory animal in biology and medicine.
Currently, such a representative device is a disposable three-way stopcock with port orientation 90° and 180° to one another. It is not, however, a precision coupler. While it suitably serves the purpose in some instances, it leaves much to be desired in a number of applications. For example, it clearly has become the poorest link in modern high fidelity recording and monitoring systems wherein maximum efficiency in hemodynamic data gathering is of utmost importance. Minor disturbances can adversely affect the accuracy of such recording and monitoring systems. The entrapment of air bubbles in a 90° angulated conduit has a high probability of occurrence and hampers efficient pressure transmission. When blood pressure is being monitored, the air bubbles generally alter the pressure signal by producing damping and distortion of the pressure wave form. Additionally, because the stopcock is constructed with generally opaque materials, complete removal of bubbles by prior vigorous flushing with a physiological fluid can seldom be ascertained with satisfactory certainty.
The conventional three-way stopcock is a simple but also an awkward design. When in actual use, the stopcock assembly assumes an array of 3 tubings connected at right angles to one another. Moreover, while the handle of the stopcock is usually marked to indicate which tubing is shut off, clinical and laboratory experience has shown that it remains often difficult to verify at a glance which flowthrough system is in operation. Additionally, the right angle orientation of the connector ends does not lend itself as a visual reminder that the female connectors are generally intended to conduct fluid into the stopcock while the male connector serves as the exit port.
Accordingly, it is the primary object of this present invention to provide a novel four-way valve for use in biology and medicine.
Another object is to provide a novel four-way valve with its end connectors designed to provide a more direct pathway across the coupler (valve) consequently eliminating the trapping of air bubbles and the accompanied loss in monitored pressure response.
An additional object of the present invention is to provide a valve design so that any professional or technical operator can easily identify the two female connectors as generally being intended as input ports at one end of the valve body and the male connector as the singular output port at the opposite end.
A further object of the present invention is to provide a fail-safe valve stem against leaks due to either excessive pressure or forced-turning of the valve stem handle against a "dead-stop".
Another object of the present invention is to provide a four-way valve which clearly identifies not only the port closed to fluid movement, but which also simultaneously indicates the conduit which is opened.
Still another object of the present invention is to provide a valve with a clear transparent structure for direct visual observation of the interconnecting ports.
A further object of the present invention is to provide a four-way valve which is economically feasible for disposal after a single use, particularly in a clinical environment, yet durable enough for repeated use in non-clinical applications.
Other objects and advantages of the present invention will become more apparent to those experienced in the use of stopcocks in the art to which pertains the present invention from the following description of the preferred embodiment written in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of the four-way valve body;
FIG. 2 is schematic diagram of the valve stem and FIG. 2A is the stem of FIG. 2 rotated 90°;
FIGS. 2B and 2C are cross-sections of FIGS. 2 and 2A taken along lines 2B--2B and 2C--2C respectively;
FIGS. 2D-2E are cross-sections of FIGS. 2 and 2A taken along lines 2D--2D and 2E--2E respectively;
FIGS. 3-5 illustrate the three positions of the valve stem for providing each of the three singly directed flows commonly provided by the conventional three-way stopcock;
FIGS. 6 and 7 show the two operating positions for providing dual input flows through the valve; and
FIGS. 8-12 show the five possible positions which effectively close all three ports simultaneously.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, valve 10 includes a valve body 33 made of transparent polycarbonate thermoplastic, thus giving this structural component exceptionally high impact, tensile, shear and flexual strength. The two Luer-Lock female connector ends 30 and 31 are separated by an angle of 72°. Male connector end 32 is located equidistantly, as measured by an arc of 144°, between each of the two female connectors. Valve body or housing 33 defines spaced ports 12, 14, and 16 to communicate respectively with connectors 32, 30, and 31. In this manner the ports have the same angular spacing about housing 33 as their corresponding connectors. The centrally located valve body 33 is a hollow cylinder in design, defining a countersunk bore having one face 34 which is recessed to provide an annular wall or flange 35 at the periphery. Portions of face 34 overlying the three conduits or ports within valve body 33 are further recessed in a rectangular manner at 36, 37, 38, and filled with a (curable) red marker medium. The centrally located bore 39 receives a valve stem 18 in a pressed-fitted manner.
The valve stem consists of the stem proper 40 and the finger-handle knob 41 as shown in FIG. 3. The bored holes or channels 42 and 43 are directed centrally to the stem's axis where they communicate with other bored holes or channels 44 and 45. The three arcs 46, 47 and 48 separating the channels are equal to one another, each being formed by an angle of 72°. The face of the finger-handle 41, shown in the left in FIGS. 2D and 2E, has four cut-out portions or slots 49, 50, 51 and 52 which coincide in angular degrees to the channels 42, 43, 44 and 45 in valve stem 40. Additionally, end face 53 of the finger-handle knob 41 is imprinted in black with the word OFF, followed by an arrow in the direction shown.
The three standard operational functions of the conventional three-way stopcock are illustrated with this novel four-way valve in FIGS. 3-5. Conventionally, only one female port may be opened to the male connector at any one time. FIG. 3 shows the valve stem position for closing off the female port 14 to connector 30, as indicated by the imprinted word OFF and the directional arrowhead. Additionally, however, the red marker 36 for the female connector 31 and the red marker 38 for the male connector 32 are clearly visible through the slots 52 and 50 respectively of the valve stem handle. Thus, ports 16 and 12 are connected, and the valve handle indicates the channels which are open as well as the ones which are closed. Turning the valve stem handle counterclockwise 72° sets the operating function for an open connection between port 14 of female connector 30 and port 12 of male connector 32, while closing off port 16 of female connector 31, as shown in FIG. 4. Again, if the valve stem is now turned an additional 144°, the operating position is set as shown in FIG. 5. In this case, port 12 of male connector 32 is no longer communicating with ports 14 and 16 for either of the two female connectors, and the operator can visually confirm at a glance that port 14 is opened to port 16.
A fourth function which is not provided by the conventional three-way stopcock is shown in FIGS. 6 and 7. From the valve stem position observed in FIG. 5, turning the valve handle 72° in either direction will render visible all three red markers 36, 37, 38 indicating that both ports 14 and 16 of female connector ends 30 and 31 are in communication with port 12 of male connector 32. In these two cases, the directional indicator OFF is non-aligned with any port since it no longer points to one of the three connectors. However, the arrowhead may be used to adjust its point at either line marker or vertical slots 54 or 55 on the valve body flange 35 for "dead center" alignment with the inner conduits of the valve body.
A detent mechanism is provided to locate the valve stem in the proper position once a particular mode is selected. In this preferred embodiment as shown in FIGS. 1, 2D and 2E, the detent mechanism includes a number of recesses 70 which correspond to the ports 12, 14 and 16 and other various positions 54, 55, 56, 57, 58, 59 and 60 about flange 35, and diametrically extending rod 72 is arranged for movement within slot 76 of the valve stem finger knob 41. The openings of slot 76 are arranged to register with recesses 70 such that rod 72 will extend into opposed recesses once the desired position is selected. Coincident with each recess 70 is a vertical slot which corresponds to each of the above-noted positions 54, 55, 56, 57, 58, 59 and 60 and ports 12, 14 and 16. These slots divide the housing into ten (10) resilient parts which flex outwardly when engaged by rod 72 and return to a normal position when rod 72 registers with a recess 70. In this manner the operator can readily perceive when the proper position as selected has been reached. Furthermore, the valve will be maintained in a selected position until the resilient bias of a housing part is overcome by the operator in selecting another mode of operation.
Another function not provided by the conventional three-way stopcock is the provision for closing all three ports simultaneously. The four-way valve can provide this condition as illustrated in FIGS. 8-12. Five positions are available for this function. In each case, it is a simple matter of off-setting the valve stem 36° (one click notch of the detent mechanism) from either of the three connectors, such that none of the three red markers 36, 37, 38 are visible through the slots of the valve stem handle. Line markers 56, 57, 58, 59 or 60 correspond to those five positions where all three ports are closed. As in the previous case, the directional arrowhead of the handle may be used for precise alignment with the line markers 56, 57, 58, 59 or 60 located on the valve body flange 33.
It should be noted that the four-way valve is designed without any provisions for "dead-stops" at any of the operating positions. Experience with the conventional three-way stopcock has shown that such stops are often inadvertently over-run in which case, as a result of adverse stress of the valve body, leaks are of common occurrence. The valve stem of the four-way valve may be continuously rotated on its axis, going through a resistance change for each operating position. The unrestricted turning of the valve stem eliminates this problem. To further facilitate quick positioning of the valve stem, however, a change in sudden resistance to turning is provided by an appropriate detent mechanism with the valve stem.
It is also noted that while this four-way valve was designed with simplicity in mind, it was done without sacrificing either safety in or efficiency of operation. Also, the four-way valve achieves in doing as a simple device that which heretofore has required both the conventional three-way and four-way stopcocks. The latter, however, is very rarely used clinically because it is awkward, confusing and lacks mechanical positioning guides. Hence, for lack of a proper interconnector, it has been customary in clinical applications, for example, to administer a second intravenous fluid simultaneously with the first by introducing a needle-adapted second I.V. tubing into the first tubing, a technique which works but which leaves much to be desired in terms of patient safety. The four-way valve (stopcock) described herein would correct this deficiency as well as resolve other problems known to those versed in the use of stopcocks.
Although, the Figures show the four-way valve with some Luer-Lock type connections, it is considered to be advantageous that the valve, on a large production volume, be made with Luer-Locks on all three connectors. This would safeguard against accidental disconnections of tubing at the bedside, notably a not too infrequent occurrence in coronary intensive care units. Also, the preferred embodiment was shown as having two (2) female and one (1) male connector, but the configuration could just as easily have one female and two male connectors.
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The disclosure relates to a four-way valve, incorporating a fail-safe pivotal valve stem, a finger knob indicating simultaneously both closed and opened ports, and three connector fittings oriented in a Y configuration about the centrally located valve stem body for connection with various types of tubing or catheters. A number of channels bored into the valve stem are oriented to connect various ports within the valve housing in a number of combinations depending on the valve stem position. Detent means are provided to lock the valve stem in a selected position and prevent inadvertent opening or closing of a selected port or ports.
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BACKGROUND OF INVENTION
The present invention relates generally to methods for manufacturing refractory blocks used in lining a furnace in which is conducted a process which produces slag, and more particularly to a method for treating a refractory block to improve its resistance to slag penetration.
In a typical manufacturing operation for forming a refractory block, a mixture of coarse and fine grains of uncured refractory material are initially formed into a block consisting essentially of relatively coarse grains in a matrix of relatively fine grains located in the interstices between the coarse grains. The fine grains are composed of a refractory material which is either the same as the refractory material of which the coarse grains are composed or of a refractory material which is compatible with the refractory material in the coarse grains, or both. A refractory material is compatible with another refractory material if it does not flux or reduce the melting point of the other refractory material during high temperature operating conditions.
The uncured block of refractory material has pores extending from the surface of the block inwardly along the matrix in the interstices between the coarse grains.
After formation, the uncured block of refractory material is subjected to a sintering operation to form a fully cured block of refractory material. The fully cured block is less porous than the unsintered block, but it still has some pores extending from the surface of the block inwardly along the matrix, and, during operating conditions in a furnace, slag can enter the pores in the fully cured sintered refractory block. These pores have cross-sectional spaces which are sufficiently large to permit penetration by the slag.
When a refractory block is penetrated by slag, the refractory block undergoes deterioration for a thickness substantially equal to the depth of slag penetration. More particularly, slag which has penetrated into the pores of the refractory block reacts with the refractory in the interior of the block, creating a new mineral different in composition from the rest of the refractory block. This new mineral expands and contracts at a rate different than the rest of the refractory block, creating a condition known as spalling in which layers of refractory material one to two inches thick flake off from the refractory block. Spalling reduces the effectiveness of the refractory block and reduces the life of the refractory lining composed of such refractory blocks, and this is undesirable.
Normally, refractory blocks are provided with a composition which has a minimal reaction with the slag, but such reactions can never be eliminated completely because, in order to do so, the refractory would have to be composed of material exactly the same as the slag, and this would cause the refractory block to become molten during operation of the furnace. Moreover, the slag from the furnace processing operation varies in composition during processing, so that a refractory composition which has a minimal reaction with a slag of one composition could have increased reaction when the slag undergoes a change in composition.
Among the prior art, Eusner, et al. U.S. Pat. No. 2,792,214 teaches that the rate of refractory deterioration can be reduced by reducing the porosity of the refractory block. Eusner discloses impregnating the refractory block with molten metal to fill the pores of the block and then oxidizing the metal to form a refractory metal oxide.
Church, et al. U.S. Pat. No. 4,077,808 teaches impregnating a ceramic block, composed of alumina, with phosphoric acid and then heating to react the phosphoric acid with the alumina to produce a complex aluminum phosphate which fills or partially fills the pores in the ceramic block, to harden and strengthen the ceramic block.
The ceramic block, thus hardened and strengthened, is used for mechanical or structural purposes. Church teaches that the ceramic block must be in an uncured or unsintered state in order to accomplish the aims of the Church procedure. If the ceramic block is fully cured before it is subjected to Church's impregnating step, the block is insufficiently porous to accomplish the aims of the Church procedure. Church also contemplates subjecting the ceramic block to an impregnating treatment with a solution of a metal salt which, upon heating, can be converted into a metal oxide, to fill or partially fill the pores of the uncured ceramic block, but this impregnating step must be performed before the step in which the ceramic block is impregnated with phosphoric acid or, according to Church, the treatment will not work. According to Church, a procedure in which impregnation with phosphoric acid precedes impregnation with a salt solution convertible to an oxide, has been found to produce a block retaining a high degree of porosity.
In describing the importance of assuring that the ceramic block is uncured when it undergoes the impregnation treatments described in the Church patent, Church states that the production of strongly bonded refractory materials has been found to require the presence of small pores, gaps, cracks or interstices and that, if these spaces are too small, then the chemical solution cannot penetrate properly.
SUMMARY OF THE INVENTION
The present invention constitutes a method for improving the resistance to slag penetration of a refractory lining block for a furnace in which is conducted a process which produces slag. In one embodiment, the method comprises the step of forming a porous block of uncured refractory material consisting essentially of relatively coarse grains of a first refractory material in a matrix of relatively fine grains of any refractory material which is compatible with the refractory material in the coarse grain. The fine grains can be either the same material as the material of the coarse grains or a material which does not flux the material of the course grain, both being included within the term "compatible."
The porous block of uncured refractory material is then sintered to form a fully cured block which is less porous than was the unsintered block but which still has some pores extending from the surface of the block inwardly along the matrix between the coarse grains. These pores have cross-sectional spaces which are sufficiently large to permit penetration by slag.
In order to increase the block's resistance to penetration by slag, the block is subjected to two impregnating steps. In the first impregnating step, the block is soaked in a first liquid which penetrates the pores of the block and impregnates the block. This first liquid has a composition which reacts with the refractory material in the block to form, in the matrix, a reaction product which is compatible with all the refractory material in the block and which, upon formation, reduces the pore size, i.e., the cross-sectional area of the pores, to decrease the penetrability of the pores by the slag. After the soaking step, the block is removed from the first liquid and heated, while still impregnated with the first liquid, to promote the reaction for forming the reaction product and to fuse together, by the heat of the reaction, discrete portions of the reaction product.
After the heating step, the block is soaked in a second liquid containing very fine particles of a refractory material which is compatible with the refractory material of which the block is composed and with the reaction product, to impregnate the block with the second liquid and deposit the very fine particles contained in the second liquid in the pores of the block, to further decrease the penetrability of the pores by the slag.
As the first reaction product forms in the pores, it expands to fill the pores, and in one case the expansion occurs in an exfoliative manner. This reduces the cross-sectional space in the pores and reduces substantially the extent to which slag can penetrate each of the pores. However, in most instances, some slag is still capable of penetrating the pores, and this is undesirable.
When the fine particles in the second liquid are deposited in the pores, this further decreases the cross-sectional spaces in the pores to such an extent that, for slags having surface tensions conventionally encountered in most slag-producing processes, the pores are impenetrable to the slag, notwithstanding the existance of small, open pore mouths at the surface of the refractory block.
Because the cross-sectional space of the pores, before impregnation with the second liquid, is relatively small, it is important that the particles in the second liquid which are to undergo deposition within the pores, are of a very fine size. Otherwise, these particles could not enter the pores. For example, in a typical embodiment, the fine particles of refractory material which are normally present in the matrix of the refractory block, before sintering, have a size in the range minus 100 to minus 200 mesh. The very fine particles which are deposited in the pores upon impregnation with the second liquid have a size in the range of minus 600 mesh (minus 2 microns).
The refractory material, of which the very fine particles are composed, is reactive with the first impregnating liquid to produce a reaction product which is compatible with the refractory material in the block and which will be retained within the pores. Unless the very fine particles react to form such a reaction product, they will be loose within the pores in the same state in which they entered, and may not be readily retained within the pores. In some instances, the block may contain sufficient residual first liquid, at the time of the second soaking step, to react with the very fine particles to produce a desired reaction product. However, in those instances where the block does not contain sufficient residual first liquid, the block may be soaked a second time in the first liquid, after the very fine particles have been deposited in the pores, to provide the necessary first liquid for producing the desired reaction product upon reaction with the material of which the very fine pores are composed. As with the first impregnating step, heating may be necessary, after soaking, to promote the desired reaction.
After being subjected to the impregnating and reacting treatments described above, the block is ready to be assembled with other such blocks into a furnace refractory lining having a relatively high resistance to slag penetration.
In another embodiment of the present invention, the method comprises the following steps. First, a block of uncured refractory material is formed and then sintered to produce a fully cured block, less porous than the unsintered block, but having some pores extending inwardly from the surface of the block. These pores have cross-sectional spaces which are sufficiently large to permit penetration by slag.
The block is then soaked in a first liquid which penetrates the pores and impregnates the block. The impregnated block is then subjected to a first heating step under conditions which form, from the first liquid, a product which is compatible with the refractory material of which the block is composed and which, upon formation, builds up as a layer on the grains of refractory material already in the block. This reduces the pore size, i.e., the cross-sectional area of the pores, to reduce the penetrability of the pores by slag.
Thereafter, the block is soaked in a second liquid containing very fine particles of a refractory material which is compatible with the refractory material of which the block is composed and with the product formed during the first heating step. This impregnates the block with the second liquid and deposits the very fine particles in the pores of the block to further decrease penetrability of the pores by slag.
After the second soaking step, the block is fired, either before or after it is assembled into the refractory lining of a furnace. During firing, the refractory material of which the very fine particles are composed forms a ceramic bond with the product formed during the first heating step. This enhances the retention of the very fine particles within the pores. In addition, during the first step, in most cases, a ceramic bond is formed between the product formed during the first heating step and the original refractory material of the block. In other cases, the product formed during the first heating step has the same composition as the primary material of which the refractory block was originally composed, and the product then forms an additional layer upon the original refractory material.
After the two impregnating and heating steps, the pores of the block have cross-sectional spaces which are sufficiently small as to be substantially impenetrable to slag. For reasons explained above, this condition of impenetrability occurs notwithstanding the existance of small, open pore mouths at the surface of the refractory block.
Other features and advantages are inherent in the method claimed and disclosed or will become apparent to those skilled in the art from the following detailed description.
DETAILED DESCRIPTION
In one embodiment in accordance with the present invention, a block of refractory material is formed from relatively coarse grains of alumina in a matrix of relatively fine grains of alumina and chromia. The coarse grains of alumina constitute about 70-80% of the refractory block and have a particle size of plus 100 mesh. The fine grains of alumina in the matrix constitute about 10-15% of the refractory block and have a particle size of minus 100 mesh. The fine grains of chromia in the matrix constitute about 10-15% of the refractory block and have a particle size of minus 200 mesh.
The coarse grains of alumina and the fine grains of alumina and chromia are formed into a porous block of uncured refractory material and then sintered in a conventional manner to form a fully cured block which is less permeable than the unsintered block, but which still has some pores extending from the surface of the block inwardly along the matrix between the coarse grains, and these pores have cross-sectional spaces which are sufficiently large to permit slag to penetrate through the pores into the interior of the refractory block. Penetration of slag is reduced by subjecting the block to a pair of impregnating steps.
In the first impregnating step, the block is soaked in phosphoric acid having a concentration in the range 50-95% (85% preferred). The phosphoric acid enters the pores of the refractory block and reacts with the fine grains of alumina in the matrix and with adjacent surface portions of coarse alumina grains to form an aluminum ortho-phosphate reaction product which is compatible with both the alumina and chromia in the block and which, upon formation, reduces the cross-sectional area of the pores to decrease the penetrability of the pores by the slag. The aluminum ortho-phosphate reaction product replaces some of the fine alumina particles entirely and other of the fine alumina particles partially and also forms along the outer surface portions of the coarse alumina particles adjacent the pores.
Formation of the aluminum ortho-phosphate reaction product is enhanced by removing the block from the phosphoric acid in which it was soaking and then heating the block, while still impregnated with the phosphoric acid, to promote the reaction between the alumina and the phosphoric acid and to fuse together, by the heat of the reaction, discrete portions of the aluminum ortho-phosphate reaction product. The heating step is conducted at a temperature typically in the range 400°-450° F. (204°-232° C.). The temperature at which the heating step is conducted is no higher than necessary to promote the reaction between the phosphoric acid and the alumina.
Upon formation, the aluminum ortho-phosphate reaction product expands, typically in an exfoliative manner, to fill or partially fill the pores, thereby reducing the cross-sectional space into which slag may penetrate.
Notwithstanding the fact that the size of the pores is reduced, thereby impeding penetration of the pores by slag, it may still be possible for some slag to penetrate the pores, and this is undesirable.
Accordingly, after the heating step, the block is subjected to a second impregnating step wherein the block is soaked in a second liquid comprising water containing very fine particles of alumina (e.g., less than 2 microns (minus 600 mesh)). This impregnates the block with the second liquid and deposits the very fine particles of alumina within the pores, to further decrease the penetrability of the pores by the slag. It is important that the second liquid contain very fine particles of alumina in the size range set forth above. This is because, if the particles in the second liquid were too large, these particles could not enter the pores as the latter have a reduced size resulting from the formation therein of aluminum ortho-phosphate formed after the first impregnating step.
To retain the very fine alumina particles in the pores and keep them from falling out, it would be desirable to react the very fine aluminum particles with phosphoric acid to produce particles of aluminum ortho-phosphate reaction product which would fuse together from the heat of reaction or expand, or both. Such a reaction product, formed from the very fine alumina particles, would be retained within the pores and would not fall out as might be the case with the very fine alumina particles when they were merely deposited within the pores.
A reaction between the very fine alumina particles and phosphoric acid can be accomplished in two ways. In one way, the reaction occurs between the very fine alumina particles and any residual phosphoric acid which remains unreacted within the refractory block after the heating step following the first impregnating step. Another way comprises soaking the refractory block in phosphoric acid after removing the block from the second liquid containing the very fine alumina particles. When using either of these two ways it may be necessary to subject the block to another heating step, in the same temperature range as the heating step described above. This second heating step promotes the reaction between the alumina in the very fine particles and the phosphoric acid with which the block is impregnated to form the desired aluminum ortho-phosphate reaction product.
Examples of another embodiment of a method in accordance with the present invention are set forth below.
In all of these examples, the refractory block is subjected to a plurality of processing steps, in the following sequence: a first soaking step, a first heating step, a second soaking step and a second heating step. Some of the features and conditions of these examples are summarized in Table I, below.
TABLE I______________________________________Composi-tion of First First Second SecondRefractory Soaking Heating Soaking HeatingEx. Block Liquid Step Liquid Step______________________________________A Magnesia Chromic 2000° F. alumina above acid (1093° C.) suspen- 2800° F. in re- sion (1538° C.) ducing atmos- phereB Magnesia Chromic Same as silica above acid "A" suspen- 2800° F. sion (1538° C.)C Silica Chromic Same as silica above acid "A" suspen- 2800° F. sion (1538° C.)D Silica Chromic Same as magnesia above acid "A" suspen- 2800° F. sion (1538° C.)E Alumina Chromic Same as magnesia above acid "A" suspen- 2800° F. sion (1538° C.)F Silica Silicic Boiling Chromia above acid point for suspen- 2800° F. silicic sion (1538° C.) acidG Magnesite- Chromic Same as Magnesia abovechrome acid "A" suspen- 2800° F. sion (1538° C.)______________________________________
The magnesia block of examples A and B may have a composition consisting essentially of 90-99 wt.% MgO with the balance being impurities such as Al 2 O 3 , Fe 2 O 3 , CaO and SiO 2 .
The silica block of examples C, D and F may have a composition consisting essentially of 95-98% SiO 2 with the balance being impurities.
The alumina block of example E may have a composition consisting essentially of 60-99 wt.% Al 2 O 3 and 5-39 wt.% SiO 2 with any balance being further impurities.
The magnesite-chrome block of example G may have a composition consisting essentially of 55-89 wt.% MgO, 4-30 wt.% Cr 2 O 3 , 3-18 wt.% Fe 2 O 3 , 2-30 wt.% Al 2 O 3 and 1-20 wt.% SiO 2 .
The refractory blocks of examples A through G may be composed of grains having grain sizes conventionally available in commercial refractory blocks used for lining furnaces in which are performed processes producing slag. A typical range for such grain sizes is as follows:
______________________________________+8 mesh 11%-8 mesh to +20 mesh 27%-20 mesh to +100 mesh 26%-100 mesh 36%______________________________________
The chromic acid (H 2 CrO 4 ) and silicic acid (H 2 SiO 3 ) of the examples may each have a concentration in the range 50-100%, with a saturated (or even supersaturated) concentration preferred.
The first heating step of examples A through E and G may be conducted in an atmosphere of carbon monoxide (CO) to reduce to Cr 2 O 3 the CrO 3 remaining after the H 2 O is driven off from the chromic acid (H 2 CrO 4 ). The chromia (Cr 2 O 3 ) which remains builds up as a layer on the grains of refractory material originally in the block.
The first heating step of example F boils off the H 2 O from the silicic acid leaving SiO 2 (silica) which builds up as a layer on the grains of refractory material originally in the block. In lieu of silicic acid, the first soaking liquid may comprise ethyl orthosilicate dissolved in alcohol or other liquid reagent containing SiO 3 -- ion.
The alumina suspension of example A may be composed of very fine particles (minus 1 micron) of alumina suspended in water and may have the consistency of a slurry.
Preferably, in the first soaking step of all the examples, the refractory block is immersed in a first soaking liquid which has been heated to its boiling point. This agitates and expels from the pores of the block air which is entrapped in the pores, thereby assisting in reducing porosity during the subsequent processing steps.
The silica suspension of examples B and C is composed of about 75-80 wt.%, for example, of very fine particles (minus 1 micron) of silica (SIO 2 ) suspended in a conventional, commercially available liquid reagent containing about 75-80 wt.% SiO 3 - - ion in water.
The magnesia suspension of examples D, E and G may be composed of very fine particles (minus 1 micron) of magnesia suspended in water.
The chromia suspension of example F may be composed of very fine particles (minus 1 micron) suspended in a liquid reagent of the type described above in connection with examples B and C.
The very fine particles of alumina and magnesia, in examples A, D, E and G may be suspended in liquid media other than water, e.g., alcohol, ether, gasoline or other appropriate liquid hydrocarbons.
The concentration of the very fine particles in the liquid carrying medium is preferably the maximum concentration that will maintain the very fine particles in suspension, and the liquid utilized as the carrying medium is preferably that liquid which will maximize the amount of very fine particles which will be maintained in suspension.
The second heating step is a firing step which may be conducted prior to the assembly of the refractory block into the refractory lining of a furnace or after assembly, during an initial fire-up of the furnace or during an actual processing operation in the furnace. At the time of the second heating step, there are present, in the pores of the block, very fine particles which have remained in the pores after the second soaking step. During the second heating step, the material in these particles develops a ceramic bond to the refractory material which formed, in the pores during the first heating step, as additional layers on the grains of refractory material originally in the block. Also, during the second heating step, the material which formed during the first heating step develops a ceramic bond to the refractory material originally in the block (except in example F).
More particularly, in all of examples A through E and G, during the second heating step, the chromia formed during the first heating step develops a ceramic bond and/or is chemically bonded to the refractory material originally in the block. In examples A, B and G, the chromia is bonded to magnesia, in examples C and D, the chromia is bonded to silica and, in example E, the chromia is bonded to alumina.
Similarly, during the second heating step, in example A, the alumina in the very fine particles remaining from the second soaking step is bonded to the chromia formed during the first heating step; in examples B and C, the silica in the very fine particles is bonded to the chromia; and in examples D, E and G, the magnesia in the very fine particles is bonded to the chromia. In example F, the chromia in the very fine particles is bonded to the silica formed during the first heating step.
Impregnation of the refractory by the impregnating liquids may be enhanced by boiling the impregnating liquid with the refractory body soaking in the liquid or by employing a vacuum technique in which the refractory body is placed under a vacuum before the body is soaked in the impregnating liquid. The impregnating liquid is then introduced into the evacuated chamber containing the refractory body to engulf the latter following which the vacuum is released. Both of these enhancement techniques are applicable to any soaking step involving an impregnating liquid, and both techniques function to remove air from the pores of the refractory body thereby to enhance impregnation.
The foregoing detailed description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications will be obvious to those skilled in the art.
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A block is formed from uncured grains of refractory material. The block is sintered to fully cure the block which, as sintered, has pores extending inwardly from the surface of the block. The fully cured block is soaked in a first liquid to impregnate the block with the first liquid which, upon heating, forms into a material which at least partially fills the pores, and the filling material is compatible with the original refractory material of the block. The block is then soaked in a second liquid containing very fine particles of refractory material which are deposited in the partially filled pores. Upon heating, the very fine particles are reacted with a compound at least part of which originates with the first liquid to form a reaction product which further fills the pores. These procedures enhance the resistance of the block to slag penetration.
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RELATED APPLICATIONS
[0001] This is a non-provisional patent application that claims the benefit of the provisional patent application Ser. Nos. 60/623,674 for a VEHICLE HAVING A UNIVERSAL JOINT DEVICE AND A PROCESS OF MAKING THE SAME, filed on Oct. 29, 2004 and 60/636,190 for a UNIVERSAL JOINT ASSEMBLY FOR AN AUTOMOTIVE DRIVELINE SYSTEM, filed on Dec. 15, 2004, which are hereby incorporated by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The subject invention relates generally to a driveline system for a vehicle transmission. More particularly, the present invention relates to a universal joint component of the driveline system and a method of forming the same.
[0004] 2. Description of the Prior Art
[0005] A drive axle assembly of an automotive vehicle transmits torque from an engine and a transmission to drive vehicle wheels. The drive axle assembly changes the direction of the power flow, multiplies torque, and allows different speeds between the two of the drive wheels. The drive axle assembly includes a plurality of components engaged in operative communication one with the other. One of these components is a universal joint. Typically, the universal joint includes a pair of bifurcated yokes or yoke portions, which are secured to drive shafts and which are interconnected by a cruciform for rotation about independent axes. The cruciform includes four orthogonal trunnions with each opposing pair of axially aligned trunnions mounted in a pair of aligned bores formed in the bifurcated yokes.
[0006] Typically, a bearing cup is secured in each bore and a bearing assembly is retained in the bearing cup such that each yoke is supported for pivotal movement relative to a pair of the trunnions. Various conventional universal joints having yoke portions are known to those skilled in the vehicle driveline art and are widely used in the automotive industry today. These universal joints are disclosed in U.S. Pat. Nos. 4,307,833 to Barnard; 5,601,377 to Ohya; 5,622,085 to Kostrzewa; 5,845,394 to Abe et al.; 6,162,126 to Barrett et al.; 6,280,335 to Wehner et al.; 6,336,868 to Kurecka et al.; 6,408,708 to Sahr; 6,591,706 to Harer et al.; and 6,736,021 to Adams et al.
[0007] The U.S. Pat. No. 5,601,377 to Ohya, for example, teaches an automobile steering column that transmits the rotation of the steering wheel to the steering gearbox. For increasing the degree of freedom of geometric arrangement of the steering system, the steering column has a plurality of steering shafts which are connected with each other by universal joints. The universal joint, taught by the U.S. Pat. No. 5,601,377 to Ohya, has a pair of conventional yokes and a cross member. Each yoke has a base portion and a pair of arm portions or lugs opposed to each other in a diametral direction of the yoke and extend in an axial direction of the yoke. Each arm portion has a circular opening and sides extending in a parallel relationship with the axial direction of the yoke. The yoke of the U.S. Pat. No. 5,601,377 to Ohya is taught to be connected to a steering shaft and is not subjected to numerous rotational movements as, for example, a yoke portion connected to a universal joint of a driveline and is, therefore, not considered as being feasible for use on the driveline. In addition, the yoke does not include reinforcing features of any kind to prevent bending of the arm portions during rotation of the yoke.
[0008] The U.S. Pat. No. 5,845,394 to Abe et al., for example, teaches a method of manufacturing a yoke portion having two spaced lugs for a universal joint from a blank of a sheet metal to receive the yoke portion of a uniform thickness. Similar to the yoke taught by the aforementioned U.S. Pat. No. 5,601,377 to Ohya, the spaced lugs are not reinforced to provide structural integrity of the yoke portion. Again, the yoke portion is taught to be connected to a steering shaft and is not subjected to numerous rotational movements as, for example, a yoke portion connected to a universal joint of a driveline and is, therefore, not considered as being feasible for use on the driveline.
[0009] To reduce the effect of vibration and the resulting noises, manufacturers have used various methods to construct drive shafts and universal joints connected thereto. Typical prior art yoke portions are iron cast to provide durability but are difficult to balance.
[0010] The opportunity exists for an improved universal joint and method of manufacturing the same that will reduce the mass of the yoke portion thereby reducing the effect of vibrations and the resulting noises, add structural integrity to the universal joint, make it easier to balance, and increase performance of drive line applications at a low cost and a high volume.
BRIEF SUMMARY OF INVENTION
[0011] A differential assembly for an automotive driveline system includes a transmission device, a differential device, and at least one drive shaft that extends between the transmission and differential devices. The drive shaft presents an operative communication with the transmission device and the differential device. A universal joint device rotates around a longitudinal axis and presents operative communication with the transmission device and the differential device. The universal joint device includes at least one yoke portion having a dish defining an internal surface and an external surface. A generally equal thickness is defined between the internal surface and the external surface of the dish to form a generally monolithic and tubular construction of the yoke portion. The dish is defined by a bottom and an annular wall integral with the bottom. The annular wall extends to a pair of spaced lugs diametrically disposed with respect to one another. Each lug extends outwardly to a head. Each lug presents a neck being wider in width than the head and sloping side walls interconnecting the head with the neck for reinforcing the yoke portion as the yoke portion rotates around the longitudinal axis. Each lug is reinforced by at least one indentation or dimple press formed in the lug in a shape of a gusset or a rib.
[0012] A connector extends between the yoke portion to mechanically engage at least one of the transmission devices and the differential device to yoke portion thereby defining the aforementioned operative communication. The inventive yoke portion reduces vibration of the universal joint connected to the yoke portion of the generally equal thickness as the universal joint rotates about the longitudinal axis.
[0013] An advantage of the present invention is to provide an improved yoke portion for a universal join that is stamped from a sheet metal presenting a light weight alternative to an iron cast yoke portion known in the prior art, which reduces the effect of vibrations and the resulting noises.
[0014] Another advantage of the present invention is to provide an improved yoke portion that reduces the mass of the improved yoke portion thereby making it easier to balance and increase performance of the driveline applications at a low cost and a high volume.
[0015] Still another advantage of the present invention is to provide an improved yoke portion having a pair of spaced lugs and at least one gusset defined in each of the spaced lugs to provide structural integrity to the yoke portion that reduces the effect of vibrations and the resulting noises and increases performance of the driveline system at a low mass.
[0016] Still another advantage of the present invention is to provide an improved yoke portion wherein each spaced lug presents a central axis and sloping side walls inclined from the head to the neck thereby reducing stress applied to the yoke portion and preventing the spaced lugs from bending as the yoke portion rotates around the longitudinal axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
[0018] FIG. 1 shows an elevational view of a vehicle frame having a driveline system;
[0019] FIG. 2 is an exploded view of a universal joint assembly;
[0020] FIG. 3 is a perspective view of a yoke portion of the universal joint assembly;
[0021] FIG. 4 is a cross sectional view of the yoke portion shown in FIG. 3 ;
[0022] FIG. 5 is an elevational view of the yoke portion shown in FIG. 3 ;
[0023] FIG. 6 is a side and partially cross sectional view of the yoke portion shown in FIG. 3 connected laser or spin welding to a drive shaft of various diameters;
[0024] FIG. 7 an end view of the yoke portion shown in FIG. 6 ;
[0025] FIG. 8 is a perspective view of an alternative embodiment of the yoke portion of the universal joint assembly;
[0026] FIG. 9 is a cross sectional view of the yoke portion shown in FIG. 8 ;
[0027] FIG. 10 is an end view of the yoke portion shown in FIG. 8 ; and
[0028] FIG. 11 is a side and partially cross sectional view of the yoke portion shown in FIG. 8 mechanically connected to the drive shaft;
[0029] FIG. 12 is a top view of the progressive stamping stages of forming the yoke portion;
[0030] FIG. 13 is a cross sectional view of the yoke portion having an annular sleeve circumscribing an opening defined in spaced lugs of the yoke portion formed by a stamping process;
[0031] FIG. 14 is a fragmental perspective view of the yoke portion having the annular sleeve taken from the inner side of the yoke portion; and
[0032] FIG. 15 a cross sectional view of an alternative embodiment of the yoke portion having the spaced lugs of increased thickness formed by a stamping process.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Referring to FIG. 1 , a chassis of an automotive vehicle, generally shown at 10 , includes a frame 12 and a driveline mechanism. The driveline mechanism includes a transmission assembly 14 , a differential assembly 16 , and two universal joints, generally indicated at 18 , extending between the transmission assembly 14 and the differential assembly 16 presenting an operative communication therebetween. The universal joint 18 rotates around a longitudinal axis A during its operational mode. The universal joint 18 , as better illustrated in FIG. 2 , includes a first drive shaft 19 and a second drive shaft 20 with a pair of yokes, such as, for example a first yoke 24 and a second yoke 26 . The first yoke 24 is attached to the first drive shaft 19 and the second yoke or yoke portion 26 is attached to the second drive shaft 20 .
[0034] A connector or cruciform assembly, generally shown at 28 , interconnects the first yoke 24 and the second yoke 26 . The cruciform assembly 28 includes a cross member, generally indicated at 30 , has a central hub 32 and a pair of first trunnions 34 and 36 and a pair of second trunnions 38 and 40 . The first trunnions 34 and 36 are orthogonal with respect to the second trunnions 38 and 40 , with all of the trunnions 34 , 36 , 38 , and 40 aligned within a common plane. The first trunnions 34 and 36 are cylindrical and are adapted for insertion into the first yoke 24 . Similarly, the second trunnions 38 and 40 are cylindrical and are adapted to be inserted into the second yoke 26 . The cruciform assembly 28 and the first yoke 24 are known to those skilled in a differential art and are not described and/or illustrated in great details.
[0035] Referring to FIGS. 3 through 7 the second yoke 26 is illustrated in great details showing a preferred embodiment of the present invention. The second yoke 26 is connected to each of the terminal ends of the second drive shaft 20 and presents an internal surface, generally indicated at 42 , and an external surface, generally indicated at 44 . The second yoke 26 presents a generally equal thickness defined between the internal surface 42 and the external surface 44 . A cup portion or a dish 46 of the second yoke 26 includes a frustoconical configuration. The cup portion 46 has a bottom or base 50 defined by an upper annular wall 52 .
[0036] A pair of spaced lugs 58 and 60 extend outwardly to a head 62 , 64 , respectively, from the annular wall 52 . Sloping side walls 66 and 68 interconnect each of the heads 62 and 64 with the annular wall 52 to define a neck, generally indicated at 70 , of each of the spaced lug 58 and 60 . Each sloping side wall 66 and 68 presents an acute angle defined between the axis A and each sloping side wall 66 and 68 . Each of the spaced lugs 58 and 60 includes an opening 72 . Preferably, the diameter of the opening 72 equals the distance defined between the opening 72 and the bottom or base 50 the cup portion 46 . The spaced lugs 58 and 60 are oriented diametrically with respect to one and the other. Each of the spaced lugs 58 and 60 includes an annular sleeve 74 integral with and circumscribing the opening 72 . The annular sleeve 74 extends outwardly from the internal surface 42 of the second yoke 26 . The annular sleeve 74 presents a mechanical engagement with a pair of the first 34 , 36 or second 38 , 40 trunnions of the cruciform assembly 28 in a manner known to those skilled in the differential art. In addition, the annular sleeve 74 provides additional structural reinforcement for locking the pair of the first 34 , 36 or second 38 , 40 trunnions of the cruciform assembly 28 within and between the spaced lugs 58 and 60 .
[0037] A plurality of notches 78 and 80 are defined in the annular wall 52 . A pair of oppositely spaced tabs 82 and 84 is defined between each of the notches 78 and 80 . Each of the spaced tabs 82 and 84 terminates in a folded lip portion 86 to strengthen the second yoke 26 in this area of cut off. A pair of dimples 90 and 92 are formed in each of the spaced lugs 58 and 60 . Each dimple 90 and 92 is concavely curved to define a cavity as viewed from the external surface 44 of the yoke portion and a beveled configuration as viewed from the internal surface 42 . Each dimple 90 and 92 extends from each spaced lug 58 or 60 to the bottom or base 50 the cup portion 46 with each of said dimples 90 and 92 formed below the annular sleeve 74 . The dimples 90 and 92 are designed to strengthen the spaced lugs 58 and 60 .
[0038] Referring to FIG. 6 , the yoke portion 26 is connected to the first drive shaft 19 or the second drive shaft 20 of various diameters, which may vary from 3″ to 3.5″, respectively, by welding. Preferably, laser welding is used to connect. Laser welding uses amplified light as the source to produce the weld, i.e. specific wave length of light to accomplish the welding process. As a high production welding process, laser welding produces deep penetration welds with minimum heat effective zones and has the advantage of welding dissimilar metals while producing very low heat. Laser welding is faster, cleaner, and more cost effective for manufacturing the inventive concept.
[0039] Alternatively, the yoke portion 26 and the drive shaft 19 or 20 may be connected by spin or friction welding. Spin or friction welding uses heat generated by rotational friction at the joint line defined between the yoke portion 26 the drive shaft 19 or 20 to weld them together. A machine (not shown) applies pressure axially while rotating one of the part, such as, for example, the yoke portion 26 against its stationary positioned mate, such as, for example, the drive shaft 19 or 20 , and the resulting friction generates heat that melts the parts together. Advantages of the spin welding process, used in the present invention, include high quality permanent joints, hermetic seals, lower equipment costs, ease of assembly, energy efficient operation, no ventilation required, immediate handling, entrapment of other parts, far-field welding capability and no additional material requirements.
[0040] The second yoke 26 includes an alternative embodiment, generally shown at 100 in FIGS. 8 through 11 . The second yoke 100 presents a generally equal thickness defined between the internal surface, generally indicated at 102 , and the external surface, generally indicated at 104 . A cup portion or dish 106 of the second yoke 100 includes a frustoconical configuration. The cup portion 106 has a bottom or base defined by an annular wall 110 and forming the cup portion 106 . A neck 112 extends outwardly from the annular wall 110 . The neck 112 has a diameter sized to receive the drive shaft 20 .
[0041] As best shown in FIGS. 10 and 11 , a plurality of circumferentially spaced female connectors 116 are defined in the neck 112 to mechanically engage the second drive shaft 20 . A plurality of male connectors or protuberances 118 are defined in the internal surface of the drive shaft 20 . The male connectors 118 of the drive shaft 20 mechanically engage the female connectors 116 of the second yoke 100 , thereby preventing longitudinal and lateral movement of the second yoke 100 during rotation of the universal joint 18 about the longitudinal axis A, which reduces vibration of the universal joint 18 connected to the second yoke 100 .
[0042] A pair of spaced lugs 120 and 122 extends outwardly from the cup portion 106 . Each of the spaced lugs 120 and 122 presents an opening 124 . The spaced lugs 120 and 122 are oriented diametrically with respect to one and the other. Each of the spaced lugs 120 and 122 includes an annular sleeve 126 integral with and circumscribing the opening 124 . Each of the spaced lugs 120 and 122 includes side walls 128 and 130 sloping relative the longitudinal axis A. The dish 106 and each of the sloping side walls 128 and 130 are interconnected by scalloped corners, as shown in FIGS. 8 and 10 . Alternatively, the dish 106 and each of the sloping side walls 128 and 130 are interconnected by non-scalloped corners, not illustrated in the present invention. The annular sleeve 126 extends outwardly from the internal surface 102 of the second yoke 100 . The annular sleeve 126 presents a mechanical engagement with a pair of the first 34 , 36 or second 38 , 40 trunnions of the cruciform assembly 28 in a manner known to those skilled in the differential art. In addition, the annular sleeve 126 provides additional structural reinforcement for locking the pair of the first 34 , 36 or second 38 , 40 trunnions of the cruciform assembly 28 within and between the spaced lugs 120 and 122 . A plurality of notches 132 and 134 are defined in the cup portion 104 .
[0043] A pair of oppositely spaced tabs 136 and 138 is defined between each with each notch 132 and 134 . Each of the spaced tabs 136 and 138 terminates in a folded lip portion 140 to strengthen the second yoke 100 in this area of cut off. An indentation or muscle, generally indicated at 142 , is deformed in each of the spaced lugs 120 and 122 for strengthening the spaced lugs 120 and 122 . The muscle 142 is formed by stamping the external surface 104 of the second yoke 100 to form a concavely curved cavity, which extends to a convexly curved portion of the gusset 142 as viewed from the internal surface 102 . Preferably, the gusset 142 presents a triangular configuration as viewed from the external surface 104 of the second yoke 100 and a beveled triangular configuration as viewed from the internal surface 102 .
[0044] The yoke portions 26 and 100 are formed by a progressive stamping, generally shown at 150 in FIG. 12 , which is distinguished from machining, the shaping of metal by removing material (drilling, sawing, milling, turning, grinding, etc.) and from casting, wherein metal in its molten state is poured into a mold, whose form it retains on solidifying. The progressive stamping 150 is a metalworking process that can encompass punching, coining, bending and several other ways of modifying metal raw material, a strip of metal, generally indicated at 152 , as it unrolls from a coil (not shown), supplied by an automatic feeding system (not shown). The automatic feeding system pushes the strip of metal 152 in a progressive direction 154 through all of the stations or stages of the progressive stamping 150 , as discussed further below. Each station performs one or more operations until a finished part, such as the yoke portion 26 or 100 is formed. These operations are performed by a progressive stamping die (not shown). The progressive stamping die is placed into a reciprocating stamping press (not shown). As the reciprocating stamping press moves up, the progressive stamping die opens. When the progressive stamping press moves down, the progressive stamping die closes.
[0045] When the stamping press opens, the strip of metal 152 is feed therein by the automatic feeding system pushes the strip of metal 152 in the progressive direction 154 , as best illustrated in FIG. 12 . As the stamping press closes, the progressive stamping die performs work on the raw material.progressive stamping die, such as punching a contour 156 of the yoke portion, which includes the aforementioned spaced luggs and a bottom of the yoke portion. As the progressive stamping 150 proceeds, the openings 72 , 124 are punched out in each of the spaced lugs and the bottom of the yoke portion is stamped or deformed into the aforementioned dish. As the automatic feeding system pushes the strip of metal 152 in the progressive direction 154 , the spaced lugs are bent to extend substantially perpendicular to the bottom of the yoke portion. As the strip of metal 152 is feed along the progressive direction 154 a button member 160 is inserted between the spaced lugs to provide a support for the spaced lugs as a pair of opposite die members 162 and 164 are oriented to form the annular sleeves 74 or 126 . The mechanical aspects of the opposite die members 162 and 164 are known to those skilled in the stamping art. A pair of sliding mechanisms 166 and 168 of the respective opposite die members 162 and 164 terminated into a press die 170 and 172 . The diameter of each press die 170 and 172 is larger than the diameter of the openings 72 , 124 to facilitate stamping of the annular sleeves 74 , 126 as the sliding mechanisms 166 and 168 are moved towards one and the other in the respective punching directions 172 and 174 as the press dies 170 and 172 force the metal around the openings 72 , 124 into the annular sleeve 74 and 126 . The final stage of the progressive stamping 150 separates the finished part, i.e. the yoke portion 26 and 100 from a carrying web or link 178 . The carrying web or link 178 , along with metal that is punched away in the previous operations, is treated as scrap metal.
[0046] The yoke portion 26 and/or 100 are manufactured from a high strength low allow steel manufactured by Worthington Steel Company. Preferably, a cold bending process is used to manufacture the yoke portion 26 . As compared to prior art heat treated of steel processes that leave carbon content on the part, which prevents two part from being properly fused in laser welding process, the cold bending is the most practical, accepted, and economical way to make large-radii bends and preserving structural integrity of the part, such as, for example, the yoke portion 26 .
[0047] While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A driveline system for an automotive driveline system includes a transmission device, a differential device, and a universal joint having a drive shaft presenting terminal ends and interconnecting the transmission and differential devices. A yoke is connected to each of the terminal ends of the drive shaft and presents an internal surface and an external surface having generally equal thickness defined therebetween to form a dish of the yoke having a tubular monolithic structure. The yoke portion includes a bottom and a pair of spaced lugs each presenting sloping side walls for reinforcing the lugs as said yoke is rotated around a longitudinal axis.
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FIELD OF THE INVENTION
[0001] This document describes a corn treatment process for high-yield production of whole nixtamal, and particularly refers to the process and the reactor for the process mentioned above.
BACKGROUND OF THE INVENTION
[0002] The current state of art used in tortilla factories for the production of nixtamal is practically the same one applied since the days of the Spanish Conquest, varying only in the tools and fuel used. Essentially, the process consists in placing the corn, with no previous flush, in an open container or tank, to which lime and plenty of water is added to make a mixture. A burner is placed at the bottom of the container or tank, usually of butane gas, which burns until boiling (temperature may vary between 88 and 96 Celsius degrees, depending on the elevation above sea level). The necessary boiling time varies from 60 to 90 minutes, depending on the amount of corn, container or tank capacity and burner efficiency, among other factors.
[0003] Then, the mixture is left to rest with the cooking water for a period of 5 to 12 hours. After that period, the boiled mixture is flushed and milled.
[0004] Nixtamal produced this way losses most of the corn pericarp. Pericarp is mainly comprised of insoluble vegetable fiber, vitamins, minerals, and antioxidants found in corn grain, and when cooked in the traditional way, those nutrients are dissolved due to excess of lime and are lost when the cooking water is disposed of in the drains. These solids and the excessive lime contaminate the process wastewater, known in rural areas as “nejayote”.
[0005] The yield of processed corn as described above, expressed as the ratio of kg of produced tortilla vs kg of used corn varies approximately from 1,300 to approximately 1,450 kg of tortilla per approximately 1,000 kg of corn.
[0006] Approximately 80% of traditional tortilla factories, such as small family businesses, work within a production range from 100 to 300 kg of tortillas per day. In order to achieve that amount, they need to produce or obtain from 130 to 400 kilograms of nixtamal on a daily basis. Most of the tortilla supply in Mexico is produced in this type of business as well as from similar businesses using nixtamal flour as raw material.
[0007] The economic outcomes of tortilla factories highly depend on the characteristics of the nixtamal used as well as on the quality of tortillas. However, the way of cooking corn hasn't been recognized enough and there is no equipment with new technology that improves the traditional procedure, equipment to help increase profitability and quality of the product and at the same time that such equipment is compact, easy to install and operate and with a quick return on investment.
[0008] The current way of processing corn in order to obtain nixtamal is susceptible to be substantial improvement. An example of these improvements can be seen in the Mexican patent application no MX/a/2012/003179 filed on Mar. 14, 2012 by the same applicant, wherein an alternative process for thermal treatment of corn for production of nixtamal is described.
[0009] Considering these opportunities for improvement, a new and special equipment has been designed, allowing operation under the required conditions of this new process, under different and controlled conditions to produce a better nixtamal, specially a high-yield whole nixtamal, i.e., a nixtamal from which a better quality tortilla may be obtained, soft, flexible and more resistant, among other advantageous characteristics; all this without the need of additives. In such tortilla all the corn components are preserved with a higher yield of tortillas in order to improve business profitability and the quality of tortilla.
[0010] 55% of all tortilla factories in Mexico use corn as raw material to produce nixtamal which, when milled, produces the necessary dough to make tortillas. The rest of the tortilla factories use nixtamalized corn flour, an industrial product that, when mixed with water in a mixer, produces the dough to make tortillas.
[0011] The transformation rate of Corn/Tortilla with the traditional system depends on the level of control of the tortilla factories, where approximately 1,300 to approximately 1,450 kg of tortilla are made for each 1,000 kg of flour. Tortilla factories that use nixtamalized corn flour operate within a range from approximately 1,800 to approximately 1,900 kg of tortilla for approximately each 1,000 kg of corn flour.
[0012] When operating a tortilla factory with high yield whole nixtamal, such as the one produced with the process and the equipment described in the patent application herein, a yield or transformation rate of approximately 1,750 to approximately 1,850 kg out of approximately 1,000 kg of corn is obtained by using corn as raw material.
[0013] In the traditional system, the pericarp is dissolved, hydrolyzed, and is separated during the flush, thus practically all of the pericarp is discarded, which constitutes an important loss that affects the producer's profitability and that affects product quality, as well as consumers, since valuable components from the pericarp are lost, such as vegetable fiber, vitamins, minerals, antioxidants and nutraceutical (nutritional and pharmaceuticals) substances, which are natural components of corn.
SUMMARY OF THE INVENTION
[0014] This document introduces a different, new process, as well as the reactor specially designed for this process. The process described is for a deep heat treatment for corn for high yield production of whole nixtamal, however, we must remark that the process may be applied to other products, such as any type of grains, cereal or legume, among others. In order to prevent repetitions, we shall refer hereinafter as “product” to any type of grain, cereal or legume, including but not limited to “corn”.
[0015] The procedure starts when product is introduced into the reactor previously filled with water. Product suspended in water is then stirred with compressed air so bad grains, foreign particles, dirt and pesticide residues among other items are eliminated. This process is performed at room temperature. Once corn is clean, water is discharged to an auxiliary tank where it is recycled through a filter, preferably a sand or gravel type filter by means of a pump, until clarified for its subsequent use. Water, from a heater, preferably from a solar heater, heated from approximately 50° C. to approximately 70° C. is then added to the reactor. Hydrated lime or quicklime is also added in a proportion which may vary from one (1) to twenty (20) parts per one thousand parts of product. A metal container with a sample containing a specific weight of the product is introduced into the reactor as a process control element. Heat is added to raise water temperature in the reactor up to an approximate range from 70° C. to approximately 100° C. Once temperature is reached, heat supply is stopped and an idle period from approximately 20 to approximately 50 minute follows, in order to homogenize moisture of internal components of the product. At the end of this idle period heat is back on to increase temperature in the reactor tank up to a level within a range from approximately 100° C. to approximately 130° C. approximately, increasing tank inner pressure to a range from approximately 0.1 to approximately 2.1 kg/cm 2 . When reaching the above targets, heating is off and a constant temperature idle period begins from approximately 5 to approximately 30 minutes. When this second idle period ends, reactor inner pressure is lowered to atmospheric pressure level, thus decreasing inner temperature. The reactor can be opened at this time to take out the corn sample from the metallic container to know its weight. By comparing its weight with the original one, and also considering the required characteristics of the nixtamal, the process may be either considered as complete or nixtamal is kept inside the reactor for an additional period of time before starting the final cooling process. Treated water is used for the cooling phase in order to diminish microbiological content, preferably using UV radiation and adding ozone gas. By using treated water, more hygienic and longer lasting dough and tortillas are obtained without the need of preservation additives.
[0016] Therefore, the invention has the purpose of offering a different technology from the traditional one in order to cook by this new way corn, grains, cereals or legumes, among others, in a deep fashion, increasing this way their internal temperature and moisture in such a manner as to obtain a more homogenously internal cooked product, thus producing a higher yield, such as high yield whole nixtamal. Along with this purpose, it is also intended to provide a different final product, better than that obtained in the traditional fashion. By using the method of the present invention corn pericarp can be preserved in the grain and obtaining, by using this cooking technology, top quality, longer lasting, softer and more flexible tortillas without needing the addition of food additives.
[0017] Also, derived from the above, there is the purpose of obtaining a higher yield of corn; by using this method yield increases 25 to 30%; in other words, more tortillas from the same amount of corn are obtained. Whereas by using the traditional system an average of 1,400 grams of tortillas is obtained from 1,000 g of corn; this new processing technology allows obtaining a yield within the range from approximately 1,750 to approximately 1,850 grams of tortilla out of the same 1,000 grams of corn.
[0018] Thus, another purpose is to practically keep the whole pericarp and to reduce pollution of wastewater since its organic solids content is lesser.
[0019] Another purpose is to reduce fuel consumption between 30 to 50% so the combustion emissions, greenhouse effect gases, are reduced in the same rate.
[0020] An added purpose is to reduce processing time, specifically total process time is reduced to less than 120 minutes, whereas cooking time in a traditional system lasts from 6 to 14 hours.
[0021] This new technology for cooking corn and other grains, satisfactorily solves the problems with the current technique in tortilla factories that use corn as raw material, problems that affect productivity, quality of tortillas, combustion gas emissions and contaminated water discharges. Therefore, another goal of this technology is to improve the environmental conditions and contribute with the following:
To significantly reduce the time needed to cook corn for obtaining nixtamal. To prevent from losing an important vegetable fiber, vitamins, minerals, antioxidants and nutraceutical substances that are part of the grain, which means a loss that affects production costs and diminishes nutrition properties of tortilla. To significantly reduce polluted wastewater flow and contents of organic solids. To reduce production costs by decreasing fuel consumption required for cooking, savings from 30% to 40% of fuel consumption necessary to cook corn.
[0026] An important positive consequence of the reduction in fuel consumption is the decrease, at the same rate, of the emission of combustion gases, especially CO 2 , gases that cause greenhouse effect in the atmosphere, which contributes in increasing environmental temperature, a cause of changes in weather patterns.
[0027] Another important advantage is that tortillas made using high yield whole nixtamal, or the end product after cooking, is to obtain better nutritious characteristics since practically all the components from pericarp are preserved, such as: insoluble vegetable fiber or dietary fiber, vitamins, minerals, antioxidants, nutraceutical substances (substances that contribute with nutritional and pharmaceutical benefits), and elements that are a part of the corn grain, among others. In the traditional process, the components above are mostly lost since those are diluted in the cooking water and are discarded in the drains. Also, by using this new system, tortilla obtained is better digested and absorbed due to its additional fiber content and a better gelatinization of corn starches, tortilla advantages that can only be obtained from the deep cooking process, at higher pressure and temperature; work conditions that are not found in the traditional process technique.
[0028] By increasing content of vegetable fiber or dietary fiber as well as the fiber formed by cellulose and hemicellulose that can not be digested by the gastrointestinal system, a satiety sensation is produced, thus decreasing appetite and reaching satisfaction with a lesser ingestion of food. Additionally, this kind of fiber stimulates the intestinal tract and improves bowel movement.
[0029] These advantages shall benefit millions of consumers since tortilla is the base of Mexico's staple diet.
[0030] Annual consumptions per capita are reported in Mexican surveys in the level of 120 kilograms, which means 328 grams daily, equivalent to approximately 12 tortillas daily.
[0031] The results shown in this document have been obtained in the field and at a normal tortilla factory scale, since in addition to the designing and building of this special cooking system for cooking corn for the production of high yield whole nixtamal, which is the purpose of this application, a commercial stone mill was also installed to mill nixtamal and produce dough, along with a commercial tortilla machine in order to produce tortillas. Therefore we have a pilot installation capable of producing the new high yield whole nixtamal and to transform it into dough to elaborate 3,000 tortillas per hour, of better quality than the standard tortilla. This installation has been operating on a daily basis during several weeks with the results shown herein.
BRIEF DESCRIPTION OF THE FIGURES
[0032] The particular characteristics and invention advantages, as well as other objectives of the invention will be shown in the following description, related to the attached figures, which:
[0033] FIG. 1 shows a flow diagram of the process for the thermal treatment of a product.
[0034] FIG. 2 shows a process equipment layout drawing.
[0035] FIG. 3 shows in detail the reactor cross section.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The characteristic details of this new system for processing corn and other grains, cereals or legumes, will be given in the following description. For future reference, the term “product” should be understood as corn and other grains, cereals and/or legumes that are subject to the process of the present invention, by means of the reactor of this invention.
[0037] The term “approximately” should be also taken as a finite term. The term “approximately” specifically provides an additional determined range defined as an additional range of approximately ±10%. For instance, but not limited to, it is said “approximately 100° C. to approximately 130° C”, the exact range is between 90° C. and 143° C., or between 110° C. to 143° C., or 90° C. to 116° C., or between 110° C. to 116° C. Either of the above possibilities is covered by the term “approximately”.
[0038] The system to be described is intermittent or by batches in which the product is processed in different amounts according to the size of the selected reactor and to the amount desired to be processed since loads may be made of a fraction of the rated capacity.
[0039] In any case and in all reactor sizes the process to be described and as shown in FIG. 1 , shall be the same. The following description makes reference indistinctively to FIGS. 1 , 2 , and 3 .
[0040] Container of reactor ( 1 ) is loaded with clean water at room temperature. Then the product load to be processed is added. It is preferable that the water-product proportion is within the range of approximately 0.7 to approximately 1.5 parts of water by one part of product, this proportion may vary according to the product to be processed. A container, preferably metallic, containing a sample with a specific weight content of the product is placed into the product. It is desired that the sample has a specific weight content of the product, for instance, one (1) kilogram of the product to be processed. When product and water are inside the reactor container ( 1 ), compressed air is applied from the bottom of reactor ( 1 ), provided by an air compressor ( 5 ) to shake the water-product mixture and to get rid of adhered dust with potentially pesticide residues in the surface of the product, as well as to separate by floatation, foreign particles, bad grains or pieces of corn cobs, among others. Compressed air is injected through at least a metallic pipe; said pipe directs compressed air towards the bottom of the reactor, for product stirring. It is preferred that the pressure of compressed air be in an approximate range from 3 to aproximately 7 kilogram per square centimeter. The approximate time of agitation is between approximately 35 to approximately 120 seconds, preferably from approximately 45 to 90 seconds.
[0041] When injection of compressed air is finished, floating material is separated from the reactor container ( 1 ) and wastewater is discharged into a recovery tank ( 2 ) where it is clarified by a centrifuge pump ( 3 ) and a filter ( 4 ), preferably a sand or gravel type filter through which wastewater is circulated in order to be clarified to reuse it in the following production batch. An option is to completely discard this water and use clean water in the next production batch.
[0042] Subsequently, the access lid ( 12 ) located on top of the reactor is closed with quick closing devices, which are fixation devices among which is preferred the one-hand clamps, which facilitate opening and closing the reactor lid in a safe fashion and withstand the thrust of the pressure while keeping the lid in place.
[0043] The reactor container ( 1 ) is loaded with clean water and heated to a temperature that may vary from approximately 50° C. to approximately 80° C. It is preferred that this heated water be supplied by a solar water heater ( 6 ). Lime is then added as slurry, either as slacked lime, calcium hydroxide or quicklime, calcium oxide, in a proportion related to the product, which may vary within the range of approximately 1 to approximately 20 parts per million, depending on the quality of the product and the desired characteristics of the nixtamal to be produced. The lid is closed after adding lime.
[0044] After adding lime to the container with the product and hot water, the lid is closed to shake the mixture with compressed air from the air compressor ( 5 ) for a time from approximately 35 seconds to approximately 120 seconds, preferably from approximately 45 to approximately 90 seconds, and better still from approximately 50 to approximately 85 seconds approximately, thus stirring the product-water-lime mixture in order to obtain an homogenous mixture of the components. Compressed air is injected through at least one pipe. Compressed air pressure is preferred at a range from approximately 3 to approximately 7 kilograms per square centimeter.
[0045] At the end of the agitation period, the main fuel valve is opened and the gas burner ( 7 ) is ignited, the gas flow is adjusted by means of a rotameter or flow meter ( 8 ). Gas flow is adjusted in order to reach a determined temperature. Combustion gases are injected from the combustion chamber ( 9 ) to the reactor, surrounding the reactor container ( 1 ). Diverse heat sources may be used, such as water steam generated by an external boiler or solar energy. Steam may be live steam into the pressure tank or by internal steam exchangers. Heat is generated in the combustion chamber, generating combustion gases at a temperature range between approximately 500° C. to 600° C. It is better that the combustion chamber ( 9 ) be a metallic container designed to stand inner temperatures of up to 800° C., this temperature is necessary to assure the maximum efficiency of gas combustion. The combustion chamber ( 9 ) is thermally insulated in order to prevent heat losses and has a device to control flow of atmospheric air through the combustion chamber. The combustion chamber ( 9 ) may be metallic and welded to the external wall of the reactor, specifically to the lower wall and to the bottom of the outer metallic concentric tank ( 23 ). The combustion chamber ( 9 ) directs the flow of hot gases into a second heat transfer chamber through an annular gap located between the reactor container wall ( 1 ) and the external tank ( 23 ), gap located and designed with an area to direct gas flow at a certain velocity in order to obtain the maximum heat transfer to the interior of the pressure tank. The reactor has a heat transfer rate to the interior of the pressure tank of approximately 1,800 to 2,200 BTU per hour per kilogram of product to be processed. It is preferred that the velocity be approximately 2 to approximately 7 meters per second. The reactor has three additional heat transfer chambers in the interior of the tank, formed by concentric-ring-shaped directional partitions ( 25 ) where such directional partitions may be metallic and welded to the exterior or interior walls of the reactor container ( 1 ) and the external tank ( 23 ), respectively. Each heat transfer chamber has its annular gap located between the reactor container ( 1 ) and the external tank ( 23 ) with the purpose of directing gas flow from one heat transfer chamber to the next chamber and up to the gas outlet in the chimney stack.
[0046] Burner ( 7 ) is kept burning until temperature inside the reactor reaches a temperature which may vary from approximately 60° C. to approximately 100° C.
[0047] While burner ( 7 ) is ON, combustion gases surround the reactor container ( 1 ) and are contained for additional periods of time surrounding the reactor container ( 1 ), circulating between the reactor container ( 1 ) and an external tank ( 23 ) to the reactor container where the external tank has vertical heating blades ( 24 ) designed and located to increase heat surface and heat transfer, as well as by directional partitions ( 25 ) of combustion gases, which form together with the internal jacket wall and the external wall of the pressure tank, a duct for combustion gases between the combustion chamber and a chimney stack ( 16 ) integrated to the reactor, where such chimney stack ( 16 ) allows combustion gases to exit the reactor into the atmosphere. The directional partitions ( 25 ) and the vertical blades ( 24 ) work similarly to the furnace baffles by allowing combustion gases to be directed in specific directions, or that the combustion gases remain for a determined period of time in specific places. This means that the directional partitions ( 25 ) have the function to direct the flow of gases while the vertical flaps ( 24 ) increase heat transfer to the interior of the reactor tank, and thus, to the mixture of product, reducing the time of process and consequently, improving use of fuel. That is, both the vertical flaps ( 24 ) and the directional partitions ( 25 ) are capable of both controlling the flow of gases and achieving a high heat transfer inside the reactor container ( 1 ) in order to reduce process time and fuel consumption, and structurally reinforcing at the same time the reactor container ( 1 ). The external tank ( 23 ) is concentric to the reactor container ( 1 ) in a jacket fashion, with dimensions designed so along with the directional flaps ( 25 ) create a flow of combustion gases in the exterior of the reactor container ( 1 ) at such a velocity as to maximize heat transfer to the interior of the reactor container, thus obtaining a minimum process time and high thermal efficiency, resulting in a lower fuel consumption.
[0048] Surrounding the external tank, there is a heat insulation medium ( 19 ). The heat isolation medium ( 19 ) consists preferably of approximately 2.7 to 3.8 thick of ceramic fiber protected by an external stainless steel wall, however, other means of heat isolation may be provided. The heat insulation medium ( 19 ) is necessary to reduce heat losses and to optimize thermal efficiency of the reactor.
[0049] The chimney stack ( 16 ) is necessary to create a natural draft of air induced through the burner ( 7 ) and the combustion chamber ( 9 ), where the chimney stack ( 16 ) is necessary to obtain good combustion efficiency and to move gases through the external tank ( 23 ) to their outlet into the atmosphere.
[0050] When obtaining the desired temperature, combustion is paused, and the internal moisture conditioning period of the product begins, which may last from approximately 10 to approximately 60 minutes. Before finishing the period of the internal moisture conditioning of the product, the mixture is agitated inside the reactor container ( 1 ) by injecting compressed air from the air compressor ( 5 ). It is best that this stirring during the conditioning period lasts from 7 to 4 minutes approximately before finishing the conditioning time. Compressed air is, likewise, injected by one pipe at least. It is preferred that the pressure of compressed air is in a range of approximately 3 to approximately 7 kilograms per square centimeter. The approximate time for agitation is from 35 seconds to 120 seconds approximately and more preferably from 45 to 90 seconds approximately.
[0051] When finishing the period of conditioning of internal moisture of the product, the burner ( 7 ) is lit again, repeating the operations of opening the main fuel valve, igniting the burner ( 7 ), adjusting the flow of gas and injecting the combustion gases in such a manner to surround the reactor container ( 1 ). However, this time burner ( 7 ) is ON until inside temperature of reactor is within a range from approximately 103° C. to approximately 130° C. and/or the inner pressure is within a range from approximately 0.2 kg/cm 2 to approximately 2.2 kg/cm 2 . When reaching the required temperature, burner ( 7 ) is turned off.
[0052] Upon reaching the desired temperature in the second heating period, burner ( 7 ) is off and the second inner heat and moisture conditioning period begins for a time that may vary from approximately 5 to approximately 50 minutes, depending on the corn being processed and the desired characteristics of the nixtamal.
[0053] At the end of the second conditioning period, the steam valve ( 11 ) is opened in order to reduce inner pressure of the reactor container ( 1 ). Once inner pressure of reactor container ( 1 ) is equal to atmospheric pressure, the access lid ( 12 ) is opened and the sample container is pulled out through the access. The sample weight is compared with a desired weight. If sample weight is not equivalent to the desired weight, the inner heat and moisture conditioning period is repeated, at least partially, for a determined time according to the weight of the sample and the desired weight. The partial conditioning period essentially means that the lid ( 12 ) is closed again to continue with a determined pressure and heat. Specifically, if sample weight is not equivalent to the desired weight, burners are kept off but heat flow is maintained to the interior of the reactor, where heat flow is caused by the thermal inertia of the reactor. The additional flow of heat may vary from seconds to hours, depending on the specific weight obtained of the sample. On the other hand, if sample weight is equivalent to the desired weight, the process is finished.
[0054] At the end of the process, the obtained nixtamal is allowed to cool down; nejayote is discharged through the valve ( 17 ) and treated water from tank ( 13 ) is added, wherein it is preferred that water treatment be by radiation from UV lamps ( 14 ) and added with ozone generated by an ozone generator ( 15 ). Treated water reduces the microorganism load and thus obtaining a more hygienic and long lasting product. This treated water is used as cooling water. Simultaneously, nixtamal is agitated with compressed air by the air compressor ( 5 ). Air injection is done by at least one pipe. It is better to use a pressure of compressed air within a range from approximately 3 to approximately 7 kilogram per square centimeter. Approximate stirring time is from 35 to 120 seconds approximately and preferred from 45 seconds to 90 seconds.
[0055] When nixtamal reaches the required temperature, drain valve ( 17 ) is opened to discharge cooling water. Once the cooling water is drained, the valve ( 10 ) is opened to discharge nixtamal through the bottom of the reactor and transport it to the nixtamal mill. When opening the valve ( 10 ), the cooked and cooled mixture flows internally through the conic bottom of the reactor and exiting through the valve ( 10 ) in order to transport nixtamal to the mill where it will be transformed into dough to produce tortillas.
[0056] It is preferred that the reactor container be a metallic cylinder, which may be vertical or horizontal, closed in its top side by the access lid ( 12 ), which should be of torospherical or elliptic profile and closed in its opposite side to the access lid ( 12 ) by a cone designed in such a fashion to ease discharge of nixtamal and process wastewater. These three parts are preferably manufactured of stainless steel or other material capable of standing pressure and temperatures required by the nixtamal fabrication process. Also, it is preferred that these three parts comply with the sanitary specifications of food processing equipment.
[0057] Access lid ( 12 ) to reach the interior of reactor container ( 1 ) is equipped with quick activation devices to open and close the reactor container ( 1 ) access, as explained above. Access lid ( 12 ) has a special seal to withstand such temperatures and prevent pressure leaks.
[0058] It is preferred that the reactor have a manifold ( 18 ) that, connected to the top of the reactor and with aid of several instruments, allow monitoring inner pressure and temperature of the reactor container ( 1 ), and also permitting the safety automatic discharge of steam and manual discharge of steam. It is possible that the manifold is connected to instruments such as pressure gage, thermometer, safety valve for automatic discharge of steam, manual discharge valve of steam, among others.
[0059] The reactor may use as a full or complementary source of thermal energy, resistors located in the external chambers of the pressure tank or in the inside of the pressure tank.
[0060] Alterations to the structure described herein could be foreseen for those with knowledge in the field of the invention. However, it should be cleared that the description herein is related to the preferred modes of the invention, which are only for information purposes and should not be construed as a limitation of the invention. All modifications not arising from the spirit of this invention are included in the body of the annexed claims.
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The present invention refers to a new, different cooking process of products to be nixtamalized, for instance, corn, as well as a specially designed reactor to be used in the deep thermal treatment. Essentially, the process comprises the loading of a mixture of product to be nixtamalized and water into the container; shaking of the mixture by air injection from an air compressor; separation of floating residues and discharge of wastewater; introduction of hot and clean water into the container and the addition of lime, thus creating a product-water-lime mixture; stirring of the product-water-lime mixture by injecting air from the air compressor; igniting the burner until a target temperature is obtained in the reactor container; and turn off the burner and conditioning of moisture inside the reactor container for a determined period of time where prior to the end of the determined period of time it is proceeded to shake the cooked product-water-lime mixture by air injection from the air compressor.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 61/416,591, filed Nov. 23, 2010, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] Embodiments of the invention generally relate to measuring software quality and development productivity, and utilizing software reuse as an element of such measurements. Specific embodiments utilize a software reuse metric based on call graph analysis and a lines of code metric to determine an effective lines of code metric for measuring software quality and development productivity.
BACKGROUND
[0003] Effective measures of software quality and development productivity (hereinafter “software productivity” unless otherwise indicated) can be important tools for predicting costs and evaluating the quality or benefit of completed projects. Existing methodologies typically are variations on one or both of two techniques: (1) lines of code (hereinafter “LOC”) measures; and (2) function point analysis.
[0004] LOC measures simply count the number of lines of text of a program's source code. Cost and benefit are determined by simply calculating the dollar cost per line of code. LOC measures are simple to understand, easy to compare, and easy to collect. However, while effort may be highly correlated with LOC measures, the amount of functionality of the software is not necessarily heavily correlated to LOC. Moreover, effort is less correlated with LOC measures since the advent of so called “high-level” programming languages that may require extensive pre-programming activities such as drafting requirements and design diagrams. In that case, LOC could drastically underestimate the effort required to code software. Thus, LOC measures may provide an adequate measure of an individual programmer's raw output, but fail to capture the functional quality of that output.
[0005] Function point analysis measures the amount of functionality the software provides a user. For example, function point analysis awards more points to a program that provides a user the capability to perform ten essential business tasks than to a program that provides a user the capability to perform only four similarly essential business tasks. Different tasks may be scored differently based on metrics such as type and complexity. Function point analysis by itself does not necessarily provide a measure of how much effort went into developing the software. Further, function point analysis may include some significant element of subjectivity.
[0006] Software reuse is widely accepted as a beneficial technique for managing the cost of developing software. In particular, the reuse of quality software to save resources is a widely accepted goal. The simple LOC measures described above may actually disincent reuse. Reuse incurs the cost of learning the use of the component, which may be offset by the functionality provided by the reusable component. However, using LOC measures of “work size” or output simply accounts for the cost of learning without factoring in the benefit of reuse into the lines of code measure, which could result in an inaccurate lower productivity metric for an otherwise effective example of reuse. Thus, reuse metrics may be used to improve both LOC measures and the function point analysis. Measuring reuse may be cumbersome or even impossible. The traditional way of calculating reuse involves manual effort, where the number of lines of code of both the created code and the reused code are counted (using either manual counts or through a line counting tool) and then are used to calculate the reuse percentage. This is difficult if the source code of the reused libraries are unavailable, which is typically the case for reused software. Even when source code is available, it is difficult to manually identify the re-used parts of code from the library, so manual measures of reuse will typically over-estimate the reuse measurement when the entire library is counted.
[0007] Thus, there is a need for a convenient and automated technique for measuring code reuse. With such a technique, there is still a need for useful reuse metrics that utilize such a technique.
SUMMARY
[0008] In general, various aspects of the systems, methods, and apparatus described herein address the deficiencies of the prior art noted above. Those of ordinary skill in the art will recognize that other benefits exist beyond overcoming the above noted deficiencies of the prior art. In particular, the present invention addresses the shortcomings of prior art LOC and function point analysis by incorporating a measure of reuse. Embodiments of the present invention utilize call graph analysis in a computerized environment to efficiently analyze a software code base in an automated fashion and thereby generate such reuse measures.
[0009] In one aspect, embodiments of the present invention provide a method for determining an effective productivity measure of a code base. A computer executes a program encoded on a computer-readable medium that determines a lines of code measure and a call graph of a code base. Based on the call graph, the computer determines a measure of reuse of the code base. Then, based on the reuse measure and lines of code measure, the computer determines an effective lines of code measure.
[0010] In another aspect, embodiments of the present invention provide a method for determining a productivity measure of a code base. A computer executes a program encoded on a computer-readable medium that determines (i) a lines of code measure for each programming language represented in the code base (LOC), (ii) a duplicated code ratio for each programming language represented in the code base (R dup ); (iii) a reuse ratio for each programming language (R reuse ); and (iv) a function point gearing factor for each programming language represented in the code base (GF lung ). Based on these computed values, the computer determines an adjusted backfired function point measure for the code base according to the formula:
[0000] Σ{(LOC×(1 −R dup )/(1 −R reuse ))×GF lang}
[0011] In yet another aspect, embodiments of the present invention provide a computer program product for enabling a computer to determine a productivity measure of a code base. A non-transitory computer readable medium has encoded thereon software instructions that when executed enable the computer to perform the operations of determining a lines of code measure and a call graph, both based on a code base . The computer, executing the software instructions, subsequently determines a measure of reuse of the code base based on the call graph. Then, based on the measure of reuse and the lines of code measure, the software instructions instruct the computer to determine an effective lines of code measure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the drawings, like reference characters generally refer to the same parts throughout the different views. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
[0013] FIG. 1 illustrates a exemplary code base suitable for use with embodiments of the invention;
[0014] FIG. 2 sets forth an exemplary process for determining a reuse measure for a code base in accord with the present invention;
[0015] FIG. 3 illustrates by way of a directed graph the reuse boundary of an exemplary code base;
[0016] FIG. 4 illustrates a Software Productivity System according to an exemplary embodiment of the invention;
[0017] FIG. 5 presents the Reuse Metrics Module of FIG. 4 in more detail;
[0018] FIG. 6 is pseudo code depicting an exemplary operation of the Call Graph Module of FIG. 5 ; and
[0019] FIG. 7 is a flowchart depicting an exemplary operation of the Software Productivity System of FIG. 4 .
[0020] Items in the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles and concepts of the invention.
DETAILED DESCRIPTION
[0021] The following description presents exemplary embodiments of methods and systems consistent with the present invention, which should not be interpreted to limit the scope of the claimed invention.
[0022] FIG. 1 illustrates a Code Base 500 suited to analysis by embodiments of the invention. The Code Base 500 is embodied in human-readable software instructions or the compiled version thereof being executable by a computer having a processor and memory. The Code Base 500 includes both Created Code Units 510 and Reused Code Units 520 . Created Code Units 510 are created anew for a particular software product, and Reused Code Units 520 generally consist of preexisting materials. Reused Code Units 520 may be lines of code included in the Code Base 500 or may be libraries linked in to the Code Base 500 . The Reused Code Units 520 may be “called” (e.g., methods or functions within the library are called such that they are executed at runtime) by one or more of the Created Code Units 510 .
[0023] FIG. 2 illustrates an algorithm for determining a measurement of the Reuse Code 520 in the Code Base 500 according to an exemplary embodiment of the invention. The algorithm includes: determining the Reuse Boundary of a Code Base 500 (Step S 10 ), and determining the Reuse Code 520 of the Code Base 500 based on the Reuse Boundary (Step S 11 ).
[0024] FIG. 3 illustrates the concept of a reuse boundary in an exemplary code base. The reuse boundary is a conceptual barrier between created code and reused code and illustrates code units marked as “created” or “reused” as part of the algorithm consistent with the present invention. Demarcation of created code from the reused code is an important pre-requisite to calculate the reuse ratio. This boundary may be identified by passing the paths to the created code and reused code in separate parameters to a reuse calculation module. The invention is not restricted to this mechanism and will work with other mechanisms for distinguishing between created and reused code (e.g., providing the root package or name of the created code, etc.).
[0025] FIG. 4 illustrates an exemplary embodiment of a Software Productivity System 1 that provides productivity metrics for a code base in accord with the principles of the present invention. The Software Productivity System 1 includes a User Device 2 , a Network 3 , a Software Analysis Tool 4 and a Storage Module 400 . Although FIG. 4 depicts only one User Device 2 , one Network 3 , one Software Analysis Tool 4 , one Storage Module 400 , etc., other embodiments of the Software Productivity System 1 may include a plurality of one or more of these components. For example, in an enterprise environment, each business unit may deploy a Software Analysis Tool 4 and a Storage Module 400 . Reports generated by the Software Analysis Tool 4 may be reported to a central server (not shown) for review and further analysis.
[0026] The Storage Module 400 stores a code base, such as Code Base 500 (see FIG. 1 ) that is available to the Software Analysis Tool 4 . In one embodiment the Storage Module 400 is a source control repository. The Storage Module 400 may store any representation of a Code Base 500 , including, but not limited to, source code, binary code, pseudo-code, etc.
[0027] In one embodiment the Storage Module 400 may be a computer storage medium local to the Software Analysis Tool 4 ; and the Storage Module 400 and Software Analysis Tool 4 communicate over a system bus. In another embodiment the Storage Module 400 may be remote from the Software Analysis Tool 4 , and the two modules communicate over a network. In a network, the Storage Module 400 may include (or be part of) a distributed storage system, such as network-attached-storage (NAS) or a storage-area-network (SAN).
[0028] Information may be stored in the Storage Module 400 in one or more databases. The particular architecture of the database may vary according to the specific type of data stored, the mode of access of the data, or the intended use of the data stored in the database. A database management system (DBMS) may control and manage the storage of the data in the database using any number of query languages to access the database, including, without limitation structured query language (SQL).
[0029] The Software Analysis Tool 4 may be part of or include a computer system. In the embodiment illustrated in FIG. 4 , the Software Analysis Tool 4 includes a Reuse Metrics Module 100 , a Lines-of-Code Measurement Module 200 , and a Productivity Metrics Module 300 . Each of the Reuse Metrics Module 100 , Lines-of-Code Measurement Module 200 , and Productivity Metrics Module 300 may also be part of or include a computer system.
[0030] In each case, the computer system may include a general purpose computing device in the form of a computer including a processing unit, a system memory, and a system bus that couples various system components including the system memory to the processing unit. The computer system may include a variety of computer readable media that can form part of the system memory and be read by the processing unit. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. The system memory may include computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) and random access memory (RAM). A basic input/output system (BIOS), containing the basic routines that help to transfer information between elements, such as during start-up, is typically stored in ROM. RAM typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by the processing unit. The data or program modules may include an operating system, application programs, other program modules, and program data. The operating system may be one of or include a variety of operating systems such as the Microsoft Windows® operating system, the Unix® operating system, the Linux operating system, or another operating system or platform.
[0031] The functionality provided by the modules may be combined into fewer components and modules or further separated into additional components and modules. Additionally, the components and modules may advantageously be implemented on many different platforms, including computers, servers, data communications infrastructure equipment such as application-enabled switches or routers, or telecommunications infrastructure equipment, such as public or private telephone switches or private branch exchanges (PBX).
[0032] The Software Analysis Tool 4 and its various modules may include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types in furtherance of the functionality described herein. The computer-executable instructions constituting these items are stored temporarily or permanently in memory for execution by a processor. The program modules may be developed using any suitable programming language, which is compiled to machine language or object code to allow the processor or processors to execute the corresponding instructions.
[0033] Embodiments of the present invention may also be provided as computer-readable instructions embodied on or in one or more articles of manufacture, including the Software Analysis Tool 4 and the Storage Module 400 . The article of manufacture may be any suitable computer-readable medium, such as, for example, a floppy disk, a hard disk, a CD, a DVD, a flash memory, or a solid-state memory. In general, the programs are implemented in a programming language, compiled into machine language or virtual machine instructions, and stored in files on or in one or more articles of manufacture.
[0034] In one embodiment, the various modules that make up the Software Analysis Tool 4 are part of the same computer system, and communicate over a system bus. In a networked embodiment of the Software Analysis Tool 4 , such as an internet-based system, the various modules may be, or be hosted on, one or more computer servers.
[0035] In one embodiment, a user may enter commands and information for the Software Analysis Tool 4 , as well as view information and reports provided by the Software Analysis tool 4 , by way of the User Device 2 . The User Device 2 may be a personal computer, and a user may enter commands and information through a user interface that includes input devices such as a keyboard or a touch-screen, and pointing device, commonly referred to as a mouse, trackball or touch pad. In one embodiment, a user may interact with the Software Analysis Tool 4 using these and other input devices in conjunction with a graphical user interface (GUI) provided on the User Device 2 ; or hosted on a server (possibly a server also hosting the Software Analysis Tool 4 ), and accessed by a terminal or internet browser local to the User Device 2 .
[0036] In various embodiments the Network 3 may be implemented as a wired or wireless network. When used in a local area network(LAN), computers may be connected to the LAN through a network interface or adapter. When used in a wide-area network, computers may be connected to the WAN using a modem or other communication mechanism. Embodiments of the present invention may communicate utilizing any number of transport protocols, including, without limitation User Datagram Protocol (UDP) and Transmission Control Protocol (TCP). Furthermore, components of the system may communicate through a combination of wired or wireless paths.
[0037] As illustrated in FIG. 4 , in one embodiment the Software Analysis Tool 4 includes a Reuse Metric Module 100 . FIG. 5 presents a Reuse Metrics Module 100 according to an exemplary embodiment of the invention. In this embodiment, the Reuse Metrics Module 100 includes a Call Graph Module 110 , and a Reuse Calculation Module 120 . The Call Graph Module 110 parses the code base provided (such as the Code Base 500 illustrated in FIG. 1 ) and creates an in-memory representation of the structure of the code units and the calls between them that comprises the code base (also called a call graph representation). The Call Graph Module 110 may also mark each code unit in memory as “CREATED” or “LIBRARY”. The Reuse Calculation Module 120 uses this in-memory representation to calculate the sizes of the created code units marked as ‘CREATED’ and the re-used code units marked as ‘LIBRARY,’ separately, to calculate and output the reuse measure, which, for example, may be used by the Productivity Metrics Module 300 or transmitted to the User Device 2 for interpretation by a user.
[0038] In one exemplary embodiment, the Call Graph Module 110 determines the Reuse Boundary, the amount of created code, and the amount of reused code according to a process that involves a form of call graph analysis as illustrated in FIG. 6 . A call graph represents the dependencies of code units within a code base. Those of ordinary skill in the art would recognize that a call graph may take different forms. For example, a call graph may be a directed graph, and the call graph may be dynamic or static. A dynamic call graph can represent the executed dependencies, i.e., those calls actually performed during execution of a program. A static call graph can represent, to an acceptable degree of precision, every dependent relationship between code units across every possible execution of a program.
[0039] FIG. 6 sets forth an exemplary operation of the Call Graph 110 . To initiate the process, the Call Graph Module 110 receives a path to a Code Base 500 of created code, library code, or both. First, the Call Graph Module 110 scans the created code units of Code Base 500 using the created code path and creates a graph data structure with a “code unit” as the graph node (Step S 20 ) Each code unit object (or node) in the graph data structure includes the code unit's size, links to other code units, whether the code unit is of type ‘CREATED’ or ‘LIBRARY,’ and whether it is ‘SCANNED’ or ‘UNSCANNED.’ In one exemplary embodiment the code unit structure is a dependency graph in the form of a call graph.
[0040] Code units are first loaded into memory from the created code path which is provided as input to the Reuse Metrics Module 100 (Step L 01 ). The process of “scanning” (Steps L 03 and L 14 ) involves reading the lines of code inside a code unit to determine the size of the code unit as well as the other code units that are called from this code unit. The Call Graph Module 110 analyzes the loaded code unit to identify calls (e.g., function calls) to other code units (Step L 03 ), and adds any identified called code units to a dependency model stored in memory (Step L 07 ). It also creates the call links between code units (Step L 09 ).
[0041] Those of ordinary skill in the art will recognize that a code unit may not actually call any other code units. If the current code unit does not call other code units, the method advances to Step L 11 .
[0042] Once all the created code units are scanned and loaded into memory, the Call Graph Module 110 loops through the code units in the library path, looking for code units in memory that are marked as LIBRARY and UNSCANNED (Step L 14 ). When it finds these code units, the code units are scanned and the dependency graph model updated accordingly (Steps L 15 -L 21 ).
[0043] Loop L 12 to L 21 is repeated, with each pass searching for UNSCANNED code units in the library path and attempting to update the dependency graph model. The process is halted when a pass through the system fails to make any updates to the internal dependency graph model.
[0044] Using the process illustrated in FIG. 6 , the amount of Reused Code and Created Code may be identified, and various metrics calculated. With reference to FIG. 3 , using the processes illustrated in FIG. 6 , the Created Code may be found by summing the size of the code units marked as “CREATED” e.g.:
[0000] (Size M1 +Size M2 +Size M3 +Size M4 +. . . ) Equation 1
[0045] Reused Code may be found by summing the size of code units marked as “LIBRARY” e.g.:
[0000] (Size M5 +Size M6 +Size M7 +Size M8 +. . . ) Equation 2
[0046] According to one exemplary embodiment, the Reuse % may be calculated using Equation 3 and the computed values for Created and Reused Code:
[0000]
Reused_Code
(
Reused_Code
+
Created_Code
)
×
100
%
Equation
3
[0000] Those of ordinary skill in the art will would recognize that Reuse % may be computed using other methods. Those of ordinary skill in the art would also recognize that a call graph may be created in memory using an algorithm that is different from that shown in FIG. 6 . Other optimizations and variations to this algorithm are possible even though not explicitly mentioned. In another embodiment of the reuse calculation, “size” measure above may be replaced with a semantic measurement based on the number and complexity of the API calls that are made. Those of ordinary skill in the art would recognize that other such replacements for the size measure will be possible.
[0047] Other useful metrics may be inferred from the constructed call graph. In one exemplary embodiment, the additional metrics may be calculated by mapping the reuse libraries to reused products, and calculating the reuse ratio by product. In this case a product may represent a subset of the reused code determined by an identification mechanism. According to one exemplary embodiment, products may be mapped to their root package or namespace, and that mapping may be used to identify the reused code that belongs to that product. Other useful reuse metrics include the R.O.I. (return-on-investment) of reuse, and reuse cost avoided.
[0048] Reuse ratio by product describes how different products contribute to the reuse that is reported for a project. Reuse ratio by product may be used to validate if a product is being fully leveraged in a project, compared to other projects that are also reusing the same product. Reuse ratio by product uses a similar calculation to reuse ratio, except that it counts only the reused code that belongs to that product.
[0049] One cost of reuse involves learning the API of the reused component. As the system knows the reuse boundary and can calculate the number of unique calls across this boundary, it can calculate the R.O.I of reuse in terms of the size of the reused functionality obtained for every unique API call a programmer had to learn. The number of unique API calls that cross the reuse boundary may be calculated by counting the total number of reused code units that are called (or linked from) by any created code units. The reused functionality obtained is the sum of all the reused code sizes.
[0050] Reuse cost avoided on the project is the number of lines of code that were effectively not written in that project due to reuse. Reuse Cost Avoided is the total reused code size (e.g., in source lines of code) multiplied by the cost per LOC. In one exemplary embodiment, the reuse metrics module operates on binary code. As the cost per LOC is usually given in relation to source LOC, it needs to estimate the reused source LOC from the available measures of “created source LOC” and the “Reuse Ratio”. In such a case, reuse cost avoided may be calculated according to Equation 4:
[0000]
(
Created_Source
_LOC
)
×
(
Reuse_Ratio
)
(
1
-
Reuse_Ratio
)
×
Cost_Per
_LOC
Equation
4
[0051] Reuse metrics determined by the Reuse Metrics Module 120 may include the R.O.I of reuse of a product and reuse cost avoided for a product. The R.O.I. of Reuse of a product is a measure of all the uses of a product and a total functionality utilized versus the total unique API calls used across the reuse boundary to make use of that functionality. Products with simple and well defined (and therefore typically easier to learn) API interfaces compared to the reused functionality will have a higher R.O.I. of reuse. As already stated, R.O.I. of reuse is a measure of the return on investment realized by reusing code. In one exemplary embodiment, R.O.I. of Reuse may be determined as follows, using the reuse measures described above, and as expressed in Equation 5:
[0000]
(
CreatedSource_LOC
)
×
(
Product_Reuse
_Ratoio
)
(
1
-
Product_Reuse
_Ratio
_
×
(
#
_Calls
_Across
_Reuses
_Boundary
)
Equation
5
[0052] Reuse Cost Avoided for a product may be calculated by summing the result of Equation 4 across an entire project, as expressed in Equation 6:
[0000]
∑
1
-
n
PROJECT
(
Created_Source
_LOC
n
)
×
(
Reuse_Ratio
n
)
(
1
-
Reuse_Ratio
n
)
×
Cost_Per
_LOC
n
Equation
6
[0053] In Equation 6, the Reuse ratio refers to the product reuse ratio in that project.
[0054] FIG. 7 illustrates an exemplary operation of the Software Productivity System 1 presented in FIG. 4 . The Software Analysis Tool 4 receives the Code Base 500 from the Storage Module 400 (Step S 10 ). Next, the Lines-Of-Code Measurement Module 200 determines a lines-of-code measure of the Code Base 500 (Step S 11 ), and the Reuse Metrics Module 100 determine a measure of the reuse represented in the Code Base 500 (Step S 12 ). Finally, the Productivity Metrics Module 300 determines a software productivity measure based on the lines of code measure and the measure of the reuse represented in the Code Base 500 (Step S 13 ).
[0055] In one embodiment, the software productivity measure utilizes an Effective Functionality for Productivity metric. The Functionality for Productivity metric may be calculated according to Equation 6:
[0000]
(
Adjusted_Backfired
_Function
_Points
)
Effort
×
160
Equation
6
[0056] In an exemplary embodiment, Effort is the total hours recorded by the developers on the project, either manually or by an effort tracking system. Equation 6 calculates the amount of reuse adjusted function points created for a programmer's month of effort. Those of ordinary skill in the art will would recognize that other variations of this formula and productivity representation are equally valid, for example hours per Function Points.
[0057] Backfired Function Points is a function point analysis technique that operates on the assumption that a certain number of lines of code may equate to a certain number of function points produced by the code base. Adjusted Backfired Function Points adjusts this figure to the impact from duplication and reuse. In one exemplary embodiment, Adjusted Backfired Function Points is calculated according to Equation 7:
[0000]
∑
lang
(
LOC
×
(
1
-
R
dup
)
÷
(
1
-
R
reuse
)
-
(
n
1
×
wd
)
)
×
GF
lang
Equation
7
[0058] LOC is a lines-of-code measure associated with a particular programming language utilized in the Code Base 500 . LOC may be based on industry standard best practices associated with the programming language, or internal observations based on average or median lines-of-code measures for a given programming language. LOC may also take into account the type of program embodied in the Code Base 500 .
[0059] R dup is a duplicated code ratio for the programming language associated with the Code Base 500 . In one exemplary embodiment, R dup is calculated by identifying similar code blocks in the code base, and calculates the ratio of code that is duplicated against the entire codebase.
[0060] R reuse is the reuse ratio for the programming language associated with the Code Base 500 .
[0061] “wd” is a measure of the number of code quality defects in the created code against the total size (in backfired function points) of the codebase weighted by severity.
[0062] “n1” is a factor by which the effective lines-of-code is adjusted down for quality issues. This may be calculated using historical and experiential data points as relevant for the organization.
[0063] GF lang is a function points gearing factor used to convert a lines of code measure to a function point measure. This may be an industry standard factor for which there are multiple industry sources—Capers Jones, QSM etc. Any of these sources or even experiential or organizational data points can be used to calculate the Gearing Factor.
[0064] Adjusted Backfired Function Points provide a better measure of the effective work produced compared to Backfired Function Points as it factors in the impacts of reuse, duplication and code quality. Other combinations of these factors may be used to calculate the Adjusted Backfired Function Points. By factoring in these parameters, Adjusted Backfired Function Points effectively deals with the popular arguments against productivity measurement in Software Development—that of promoting bad quality and/or duplicated code as well as dis-incenting reuse. Those of ordinary skill in the art will recognize that other such parameters and variations could be incorporated into the formula based on the organizational or industry experience, to provide a “fair” measure of the work done that incentivizes the right behavior among developers.
[0065] In one embodiment, the Software Analysis Tool 4 may be provided in an enterprise environment. In the enterprise environment, code bases may be provided by various enterprise users to the Software Analysis Tool 4 , or each enterprise site may utilize its own instantiation of the Software Analysis Tool 4 . As size metrics and call-graphs are collected across an enterprise, this aggregated information may be used to support enterprise-wide use cases. When the top level code units (e.g., packages or namespaces) are mapped to actual products, actual product reuse % (or black box reuse %) may be calculated across different departments and applications. These measures create motivation for improving constructive reuse within the enterprise environment. Through this mapping, it is possible to determine which applications and which departments are reusing which products. This information can be used to validate actual reuse on the ground against organizational reuse policies. Validation may occur automatically if the policies are hard coded into the overall Software Productivity System 1 . Reuse of a given product can be compared across projects to determine whether the product is being optimally leveraged or only superficially reused.
[0066] Certain embodiments of the present invention were described above. It is, however, expressly noted that the present invention is not limited to those embodiments, but rather the intention is that additions and modifications to what was expressly described herein are also included within the scope of the invention. Moreover, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations, even if such combinations or permutations were not discussed expressly herein, without departing from the spirit and scope of the invention. In fact, variations, modifications, and other implementations of what was described herein will occur to those of ordinary skill in the art without departing from the spirit and the scope of the invention. As such, the invention is not to be defined only by the preceding illustrative description.
[0067] Although the exemplary embodiments described in FIGS. 2 , 6 and 7 and the accompanying text implied the performance of steps in a specific order of operation, no required order should be ascribed to those embodiments. One of ordinary skill in the art will recognize that there are variations to those embodiments, including performing operations in a different order than described.
|
Systems, methods, and apparatus for measuring software development productivity that incorporate a measure of code reuse. Embodiments of the present invention utilize call graph analysis in a computerized environment to efficiently analyze a software code base in an automated fashion and thereby generate reuse measures; and then incorporates the reuse measures in the productivity analysis.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to Chinese Patent Application No. 200410066664.4, filed Sep. 21, 2004, commonly assigned, incorporated by reference herein for all purposes.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] NOT APPLICABLE
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
[0003] NOT APPLICABLE
BACKGROUND OF THE INVENTION
[0004] The present invention is directed integrated circuits and their processing for the manufacture of semiconductor devices. More particularly, the invention provides a method and device for manufacturing a capacitor structure in a dual damascene metal interconnect for integrated circuits. Merely by way of example, the invention has been applied to a copper dual damascene structure for advanced integrated circuit devices such as mixed signal devices. But it would be recognized that the invention has a much broader range of applicability. For example, the invention can be applied to other types of metal layer such as tungsten, aluminum, and others.
[0005] Integrated circuits or “ICs” have evolved from a handful of interconnected devices fabricated on a single chip of silicon to millions of devices. Current ICs provide performance and complexity far beyond what was originally imagined. In order to achieve improvements in complexity and circuit density (i.e., the number of devices capable of being packed onto a given chip area), the size of the smallest device feature, also known as the device “geometry”, has become smaller with each generation of ICs. Semiconductor devices are now being fabricated with features less than a quarter of a micron across.
[0006] Increasing circuit density has not only improved the complexity and performance of ICs but has also provided lower cost parts to the consumer. An IC fabrication facility can cost hundreds of millions, or even billions, of dollars. Each fabrication facility will have a certain throughput of wafers, and each wafer will have a certain number of ICs on it. Therefore, by making the individual devices of an IC smaller, more devices may be fabricated on each wafer, thus increasing the output of the fabrication facility. Making devices smaller is very challenging, as each process used in IC fabrication has a limit. That is to say, a given process typically only works down to a certain feature size, and then either the process or the device layout needs to be changed. An example of a technique that allows for smaller feature sizes is called the dual damascene structure. Such damascene structure is often made of copper material for multilevel interconnect designs of conventional integrated circuit devices. High-speed microprocessors have used such damascene structure, as well as others.
[0007] The dual damascene structure includes of a via and metal trench that are filled by metal in a single metallization process. Although such structure has many benefits, there are still limitations. For example, such damascene structure includes copper material itself that migrates and causes problems with adjacent dielectric materials. Accordingly, barrier metal layers should often be used to maintain the copper from contact with dielectric materials. Unfortunately, the barrier metal layer increases resistance within the damascene structure. That is, barrier metal layers between the via and lower metal contact increases resistance, which may be detrimental to the operation and the reliability of the integrated circuit. The damascene structure is also difficult to integrate with other device elements. These and other limitations are described throughout the present specification and more particularly below.
[0008] From the above, it is seen that an improved technique for processing semiconductor devices including interconnect structures is desired.
BRIEF SUMMARY OF THE INVENTION
[0009] According to the present invention, techniques for the manufacture of semiconductor devices are provided. More particularly, the invention provides a method and device for manufacturing a capacitor structure in a dual damascene metal interconnect for integrated circuits. Merely by way of example, the invention has been applied to a copper dual damascene structure for advanced integrated circuit devices such as mixed signal devices. But it would be recognized that the invention has a much broader range of applicability. For example, the invention can be applied to other types of metal layer such as tungsten, aluminum, and others.
[0010] In a specific embodiment, the invention provides an integrated circuit device structure with a novel via to metal contact feature. The structure includes a substrate (e.g., silicon wafer), a dielectric layer overlying the substrate, and a metal interconnect (e.g., copper, tungsten, aluminum) overlying the dielectric layer. A first interlayer dielectric layer is formed surrounding and co-planner with the metal interconnect, say metal 1 . A second interlayer dielectric layer of a predetermined thickness is overlying the first interlayer dielectric layer and metal 1 . A trench opening of a first width, say metal 2 trench, is formed within an upper portion of the second interlayer dielectric layer. A first barrier layer (e.g., SiN, TiSiN, TaSiN, Ta, Ti, Mo, W, TaN, WN, MoN, TiN, including combination of these) is within and is overlying the trench opening of the first width. The preferred thickness of the barrier ranges from 5 to 50 nm. The deposition technique can be chemical vapor deposition (CVD), physical vapor deposition (PVD), ion sputtering, electron beam evaporation, or the combination of them. A via opening of a second width, say via 1 , is within a lower portion of the second interlayer dielectric layer, i.e. the bottom of metal 2 trench. The via 1 width is less than or equal to the metal 2 width. The lower portion of the second interlayer dielectric layer is coupled to the upper portion of the second interlayer dielectric layer within the predetermined thickness of the second interlayer dielectric. A second barrier layer which is thinner than that of the first barrier ranging from 3 nm to 30 nm is within and is overlying the opening of the vial opening and overlying the first barrier layer including within metal 2 trench. The barrier material can be SiN, TiSiN, TaSiN, Ta, Ti, Mo, W, TaN, WN, MoN, TiN, including combination of these. The deposition technique can be CVD, PVD, ion sputtering, electron beam evaporation, or the combination of them. The preferred thickness of the barrier ranges from 3 to 30 nm. A copper material is formed overlying the first barrier layer and the second barrier layer to substantially fill the via opening and the trench within the second interlayer dielectric layer. Preferably, the copper material includes a seed layer deposited by chemical vapor deposition and/or physical vapor deposition or other like techniques. Copper fill material is then electroplated overlying the seed layer. This embodiment can make the barrier thickness much thinner than the conventional method at the via bottom by adjusting the second barrier thickness and hence reduces the via to underneath metal contact resistance.
[0011] In an alternative specific embodiment, the invention provides a method for processing integrated circuit devices. The method includes providing a substrate and forming a dielectric layer overlying the substrate. The method also includes forming a metal interconnect overlying the dielectric layer and forming a first interlayer dielectric layer surrounding and co-planner with the metal interconnect. The method includes forming a second interlayer dielectric layer of a predetermined thickness overlying the first interlayer dielectric layer. A trench opening of a first width, say metal 2 trench, is formed within an upper portion of the second interlayer dielectric layer. A first barrier layer (e.g., SiN, TiSiN, TaSiN, Ta, Ti, Mo, W, TaN, WN, MoN, TiN, including combination of these) is formed within and is overlying the trench opening of the first width, metal 2 trench. The deposition technique can be CVD, PVD, ion sputtering, electron beam evaporation, or the combination of them with preferred thickness range from 5 to 50 nm. The method forms a vial opening of a second width with a lower portion of the second interlayer dielectric layer, the bottom of metal 2 trench, and through the trench opening. The vial width is less than or equal to the metal 2 trench width. The lower portion of the second interlayer dielectric layer is coupled to the upper portion of the second interlayer dielectric layer within the predetermined thickness of the second interlayer dielectric. The method forms a second barrier layer within and overlying the opening of the vial opening and overlying the first barrier layer including within metal 2 trench. The barrier material can be TiSiN, TaSiN, Ta, Ti, Mo, W, TaN, WN, MoN, TiN, including combination of these. The deposition technique can be CVD, PVD, ion sputtering, electron beam evaporation, or the combination of them. The preferred thickness of the barrier ranges from 5 to 50 nm. A reactive ion etch (RIE) process to partially remove the second barrier within vial is carried out. This step effectively reduces the barrier thickness at the bottom of via 1 where only the second barrier is applied. In the mean time the other parts of the structure are still covered at least by the first barrier and may be part of the second barrier. A copper material is formed overlying the first barrier layer and the second barrier layer on the sidewall of vias and trenches to substantially fill the via opening and the trench within the second interlayer dielectric layer. Preferably, the copper material includes a seed layer deposited by chemical vapor deposition and/or physical vapor deposition or other like techniques. Copper fill material is then electroplated overlying the seed layer. This embodiment makes the barrier thickness much thinner than the conventional method and hence reduces the via contact resistance.
[0012] In still an alternative specific embodiment, the invention provides method for processing integrated circuit devices. The method includes providing a substrate, which comprising a silicon bearing material. The method includes forming a first interlayer dielectric layer overlying the substrate and forming a metal interconnect within and co-planner with the first interlayer dielectric layer. The method also includes forming a second interlayer dielectric layer of a predetermined thickness overlying the first interlayer dielectric layer. A trench, say metal 2 trench, of a first width is formed within an upper portion to a surface region of the second interlayer dielectric layer. A first barrier layer (e.g., SiN, TiSiN, TaSiN, Ta, Ti, Mo, W, TaN, WN, MoN, TiN, including combination of these) is formed within and is overlying the trench of the first width. The method forms a vial opening of a with a lower portion of the second interlayer dielectric layer and through the metal 2 trench opening. The via 1 width is less than or equal to the metal 2 trench width. The lower portion of the second interlayer dielectric layer is coupled to the upper portion of the second interlayer dielectric layer within the predetermined thickness of the second interlayer dielectric. The method forms a second barrier layer within and overlying the opening of the via opening and overlying the first barrier layer including within metal 2 trench. The barrier material can be TiSiN, TaSiN, Ta, Ti, Mo, W, TaN, WN, MoN, TiN, including combination of these. The deposition technique can be CVD, PVD, ion sputtering, electron beam evaporation, or the combination of them. The preferred thickness of the barrier ranges from 5 to 50 nm The first barrier layer and the second barrier layer are substantially covering an interior portion of the trench and the second barrier covers the vial opening within the second interlayer dielectric layer. A un-isotropic RIE process to completely remove the second barrier within vial bottom is carried out. This step effectively remove the second barrier at the vial bottom, but remain the second barrier at the side wall of vial. The thickness of first and second barrier is selected so that the other parts of the structure are still fully covered at least by the first barrier after RIE. A copper material is formed overlying the first barrier layer and the remaining of second barrier layer on the sidewall of vias and trenches to substantially fill the contact opening and the trench within the second interlayer dielectric layer. The method planarizes an upper portion of the copper material. Preferably, the copper material includes a seed layer deposited by chemical vapor deposition and/or physical vapor deposition or other like techniques. Copper fill material is then electroplated overlying the seed layer. This embodiment makes copper to copper direct contact and hence greatly reduces the via contact resistance and improve the interconnect reliability.
[0013] Many benefits are achieved by way of the present invention over conventional techniques. For example, the present technique provides an easy to use process that relies upon conventional technology. In some embodiments, the method provides higher device yields in dies per wafer. Additionally, the method provides a process that is compatible with conventional process technology without substantial modifications to conventional equipment and processes. Preferably, the invention can be applied to a variety of applications such as memory, ASIC, microprocessor, and other devices. Preferably, the invention provides a way to manufacture an improved via structure with less resistance and much improved interconnect reliability performance as compared to conventional devices. Depending upon the embodiment, one or more of these benefits may be achieved. These and other benefits will be described in more throughout the present specification and more particularly below.
[0014] Various additional objects, features and advantages of the present invention can be more fully appreciated with reference to the detailed description and accompanying drawings that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIGS. 1 through 6 are simplified cross-sectional view diagrams illustrating a method of fabricating a dual damascene interconnect structure according to an embodiment of the present invention; and
[0016] FIGS. 7 through 13 are simplified cross-sectional view diagrams illustrating a method of fabricating a dual damascene interconnect structure according to an alternative embodiment of the present invention
DETAILED DESCRIPTION OF THE INVENTION
[0017] According to the present invention, techniques for the manufacture of semiconductor devices are provided. More particularly, the invention provides a method and device for manufacturing a low via to metal contact resistance in a trench first dual-damascene structure in metal interconnect for integrated circuits. Merely by way of example, the invention has been applied to a copper dual damascene structure for advanced integrated circuit devices such as mixed signal devices. But it would be recognized that the invention has a much broader range of applicability. For example, the invention can be applied to other types of metal layer such as tungsten, aluminum, and others.
[0018] A method for fabricating a trench first dual-damascene structure in an interconnect for integrated circuits is provided as follows:
1. Provide a semiconductor substrate, e.g., silicon wafer; 2. Form a dielectric layer overlying the semiconductor substrate; 3. Planarize the dielectric layer; 4. Pattern the dielectric layer to form trench regions; 5. Fill the trench regions with metal fill material; 6. Planarize the dielectric layer and patterned metal layer to expose an upper portion of the metal layer; 7. Form a capping layer overlying the planarized dielectric layer and patterned metal layer; 8. Form an interlayer dielectric layer overlying the capping layer; 9. Mask the interlayer dielectric layer; 10. Etch patterns within the dielectric layer to form trench structures within an upper portion of the interlayer dielectric layer; 11. Strip the photoresist mask; 12. Form a barrier metal layer within the trench structures; 13. Mask the trench structures with via patterns; 14. Etch contact openings through a lower portion of the barrier metal layer and through a portion of the capping layer within each of the trench structures to expose a portion of the metal layer; 15. Strip the photoresist mask; Note that this step can be done separately, i.e. to strip the resist before opening the capping layer in [32] and then further etch to open the capping layer to prevent underneath metal from exposing during resist stripping. 16. Form a barrier metal layer within the contact openings and overlying the exposed portion of the metal layer and overlying the barrier metal layer within the trench structures; 17. Perform RIE to reduce the barrier thickness at the via bottom by various degrees 18. Fill the contact opening and trench region with copper fill material; 19. Planarize the copper fill material; and 20. Perform other steps, as desired
[0039] The above sequence of steps is used to form a via structure within a dual damascene metal interconnect. As shown, the method uses at least two barrier metal layer structures. The present method provides a resulting structure, which has improved contact resistance between the metal fill layer and underlying metal interconnect layer. Further details of this method are provided throughout the present specification and more particularly below.
[0040] FIGS. 1 through 6 are simplified cross-sectional view diagrams illustrating a method 100 of fabricating a dual damascene interconnect structure according to an embodiment of the present invention. These diagrams are merely an illustration, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art would recognize many other variations, modifications, and alternatives. As shown, the method provides a semiconductor substrate 101 , e.g., silicon wafer, silicon on insulator. In a specific embodiment, the method forms a dielectric layer 103 overlying the substrate. The dielectric layer is a suitable material such as silicon dioxide, silicon nitride, borophosphosilicate glass (BPSG), fluorine containing silicon glass (FSG), carbon containing silicon oxide, spin-on materials like flowable oxide (FOX), silk, a trade mark of Dow Chemical phosphosilicate glass (PSG), low K materials, and the like. The dielectric layer is patterned with trench regions, which will support interconnect structures. A metal layer 105 fills the trench regions. Preferably, the metal is copper, but it would be recognized that other metals such as tungsten, aluminum, poly-silicon, and gold can also be used. The metal is then planarized using chemical mechanical planarization (CMP) or the like. Alternatively, the method forms a dielectric layer overlying the semiconductor substrate. The method forms a metal overlying the dielectric layer. The metal layer is patterned and a dielectric layer is formed surrounding the patterned metal layer. The method planarizes the dielectric layer and patterned metal layer to expose an upper portion of the metal layer.
[0041] In a specific embodiment, a capping layer 109 is formed overlying the planarized dielectric layer and patterned metal layer. The capping layer is made of a suitable material that is often denser than the underlying dielectric layer. The capping layer is preferably silicon nitride, amorphous silicon carbide or the like. The silicon nitride or amorphous silicon carbide is deposited using a plasma enhanced CVD (PECVD) technique, although other techniques can also be used. The capping layer can also be made of multiple layers depending upon the application. The capping layer seals the underlying metal layer and dielectric layer, as shown.
[0042] The method forms an interlayer dielectric layer 111 overlying the capping layer. The interlayer dielectric layer is made of a suitable material such as silicon dioxide, silicon nitride, fluorine containing silicon glass (FSG), carbon containing silicon oxide, spin-on materials like flowable oxide (FOX), silk, a trade mark of Dow Chemical borophosphosilicate glass (BPSG), phosphosilicate glass (PSG), low K materials, and the like. The interlayer dielectric includes an upper portion and a lower portion within a thickness of material. The upper portion includes a surface region, which can be planarized. A photo resist masking layer 115 is formed overlying the interlayer dielectric. The dielectric layer is patterned with trench regions, which will support interconnect structures, as shown in FIG. 2 . The trench regions are formed within the upper portion of the thickness and couples to the surface of the interlayer dielectric layer. The trench regions include a predetermined width and depth according to a specific embodiment. The photo resist mask is stripped using ashing techniques following RIE that transfers photo pattern into interlayer dielectric.
[0043] The method forms a barrier metal layer 203 within the trench regions. The barrier metal layer lines the sides and lower portion 201 of the trench regions. Preferably, the barrier metal layer serves as a liner, which separates an overlying metal layer from the interlayer dielectric material. The barrier metal layer is made of a suitable material such as tantalum, tantalum nitride, titanium, titanium nitride, tungsten, titanium, SiN, TiSiN, TaSiN, Mo, W, WN, MoN, any combination of these to form layered structures, and the like. Preferably, the barrier metal layer is tantalum and tantalum nitride, which are deposited using a PVD process.
[0044] Referring to FIG. 3 , the method forms a masking layer 301 overlying portions of the trench structure and interlayer dielectric layer. The masking layer exposes the lower portion 305 of the trench region. The masking layer covers edges of the trench region in a manner such that the exposed lower portion has an area that is smaller than or equal to the cross-section of the trench region. As shown, barrier metal layer is exposed. The exposed barrier metal layer will be etched to form a contact structure within the trench region.
[0045] In a specific embodiment, the method etches the exposed barrier metal layer to form contact openings 403 , as illustrated in FIG. 4 . Each of the contact openings is formed through a lower portion of the interlayer dielectric layer, through the exposed barrier metal layer, and through a portion of the capping layer. Preferably, a portion of the metal layer 401 is exposed. Depending upon the embodiment, various etching techniques can be employed. For example, etching can occur using plasma etching techniques using a RIE with fluorine and/or chlorine bearing chemistry. Alternatively, etching can occur using ion-beam sputtering. The etching is preferably selective and stops upon exposure of the underlying metal layer. A single etching process or multi-step etching processes could be used to form the contact openings. Of course, the particular etching process depends upon a variety of factors according to specific embodiments. As shown, the method strips the photoresist mask before the next process.
[0046] Referring to FIG. 5 , the method forms a barrier metal layer 501 within the contact openings. The barrier metal layer is formed overlying the exposed portion of the metal layer, overlying the barrier metal layer on the upper portion of the dielectric layer in the trench structure, and overlying the contact opening in the lower portion of the interlayer dielectric layer. As shown, the contact opening includes a single or multi-barrier metal layer and the trench region includes multiple (e.g. two) barrier metal layers, which are stacked on each other. Preferably, the barrier metal layer is thin along the bottom region. The thin barrier metal layer will result in low a contact resistance between the lower and an upper metal layer. The thickness of this barrier varies depending on the specific application and embodiment given in previous sections. The barrier metal layer also covers the exposed region of the metal layer. Preferably, the barrier metal layer 501 and barrier metal layer 203 forms a liner within each of the trench and contact opening structures.
[0047] The method then fills the contact opening and trench region with a copper fill material, as illustrated by FIG. 7 . Preferably, the metal is copper, but it would be recognized that other metals such as tungsten, aluminum, poly silicon, and gold can also be used. The copper fill material can be deposited using an electroplating process, deposition, and/or sputtering process. Preferably, the copper material includes a seed layer deposited by chemical vapor deposition and/or physical vapor deposition or other like techniques. Copper fill material is then electroplated overlying the seed layer. The metal is then planarized using chemical mechanical planarization or the like. Depending upon the embodiment, the method then performs other steps, such as cleaning or metal surface treatments as desired.
[0048] Although the above has been illustrated according to a specific embodiment, there can be other modifications, alternatives, and variations. For example, certain steps can be combined or separated. Other steps can be added without departing from the scope of the claims herein. It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.
[0049] An alternative method for fabricating a via structure in a dual damascene interconnect for integrated circuits is provided as follows:
1. Provide a semiconductor substrate, e.g., silicon wafer; 2. Form a dielectric layer overlying the semiconductor substrate; 3. Planarize the dielectric layer; 4. Pattern the dielectric layer to form trench regions; 5. Fill the trench regions with metal fill material; 6. Planarize the dielectric layer and patterned metal layer to expose an upper portion of the metal layer; 7. Form a capping layer overlying the planarized dielectric layer and patterned metal layer; 8. Form an interlayer dielectric layer overlying the capping layer; 9. Mask the interlayer dielectric layer; 10. Etch patterns within the dielectric layer to form trench structures within an upper portion of the interlayer dielectric layer; 11. Strip the photoresist mask; 12. Form a barrier metal layer within the trench structures and on the dielectric layer surface; 13. Pattern mask the contact (via) structures; 14. Etch contact openings through a barrier metal layer, a lower portion of the barrier metal layer and through a portion of the capping layer within each of the trench structures to expose a portion of the metal layer; 15. Strip the photoresist mask; 16. Form a barrier metal layer within the contact openings and overlying the exposed portion of the metal layer and overlying the barrier metal layer within the trench structures; 17. Strip the photoresist layer; 18. Etch lower portion of barrier metal layer to reduce the barrier metal thickness or to expose metal layer; 19. Fill the contact opening and trench region with copper fill material; 20. Planarize the copper fill material; and 21. Perform other steps, as desired
[0071] The above sequence of steps is used to form a via structure within a dual damascene metal interconnect. As shown, the method uses at least two barrier metal layer structures. The present method provides a resulting structure, which has improved contact resistance between the metal fill layer and underlying metal interconnect layer. Preferably, the metal fill layer is in direct contact with the underlying metal layer. Further details of this method are provided throughout the present specification and more particularly below.
[0072] FIGS. 7 through 13 are simplified cross-sectional view diagrams illustrating a method 100 of fabricating a dual damascene interconnect structure according to an embodiment of the present invention. These diagrams are merely an illustration, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art would recognize many other variations, modifications, and alternatives. Like reference numerals are used in these figures as others, but are not intended to be limiting. As shown, the method provides a semiconductor substrate 101 , e.g., silicon wafer, silicon on insulator. In a specific embodiment, the method forms a dielectric layer 103 overlying the substrate. The dielectric layer is a suitable material such as silicon dioxide, silicon nitride, fluorine containing silicon glass (FSG), borophosphosilicate glass (BPSG), spin-on materials like flowable oxide (FOX), silk, carbon containing silicon oxides, phosphosilicate glass (PSG), low K materials, and the like. The dielectric layer is patterned with trench regions, which will support interconnect structures. A metal layer 105 fills the trench regions. Preferably, the metal is copper, but it would be recognized that other metals such as tungsten, aluminum, poly silicon, and gold can also be used. The metal is then planarized using chemical mechanical planarization or the like. Alternatively, the method forms a dielectric layer overlying the semiconductor substrate. The method forms a metal overlying the dielectric layer. The metal layer is patterned and a dielectric layer is formed surrounding the patterned metal layer. The method planarizes the dielectric layer and patterned metal layer to expose an upper portion of the metal layer.
[0073] In a specific embodiment, a capping layer 109 is formed overlying the planarized dielectric layer and patterned metal layer. The capping layer is made of a suitable material that is often denser than the underlying dielectric layer. The capping layer is preferably silicon nitride, amorphous silicon carbide or the like. The silicon nitride or amorphous silicon carbide is deposited using a CVD or PECVD technique, although other techniques can also be used. The capping layer can also be made of multiple layers depending upon the application. The capping layer seals the underlying metal layer and dielectric layer, as shown.
[0074] The method forms an interlayer dielectric layer 111 overlying the capping layer. The interlayer dielectric layer is made of a suitable material such as silicon dioxide, silicon nitride, fluorine containing silicon glass (FSG), spin-on materials like flowable oxide (FOX), silk, carbon containing silicon oxides, borophosphosilicate glass (BPSG), phosphosilicate glass (PSG), low K materials, and the like. The interlayer dielectric includes an upper portion and a lower portion within a thickness of material. The upper portion includes a surface region, which has been planarized. A photo resist masking layer 115 is formed overlying the interlayer dielectric. The dielectric layer is patterned with trench regions, which will support interconnect structures, as shown in FIG. 8 . The trench regions are formed within the upper portion of the thickness and couples to the surface of the interlayer dielectric layer. The trench regions include a predetermined width and depth according to a specific embodiment. The photoresist mask is stripped using ashing techniques following a RIE process.
[0075] The method forms a barrier metal layer 203 within the trench regions. The barrier metal layer lines the sides and lower portion 201 of the trench regions. Preferably, the barrier metal layer serves as a liner, which separates an overlying metal layer from the interlayer dielectric material. The barrier metal layer is made of a suitable material such as SiN, TiSiN, TaSiN, Ta, Ti, Mo, W, TaN, WN, MoN, TiN, any combination of these to form sandwiched structures, and the like. Preferably, the barrier metal layer is tantalum and tantalum nitride, which are deposited using a PVD process.
[0076] Referring to FIG. 9 , the method forms a masking layer 301 overlying portions of the trench structure and interlayer dielectric layer. The masking layer exposes the lower portion 305 of the trench region. The masking layer covers edges of the trench region in a manner such that the exposed lower portion has an area that is smaller than the cross-section of the trench region. As shown, barrier metal layer is exposed. The exposed barrier metal layer will be etched to form a contact structure within the trench region.
[0077] In a specific embodiment, the method etches the exposed barrier metal layer to form contact openings 403 , as illustrated in FIG. 10 . Each of the contact openings is formed through a lower portion of the interlayer dielectric layer, through the exposed barrier metal layer, and through a portion of the capping layer. Preferably, a portion of the metal layer 401 is exposed. Depending upon the embodiment, various etching techniques can be employed. For example, etching can occur using plasma etching techniques using a RIE with fluorine and or chlorine bearing chemistry. Alternatively, etching can occur using ion-beam sputtering. The etching is preferably selective and stops upon exposure of the underlying metal layer. A single etching process or multi-step etching processes could be used to form the contact openings. Of course, the particular etching process depends upon a variety of factors according to specific embodiments. As shown, the method strips the photoresist mask before the next process.
[0078] Referring to FIG. 11 , the method forms a barrier metal layer 501 within the contact openings. The barrier metal layer is formed overlying the exposed portion of the metal layer, overlying the barrier metal layer on the upper portion of the dielectric layer in the trench structure, and overlying the contact opening in the lower portion of the interlayer dielectric layer. As shown, the contact opening includes a single or multi barrier metal layer and the trench region includes multiple (e.g. two) barrier metal layers, which are stacked on each other. The barrier metal layer also covers the exposed region of the metal layer. Preferably, the barrier metal layer 501 and barrier metal layer 203 forms a liner within each of the trench and contact opening structures.
[0079] Referring to FIG. 12 , the method removes a contact portion of the barrier metal layer to reduce the thickness of barrier 501 or to expose the metal layer depending on the application. Preferably, the method performs a blanket etching process without use of photomasking layers. Such blanket etching process is preferably directional. Directional etching includes, among others, reactive ion etching, plasma etching, ion-beam sputtering any combination of these, and the like. As shown, the lower portion of the barrier metal layer is exposed while the barrier metal layers on the sides of the contact opening and trench region remain intact. The method continues to the next process, which will be described in more detail below.
[0080] The method then fills the contact opening and trench region with a copper fill material, as illustrated by FIG. 13 . Preferably, the metal is copper, but it would be recognized that other metals such as tungsten, aluminum, poly silicon, and gold can also be used. The copper material can be deposited using an electroplating process, deposition, and/or sputtering process. The copper material comes in direct contact with the underlying metal layer. Preferably, the copper material includes a seed layer deposited by chemical vapor deposition and/or physical vapor deposition or other like techniques. Copper fill material is then electroplated overlying the seed layer. The metal is then planarized using chemical mechanical planarization or the like. Depending upon the embodiment, the method then performs other steps, as desired.
[0081] Although the above has been illustrated according to a specific embodiment, there can be other modifications, alternatives, and variations. For example, certain steps can be combined or separated. Other steps can be added without departing from the scope of the claims herein. It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.
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An integrated circuit device structure with a novel contact feature. The structure includes a substrate, a dielectric layer overlying the substrate, and a metal interconnect overlying the dielectric layer. A first interlayer dielectric layer is formed surrounding the metal interconnect. A second interlayer dielectric layer of a predetermined thickness is overlying the first interlayer dielectric layer. A trench opening of a first width is formed within an upper portion of the second interlayer dielectric layer. A first barrier layer is within and is overlying the trench opening of the first width. A contact opening of a second width is within a lower portion of the second interlayer dielectric layer. The second width is less than the first width. The lower portion of the second interlayer dielectric layer is coupled to the upper portion of the second interlayer dielectric layer within the predetermined thickness of the second interlayer dielectric. A second barrier layer is within and is overlying the opening of the contact opening and overlying the first barrier layer. A directional partially or completely removal of the second barrier forming a low contact resistance structure. A copper material is formed overlying the first barrier layer and the second barrier layer to substantially fill the contact opening and the trench within the second interlayer dielectric layer.
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RELATED APPLICATION
This application is a divisional of U.S. application Ser. No. 10/152,686, filed on May 23, 2002, now U.S. Pat. No. 7,026,081, which claims the benefit of U.S. Provisional Application No. 60/325,211, filed on Sep. 28, 2001 both of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to photolithography, and in particular to the design and generation of a photomask (“mask”) having sub-resolution optical proximity correction (“OPC”) features, which function to correct for optical proximity effects. The present invention also relates to the use of such a mask in a lithographic projection apparatus, which generally comprises:
a radiation system for supplying a projection beam of radiation; a support structure for supporting patterning means (e.g., mask), the patterning means serving to pattern the projection beam according to a desired pattern; a substrate table for holding a substrate; and a projection system for projecting the patterned beam onto a target portion of the substrate.
BACKGROUND OF THE INVENTION
Lithographic apparatus can be used, for example, in the manufacture of integrated circuits (ICs). In such a case, the mask may contain a circuit pattern corresponding to an individual layer of the IC, and this pattern can be imaged onto a target portion (e.g. comprising one or more dies) on a substrate (silicon wafer) that has been coated with a layer of radiation-sensitive material (resist). In general, a single wafer will contain a whole network of adjacent target portions that are successively irradiated via the projection system, one at a time. In one type of lithographic projection apparatus, each target portion is irradiated by exposing the entire mask pattern onto the target portion in one go; such an apparatus is commonly referred to as a wafer stepper. In an alternative apparatus—commonly referred to as a step-and-scan apparatus—each target portion is irradiated by progressively scanning the mask pattern under the projection beam in a given reference direction (the “scanning” direction) while synchronously scanning the substrate table parallel or anti-parallel to this direction; since, in general, the projection system will have a magnification factor M (generally <1), the speed V at which the substrate table is scanned will be a factor M times that at which the mask table is scanned. More information with regard to lithographic devices as described herein can be gleaned, for example, from U.S. Pat. No. 6,046,792, incorporated herein by reference.
In a manufacturing process using a lithographic projection apparatus, a mask pattern is imaged onto a substrate that is at least partially covered by a layer of radiation-sensitive material (resist). Prior to this imaging step, the substrate may undergo various procedures, such as priming, resist coating and a soft bake. After exposure, the substrate may be subjected to other procedures, such as a post-exposure bake (PEB), development, a hard bake and measurement/inspection of the imaged features. This array of procedures is used as a basis to pattern an individual layer of a device, e.g. an IC. Such a patterned layer may then undergo various processes such as etching, ion-implantation (doping), metallization, oxidation, chemo-mechanical polishing, etc., all intended to finish off an individual layer. If several layers are required, then the whole procedure, or a variant thereof, will have to be repeated for each new layer. Eventually, an array of devices will be present on the substrate (wafer). These devices are then separated from one another by a technique such as dicing or sawing, whence the individual devices can be mounted on a carrier, connected to pins, etc. Further information regarding such processes can be obtained, for example, from the book “Microchip Fabrication: A Practical Guide to Semiconductor Processing”, Third Edition, by Peter van Zant, McGraw Hill Publishing Co., 1997, ISBN 0-07-067250-4, incorporated herein by reference.
For the sake of simplicity, the projection system may hereinafter be referred to as the “lens”; however, this term should be broadly interpreted as encompassing various types of projection systems, including refractive optics, reflective optics, and catadioptric systems, for example. The radiation system may also include components operating according to any of these design types for directing, shaping or controlling the projection beam of radiation, and such components may also be referred to below, collectively or singularly, as a “lens”. Further, the lithographic apparatus may be of a type having two or more substrate tables (and/or two or more mask tables). In such “multiple stage” devices the additional tables may be used in parallel, or preparatory steps may be carried out on one or more tables while one or more other tables are being used for exposures. Twin stage lithographic apparatus are described, for example, in U.S. Pat. No. 5,969,441 and WO 98/40791, incorporated herein by reference.
The photolithographic masks referred to above comprise geometric patterns corresponding to the circuit components to be integrated onto a silicon wafer. The patterns used to create such masks are generated utilizing CAD (computer-aided design) programs, this process often being referred to as EDA (electronic design automation). Most CAD programs follow a set of predetermined design rules in order to create functional masks. These rules are set by processing and design limitations. For example, design rules define the space tolerance between circuit devices (such as gates, capacitors, etc.) or interconnect lines, so as to ensure that the circuit devices or lines do not interact with one another in an undesirable way. The design rule limitations are typically referred to as “critical dimensions” (CD). A critical dimension of a circuit can be defined as the smallest width of a line or the smallest space between two lines. Thus, the CD determines the overall size and density of the designed circuit.
Of course, one of the goals in integrated circuit fabrication is to faithfully reproduce the original circuit design on the wafer (via the mask). Another goal is to use as much of the semiconductor wafer real estate as possible. As the size of an integrated circuit is reduced and its density increases, however, the CD of its corresponding mask pattern approaches the resolution limit of the optical exposure tool. The resolution for an exposure tool is defined as the minimum feature that the exposure tool can repeatedly expose on the wafer. The resolution value of present exposure equipment often constrains the CD for many advanced IC circuit designs.
As the critical dimensions of the circuit layout become smaller and approach the resolution value of the exposure tool, the correspondence between the mask pattern and the actual circuit pattern developed on the photoresist layer can be significantly reduced. The degree and amount of differences in the mask and actual circuit patterns depends on the proximity of the circuit features to one another. Accordingly, pattern transference problems are referred to as “proximity effects.”
To help overcome the significant problem of proximity effects, a number of techniques are used to add sub-lithographic features to mask patterns. Sub-lithographic features have dimensions less than the resolution of the exposure tool, and therefore do not transfer to the photoresist layer. Instead, sub-lithographic features interact with the original mask pattern and compensate for proximity effects, thereby improving the final transferred circuit pattern.
Examples of such sub-lithographic features are scattering bars and anti-scattering bars, such as disclosed in U.S. Pat. No. 5,821,014 (incorporated herein by reference), which are added to mask patterns to reduce differences between features within a mask pattern caused by proximity effects. More specifically, sub-resolution assist features, or scattering bars, have been used as a means to correct for optical proximity effects and have been shown to be effective for increasing the overall process window (i.e., the ability to consistently print features having a specified CD regardless of whether or not the features are isolated or densely packed relative to adjacent features). As set forth in the '014 patent, generally speaking, the optical proximity correction occurs by improving the depth of focus for the less dense to isolated features by placing scattering bars near these features. The scattering bars function to change the effective pattern density (of the isolated or less dense features) to be more dense, thereby negating the undesirable proximity effects associated with printing of isolated or less dense features. It is important, however, that the scattering bars themselves do not print on the wafer. Thus, this requires that the size of the scattering bars must be maintained below the resolution capability of the imaging system.
Accordingly, as the limits of optical lithography are being enhanced far into the sub-wavelength capability, assist features, such as scattering bars, must be made smaller and smaller so that the assist features remain below the resolution capability of the imaging system. However, as imaging systems move to smaller wavelengths and higher numerical apertures, the ability to manufacture the photomasks with sub-resolution scattering bars sufficiently small becomes a critical issue and a serious problem.
Furthermore, as the resolution capability increases, the minimum distance (i.e., pitch) between features also decreases. This reduction in pitch makes it increasingly difficult to generate photomasks having sub-resolution assist features disposed between such closely spaced features. In other words, if features are too close together, it can be exceedingly difficult (or even impossible) to create a sub-resolution assist feature, such as a scattering bar, between such features.
Thus, there exists a need for a method of providing assist features in a photomask which eliminates the foregoing problems associated with generating the minute geometries that are necessary for assist features to remain below the resolution capability of current imaging systems.
SUMMARY OF THE INVENTION
In an effort to solve the aforementioned needs, it is an object of the present invention to provide sub-resolution assist features which are “dimension-less” (as opposed to scattering bars which have a defined width and which must be formed as a feature in the photomask) so as to eliminate the foregoing problems associated with creating sub-resolution assist features in a photomask when utilizing high resolution imaging systems. In accordance with the present invention, as explained in detail below, “dimension-less” phase-edges are utilized as sub-resolution assist features.
More specifically, the present invention relates to a photolithography mask for optically transferring a pattern formed in the mask onto a substrate. The mask includes a plurality of resolvable features to be printed on the substrate, and at least one non-resolvable optical proximity correction feature, where the non-resolvable optical proximity correction feature is a phase-edge.
The present invention also relates to a method of transferring a lithographic pattern from a photolithography mask onto a substrate by use of a lithographic exposure apparatus. The method includes the steps of forming a plurality of resolvable features to be printed on the substrate, and forming at least one non-resolvable optical proximity correction feature which is a
As described in further detail below, the present invention provides significant advantages over the prior art. Most importantly, as the phase-edges are essentially dimension-less in that there is no width dimension (or CD) associated with a phase-edge, the use of the phase-edge eliminates the need to be able to create an exceedingly small feature (i.e., scattering bar) on the mask. Moreover, the phase-edges can be readily placed between features regardless of the pitch between the features. Thus, by utilizing phase-edges as OPC features, it is possible to provide OPC in certain mask environments that can not accommodate known OPC techniques, such as scattering bars.
Additional advantages of the present invention will become apparent to those skilled in the art from the following detailed description of exemplary embodiments of the present invention.
Although specific reference may be made in this text to the use of the invention in the manufacture of ICs, it should be explicitly understood that the invention has many other possible applications. For example, it may be employed in the manufacture of integrated optical systems, guidance and detection patterns for magnetic domain memories, liquid-crystal display panels, thin-film magnetic heads, etc. The skilled artisan will appreciate that, in the context of such alternative applications, any use of the terms “reticle”, “wafer” or “die” in this text should be considered as being replaced by the more general terms “mask”, “substrate” and “target portion”, respectively.
In the present document, the terms “radiation” and “beam” are used to encompass all types of electromagnetic radiation, including ultraviolet radiation (e.g. with a wavelength of 365, 248, 193, 157 or 126 nm) and EUV (extreme ultra-violet radiation, e.g. having a wavelength in the range 5-20 nm).
The term mask as employed in this text may be broadly interpreted as referring to generic patterning means that can be used to endow an incoming radiation beam with a patterned cross-section, corresponding to a pattern that is to be created in a target portion of the substrate; the term “light valve” can also be used in this context. Besides the classic mask (transmissive or reflective; binary, phase-shifting, hybrid, etc.), examples of other such patterning means include:
a programmable mirror array. An example of such a device is a matrix-addressable surface having a viscoelastic control layer and a reflective surface. The basic principle behind such an apparatus is that (for example) addressed areas of the reflective surface reflect incident light as diffracted light, whereas unaddressed areas reflect incident light as undiffracted light. Using an appropriate filter, the said undiffracted light can be filtered out of the reflected beam, leaving only the diffracted light behind; in this manner, the beam becomes patterned according to the addressing pattern of the matrix-addressable surface. The required matrix addressing can be performed using suitable electronic means. More information on such mirror arrays can be gleaned, for example, from U.S. Pat. No. 5,296,891 and U.S. Pat. No. 5,523,193, which are incorporated herein by reference. a programmable LCD array. An example of such a construction is given in U.S. Pat. No. 5,229,872, which is incorporated herein by reference.
The invention itself, together with further objects and advantages, can be better understood by reference to the following detailed description and the accompanying schematic drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exemplary aerial intensity profile of a 180° phase-edge utilizing conventional illumination and varying sigma (σ).
FIG. 2 is an exemplary aerial intensity profile of a 180° phase-edge utilizing off-axis illuminations.
FIG. 3 illustrates the aerial image intensity of two phase-edges that are 200 nm apart when illuminated with conventional illumination and with off-axis QUASAR illumination.
FIG. 4 contains a set of aerial images illustrating the variations of I min resulting from various placements of a phase-edge relative to a feature edge for a given set of processing conditions.
FIG. 5 illustrates simulation results of a focus/exposure matrix (FEM) for an isolated line.
FIG. 6 illustrates an exemplary embodiment of phase-edges utilized as optical proximity correction features.
FIG. 7 illustrates simulation results of a focus/exposure matrix for an isolated line with sub-resolution phase-edges utilized as OPC features.
FIG. 8 illustrates simulation results of a 130 nm targeted isolated line when the phase-edges are placed 160 nm and 360 nm away from the isolated line.
FIG. 9 illustrates a comparison between the printability of a 50 nm chromeless scattering bar, a 40 nm chromeless scattering bar, and a single phase-edge when placed adjacent a 100 nm 5 bar pattern.
FIG. 10 illustrates an example of utilizing a single phase-edge as a sub-resolution OPC feature for intermediate pitch values that do not allow enough space for placement of a conventional scattering bar.
FIG. 11 shows the results of a focus/exposure simulation on a 100 nm chrome line pattern at a 400 nm pitch when a single phase-edge is placed between the chrome lines as shown in FIG. 10 .
FIG. 12 illustrates an example of the placement of a single phase-edge between chromeless features.
FIG. 13 illustrates an example of the formation of an inverse Bessel line utilizing sub-resolution phase-edges.
FIG. 14 illustrates the formation of an inverse Bessel line of FIG. 13 utilizing a chromeless phase-shift mask structure.
FIG. 15 shows the simulation results of an isolated 100 nm CLM inverse Bessel line and how the iso-focal point can be controlled by proper placement of the phase-edges.
FIG. 16 shows the results of a focus/exposure simulation regarding a 80 nm chrome feature.
FIG. 17 shows the ED (exposure/dose) latitude plot indicating the depth of focus for the 80 nm isolated line exposed with 0.80NA KrF imaging system and 0.85/0.55/30 QUASAR illumination.
FIG. 18 shows the results of a focus/exposure simulation regarding a 50 nm chrome feature.
FIG. 19 shows the ED (exposure/dose) latitude plot indicating the depth of focus for the 50 nm isolated line exposed with 0.80NA KrF imaging system and 0.85/0.55/30 QUASAR illumination.
FIG. 20 shows the results of a focus/exposure simulation regarding a 35 nm chrome feature.
FIGS. 21A and 21B illustrate the effect sub-resolution assist features have on diffraction patterns.
FIG. 22 shows an example of how sub-resolution phase-edges can be utilized to control line end shortening.
FIG. 23 illustrates an exemplary lithographic projection apparatus.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the optical proximity correction technique of the present invention, non-resolvable phase-edges are utilized as sub-resolution assist features. Prior to the present invention, phase-edges have typically been used to print very small features using a highly coherent exposure wavelength. This is possible because theoretically, a 180° phase-edge will provide an aerial image that has an I min (i.e., minimum light intensity) equal to zero and an infinite contrast when the phase-edge is illuminated with highly coherent light. This very strong dark image contrast only occurs when the illumination is highly coherent and it allows for over-exposing the wafer to print very small dark features. As the illumination becomes less coherent, as in the case of increasing sigma (σ) with conventional illumination, the contrast of the phase-edge aerial image is reduced and I min increases so that it is no longer zero. The foregoing is illustrated in FIG. 1 . As shown therein, for each increase in σ, the value of I min increases. However, it is noted that for each of the five examples set forth in FIG. 1 , the phase-edge is printed on the wafer as the value of I min is below the printing threshold (which is process dependent) defined by the dotted horizontal line illustrated in FIG. 1 . It is also noted that the location of the phase-edge is 800 nm as defined by the horizontal axis of FIG. 1 .
Referring to FIG. 2 , it is shown that when off-axis illumination is utilized to illuminate the 180° phase-edge, the contrast is further reduced and I min continues to increase. However, the image contrast degradation of a single phase-edge caused by strong off-axis illumination may not be sufficient to assure the phase-edge will not print. As shown in FIG. 2 , for each of the off-axis illumination conditions, the phase-edge is still printed on the wafer as the value of I min remains below the printing threshold defined by the dotted horizontal line illustrated in FIG. 2 .
It has been discovered that the contrast can be further reduced (i.e., I min further increased) by placing two phase-edges in close proximity to one another. FIG. 3 illustrates the aerial image intensity of two phase-edges that are 200 nm apart when illuminated with conventional illumination and with off-axis QUASAR illumination (which corresponds to quadrapole illumination). The two phase-edges are located at approximately 650 nm and 850 nm as defined by the horizontal axis of FIG. 3 . As shown, the conventional illumination results in two high contrast dark images at each of the phase-edges, which results in the printing of the two phase-edges (i.e., I min is below the printing threshold). However, when utilizing QUASAR illumination, the result is a very low contrast image and a high I min at each of the phase-edge locations. As shown, in FIG. 3 , each of the off-axis QUASAR illuminations results in an I min which is above the printing threshold. Thus, the phase-edges do not print on the wafer. It is noted that the distance between the phase-edges (which in the current example is 200 nm) necessary to obtain the foregoing results is process dependent in that it varies in accordance with, for example, the wavelength (λ), the numerical aperture (NA) and the illumination technique utilized by the imaging system. The optimum separation for a given set of processing conditions is readily determined by empirical methods. It is noted, however, that as a general rule, when the phase-edges are separated by greater than approximately 0.42λ/NA, the image of the phase-edge is so greatly degraded that typically the phase-edges will no longer print.
The inventors further discovered that a similar effect (i.e., a resulting low contrast image and increased I min ) occurs when a single phase-edge is brought into proximity to a chrome feature edge. In other words, by placing the phase-edge a predetermined distance away from the edge of a chrome feature and utilizing strong off-axis illumination, it is possible to prevent the phase-edge from printing on the wafer. FIG. 4 contains a set of aerial images illustrating the variations of I min resulting from various placements of a phase-edge relative to a feature edge for a given set of processing conditions.
Referring to FIG. 4 , the edge of the chrome feature is located at approximately 1000 nm as defined by the horizontal axis of FIG. 4 . As shown in FIG. 4 , when the phase-edge is positioned 800 nm, 600 nm, 400 nm or 300 nm from the feature edge, the phase-edge is printed on the wafer, as each of the corresponding values of I min is below the print threshold (defined by the dotted line in FIG. 4 ). However, when the phase-edge is positioned 200 nm, 175 nm or 150 nm from the feature edge, the phase-edge does not print, as the corresponding values of I min are above the print threshold. Specifically, I min reaches its maximum value (above the 6.0 printing threshold used in this example) when the phase-edge is between 220 nm and 180 nm away from the chrome feature edge. It is noted that as the distance between the phase-edge and the chrome feature edge continues to decrease, I min begins to decrease again such that at 150 nm, I min equals the printing threshold of 6.0. At a distance of 125 nm, I min is well below the printing threshold and as a result, the phase-edge prints on the wafer. It is again noted that the distance between the phase-edge and the edge of the chrome feature necessary to prevent the phase-edge from printing on the wafer is process dependent in that it varies in accordance with, for example, the wavelength (λ), the numerical aperture (NA) and the illumination technique utilized by the imaging system.
Another method of controlling the printability of a phase-edge (i.e., change the resulting aerial image) is to use a phase-shift other than 180°. It is noted that a phase-edge results in the generation of a strong dark image because of the total destructive interference that occurs when light on either side of the phase-edge is shifted by 180°. However, if the phase of the light were shifted by 90° instead of 180°, the intensity of the resulting image would decrease (i.e., I min would increase) due to the fact that there would only be partial destructive interference. As such, by varying the amount of the phase-shift, it is possible to increase the I min value associated with a given phase-edge such that the phase-edge is non-resolvable (i.e., I min greater than the printing threshold).
Thus, by controlling the resulting aerial image of a phase-edge with the foregoing methods, it is possible to make a phase-edge sub-resolution under a wide range of imaging conditions. As a result, as explained in more detail below, the sub-resolution phase-edge can be utilized as an optical proximity correction feature.
One of the major objectives of correcting for optical proximity effects is achieving a sufficient “overlapping process window” for a given feature size through pitch. In other words, features having the same CD should be reproduced in the same manner on the wafer regardless of pitch between given features. Prior to the present invention, the utilization of sub-resolution scattering bars has been a means of addressing this problem of CD targeting through pitch. There are essentially two main elements affecting this through pitch CD variation. The first is the exposure dose to achieve the nominal CD at best focus which can be corrected for by simply biasing the feature. The second much more complex behavior that effects the through pitch CD performance is the behavior of the CD as the focus and exposure changes. This second element can be controlled by the addition of scattering bars.
FIG. 5 illustrates the need for optical proximity correction techniques. More specifically, FIG. 5 illustrates the simulated results of a focus/exposure matrix for an isolated line having a target CD of 130 nm using 0.80NA and 0.85/0.55/30 QUASAR illumination. The simulation was conducted without utilizing any optical proximity correction techniques. It can be seen from the focus behavior that the resulting image is far from an iso-focal condition and that the depth of focus (DOF) is small (approximately 200 nm). This lack of DOF causes the isolated line to be a limiting factor in the through pitch overlapping process window. As such, it is clearly desirable to increase the DOF associated with the isolated line so as to increase the overall process window.
As stated above, prior to the present invention, this has been accomplished by utilizing sub-resolution features such as scattering bars. Indeed, by adding properly placed sub-resolution scattering bars, the DOF associated with the isolated line is increased substantially and the overlapping process window is greatly increased. However, in accordance with the present invention, sub-resolution phase-edges are utilized as the optical proximity correction features as opposed to sub-resolution scattering bars. The sub-resolution phase-edges provide significant advantages over known OPC features, such as scattering bars. For example, each phase-edge is essentially dimension-less in that there is no width dimension (or CD) associated with the phase-edge. As such, the use of the phase-edge eliminates the need to be able to create an exceedingly small feature (i.e., scattering bar) on the mask. Moreover, because the phase-edges are dimension-less, they can be readily placed between features regardless of the pitch between the features.
FIG. 6 illustrates an exemplary embodiment of how phase-edges can be utilized as optical proximity correction features. Referring to FIG. 6 , in the given example, two phase-edges are created on each side of an isolated chrome line 12 . More specifically, on the left side of the chrome line 12 , a first phase-edge 14 is created at a distance of 140 nm from the left edge of the chrome line 12 and a second phase-edge 16 is created at a distance of 340 nm from the left edge of the chrome line. Similarly, on the right side of the chrome line 12 , a first phase-edge 18 is created at a distance of 140 nm from the right edge of the chrome line 12 and a second phase-edge 20 is created at a distance of 340 nm from the right edge of the chrome line. It is again noted that the optimal placement of the phase-edges relative to one another and to the feature to achieve the desired correction is process dependent. Indeed, as with scattering bars, optimal placement of phase-edges can be readily determined by empirical methods.
FIG. 7 illustrates the improvement obtained by utilizing the phase-edges depicted in FIG. 6 as OPC features for the 130 nm line. The processing conditions utilized in the simulation are the same as those utilized in the simulation depicted in FIG. 5 . Referring to FIG. 7 , it is shown that the inclusion of the phase-edges results in a significant improvement in the depth of focus for the 130 nm line. As shown, the depth of focus becomes approximately 600 nm as opposed to the approximately 200 nm depth of focus obtained in the simulation depicted in FIG. 5 .
As noted above, the position of the sub-resolution phase-edges relative to the feature and each other will have an effect on the imaging of the isolated 130 nm feature. FIG. 8 shows the simulation results of the same 130 nm isolated line when the phase-edges are placed 160 nm and 360 nm away from the chrome line edge. As shown, utilizing this placement of the phase-edges, the dose to target is approximately 33 mJ and the through focus behavior has been over corrected beyond the ideal iso-focal behavior. Thus, such a placement is not optimal.
The phase-edges illustrated in FIG. 6 can be manufactured utilizing various processing methods. For example, by utilizing a single chrome feature, two phase-edges can be generated in the mask design. More specifically, the process steps would include forming a chrome feature having a width equal to the desired separation of the two phase-edges on a quartz substrate. Next, utilizing the chrome feature as a shield, the quartz substrate is etched to a depth necessary to create the desired phase difference between the etched portion of the substrate and the unetched portion of the substrate. Then, the chrome feature (i.e., shield) is removed and the result is the generation of two phase-edges, which are spaced apart by a distance equal to the width of the chrome feature. Of course, the chrome feature utilized to form the phase-edges can be positioned as necessary relative to the feature to be printed. In the event only a single phase-edge is desired, this can be accomplished by extending one side of chrome shield until it contacts the adjacent feature to be printed. In this instance, a single phase-edge will be formed at the location of the opposite edge of the chrome shield (i.e., the edge of the shield that does not contact the feature to be printed).
As another example of the benefits of the present invention, it is shown how the use of a single phase-edge OPC feature can be utilized in place of chromeless scattering bars. As is known, chromeless phase-shift mask (CLM) technology is showing promise as an option for imaging features as small as λ/5. CLM takes advantage of a high contrast dark image that is formed when two phase-edges come into close proximity to each other, for example, in the range of 120 nm to 50 nm for a wavelength of 248 nm. While this image enhancement is beneficial as a means to increase the resolution of an imaging system, it also increases the printability of features that are intended to be sub-resolution. As a result, for chromeless scattering bars not to print, the scattering bars must be very small (i.e., less than 50 nm) or the scattering bars must be half-toned in a manner to result in an effective size of less than 50 nm. However, it is exceedingly difficult to manufacture scattering bars having a width of less than 50 nm.
As a result of the present invention, there is no need to manufacture scattering bars having such widths. As noted above, in accordance with the present invention, a pair of phase-edges can be placed where previously a half-toned chromeless scatter bar would be formed. In the manner described above, the phase-edges are separated from each other and from the phase-edge of the primary feature in such a manner that they do not print under the given imaging conditions. Thus, by utilizing such phase-edges as OPC features, there is no need to generate scattering bars have such small width dimensions.
FIG. 9 compares the printability of a 50 nm chromeless scattering bar, a 40 nm chromeless scattering bar, and a single phase-edge when placed adjacent a 100 nm 5 bar pattern. Referring to FIG. 9 , the 5 bars (i.e., features to be printed) are placed at approximately 1000 nm, 1300 nm, 1600 nm, 1900 nm and 2200 nm as defined by the horizontal axis of FIG. 9 . As shown from this simulation, both the 40 nm chromeless scattering bar and the 50 nm chromeless scattering bar will print on the wafer, as both have an I min value that falls below the print threshold. However, the single phase-edge maintains an I min value which exceeds the print threshold and therefore does not print on the wafer. Indeed, it has been determined that under the conditions utilized in the simulation depicted in FIG. 9 , in order to obtain a chromeless scattering bar which does not print, the scattering bar must be approximately 35 nm wide (140 nm at 4×), which is beyond current photomask manufacturing capabilities. Thus, the present invention allows for the placement and use of a sub-resolution OPC feature under imaging conditions that would have previously resulted in the printing of the OPC features utilizing prior art techniques.
Another benefit of using a phase-edge as a sub-resolution assist feature is that it is possible to place a phase-edge in a space that is not wide enough to accommodate a conventional scattering bar. FIG. 10 illustrates this concept of placing a phase-edge in between fairly dense features. Referring to FIG. 10 , the chrome features 22 to be printed on the wafer have a pitch of 400 nm, which is too small to allow placement of a scattering bar between the features. However, it is possible to place phase-edges 24 between each feature 22 . Indeed, it desirable to place phase-edges between the features because strong proximity effects are present and the phase-edges can correct these proximity effects. FIG. 11 shows the results of a focus/exposure simulation on a 100 nm chrome line pattern at a 400 nm pitch when a single phase-edge is placed between the chrome lines as shown in FIG. 10 . As can be seen from the plots in FIG. 11 , the resulting 100 nm chrome lines exhibit a substantially iso-focal condition and a significant depth of focus (approximately 600 nm). Clearly, such performance results would not be possible if the phase-edges were omitted.
The phase-edges 24 disposed between the chrome features 22 illustrated in FIG. 10 can be manufactured in substantially the same manner as described above with reference to FIG. 6 . For example, first, chrome is deposited over the top surface of the quartz substrate. Next, the chrome is removed from the portions of the substrate to be etched, and then the quartz substrate is etched to a depth necessary to create the desired phase difference between the etched portion of the substrate and the unetched portion of the substrate. Next, the chrome features 22 are protected and remaining chrome on the surface of the quartz substrate is removed. The result is the structure depicted in FIG. 10 , in which phase-edges 24 are created between chrome features 22 . Of course, any other method of forming the phase-edges 24 in between the chrome features 22 can also be utilized.
FIG. 12 illustrates an example of the placement of a single phase-edge between chromeless features. In this example, the 100 nm lines are formed with both 180° phase lines surrounded by 0° phase fields and 0° phase lines surrounded by 180° phase fields. The sub-resolution phase-edge forms the transition between the 0° phase field region and the 180° phase field region. The use of the sub-resolution phase-edge provides addition capabilities to control the through focus behavior of lines at varying pitches so as to be able to increase the through pitch overlapping process window.
More specifically, referring to FIG. 12 , in accordance with the present invention, it is possible to place a phase-edge 32 between two chromeless features, one being a trench 34 and one being a mesa 36 . Both the trench feature 34 and the mesa feature 36 will print. The phase-edge 34 does not print, but does function as an optical proximity correction feature.
It is further noted that as a result of using phase-edges as sub-resolution features, two effects are created which effect the aerial image formation. The primary effect is the placement of a dark feature in a position that changes the effective pattern density, thereby changing the imaging behavior of isolated or near isolated lines to that of semi-dense lines. This effect was utilized to change the through focus behavior in the manner described above. The second effect is the phase-shifting that occurs in areas between the sub-resolution phase-edges. It is this effect that allows for phase patterns to be exploited to obtain additional advantages.
For example, by properly placing multiple phase-edges around an isolated line, the phase-shifting regions can be formed in a manner that generates behavior that can be characterized as an inverse Bessel image (i.e., a dark line with a theoretical infinite depth of focus). This is similar to printing a phase-edge with coherent light, except that in this case, strong off-axis illumination is used.
FIG. 13 illustrates an isolated chrome line 41 surrounded by four phase-edges 42 , 43 , 44 , 45 on either side of the line 41 . The phase-edges are placed in a manner so as to place the iso-focal point at the target CD feature size. To accomplish this, the phase-edges are not placed a uniform distance apart. As shown in FIG. 13 , the spacing between sub-resolution phase-edges increases as the distance from the center chrome feature 41 increases. As was illustrated previously, the placement of phase-edges alters the through focus imaging behavior of a chrome line. In this example, the phase-edges are placed 150 nm, 350 nm, 620 nm, and 920 nm away from the edge of the chrome line. This method works equally well when the chrome feature is replaced with a chromeless phase-shift structure 51 (CLM) with similar sub-resolution phase-edge placements as is shown in FIG. 14 .
FIG. 15 shows the simulation results of an isolated 100 nm CLM inverse Bessel line and how by properly placing the phase-edges to form the inverse Bessel behavior with the particular illumination conditions, the iso-focal point can be controlled in a manner that places it at the target CD value. As shown, the result is a significant increase in the depth of focus. FEM simulations were run with a chrome primary feature at target CD sizes of 80 nm, 50 nm, and 35 nm with the inverse Bessel phase-edge design. In all cases, as shown in FIGS. 16 , 18 and 20 , the location iso-focal point was able to be placed near the particular target CD. FIGS. 17 and 19 show the ED (exposure/dose) latitude plots indicating that the depth of focus for the 80 nm and the 50 nm isolated lines, exposed with 0.80NA KrF imaging system and 0.85/0.55/30 QUASAR illumination, had a DOF of 900 nm and 675 nm, respectively, at an exposure tolerance of 10%.
The improved DOF evident from the foregoing figures can be attributed to the impact sub-resolution assist features have on the diffraction pattern created by the exposure energy passing though an object at the image plan. FIGS. 21A and 21B illustrate the effect sub-resolution assist features have on the diffraction pattern. In the case of an isolated line, virtually all of the exposure energy is in the zero diffraction order (see, FIG. 21A ). By properly placing the sub-resolution phase-edges, the energy is diverted from the zero order to the higher diffraction orders in a manner that causes increased DOF (see, FIG. 21B ). While placing sub-resolution features at any location near a feature will cause exposure energy to be directed to the higher diffraction orders, as noted above, proper placement to achieve the DOF improvement is dependent upon the exposure wavelength, the illumination conditions, and the numerical aperture of the imaging system.
The ability to utilize phase-edges that do not print as an optical proximity correction feature allows for entirely new categories of correction methods. As an example, phase-edges extending out from the corners of opaque features can be used to improve corner rounding imaging in the same way serifs are currently used. Altering the distance between the main feature and a sub-resolution phase-edge along a feature can have a similar effect as what is currently achieved by placing jogs in the edges of the geometry.
As an example of the versatility of using sub-resolution phase-edges, FIG. 22 shows how line end shortening can be corrected for by placing a phase-edge 62 perpendicular to the line 61 whose end shortening is to be corrected. The phase-edge will not print in regions where it is between lines because the imaging conditions and distance to another phase-edge cause it to be sub-resolution. However, when the phase-edge is near the end of a line, the end of that line is pulled to the phase-edge because of the interaction between the phase-edge of the end of the line and the phase-edge of the correction feature. As such, very fine line end control can be achieved.
In another variation, the sub-resolution phase-edge does not need to be a straight line but can contain sub-resolution jogging. Further, as noted above, it is also possible to use phase-edges having shifts other than 180° such as 60°, 90°, or 120°.
FIG. 23 schematically depicts a lithographic projection apparatus suitable for use with a mask designed with the aid of the current invention. The apparatus comprises:
a radiation system Ex, IL, for supplying a projection beam PB of radiation. In this particular case, the radiation system also comprises a radiation source LA; a first object table (mask table) MT provided with a mask holder for holding a mask MA (e.g. a reticle), and connected to first positioning means for accurately positioning the mask with respect to item PL; a second object table (substrate table) WT provided with a substrate holder for holding a substrate W (e.g. a resist-coated silicon wafer), and connected to second positioning means for accurately positioning the substrate with respect to item PL; a projection system (“lens”) PL (e.g. a refractive, catoptric or catadioptric optical system) for imaging an irradiated portion of the mask MA onto a target portion C (e.g. comprising one or more dies) of the substrate W.
As depicted herein, the apparatus is of a transmissive type (i.e. has a transmissive mask). However, in general, it may also be of a reflective type, for example (with a reflective mask). Alternatively, the apparatus may employ another kind of patterning means as an alternative to the use of a mask; examples include a programmable mirror array or LCD matrix.
The source LA (e.g. a mercury lamp or excimer laser) produces a beam of radiation. This beam is fed into an illumination system (illuminator) IL, either directly or after having traversed conditioning means, such as a beam expander Ex, for example. The illuminator IL may comprise adjusting means AM for setting the outer and/or inner radial extent (commonly referred to as σ-outer and σ-inner, respectively) of the intensity distribution in the beam. In addition, it will generally comprise various other components, such as an integrator IN and a condenser CO. In this way, the beam PB impinging on the mask MA has a desired uniformity and intensity distribution in its cross-section.
It should be noted with regard to FIG. 23 that the source LA may be within the housing of the lithographic projection apparatus (as is often the case when the source LA is a mercury lamp, for example), but that it may also be remote from the lithographic projection apparatus, the radiation beam that it produces being led into the apparatus (e.g. with the aid of suitable directing mirrors); this latter scenario is often the case when the source LA is an excimer laser (e.g. based on KrF, ArF or F 2 lasing). The current invention encompasses both of these scenarios.
The beam PB subsequently intercepts the mask MA, which is held on a mask table MT. Having traversed the mask MA, the beam PB passes through the lens PL, which focuses the beam PB onto a target portion C of the substrate W. With the aid of the second positioning means (and interferometric measuring means IF), the substrate table WT can be moved accurately, e.g. so as to position different target portions C in the path of the beam PB. Similarly, the first positioning means can be used to accurately position the mask MA with respect to the path of the beam PB, e.g. after mechanical retrieval of the mask MA from a mask library, or during a scan. In general, movement of the object tables MT, WT will be realized with the aid of a long-stroke module (coarse positioning) and a short-stroke module (fine positioning), which are not explicitly depicted in FIG. 23 . However, in the case of a wafer stepper (as opposed to a step-and-scan tool) the mask table MT may just be connected to a short stroke actuator, or may be fixed.
The depicted tool can be used in two different modes:
In step mode, the mask table MT is kept essentially stationary, and an entire mask image is projected in one go (i.e. a single “flash”) onto a target portion C. The substrate table WT is then shifted in the x and/or y directions so that a different target portion C can be irradiated by the beam PB; In scan mode, essentially the same scenario applies, except that a given target portion C is not exposed in a single “flash”. Instead, the mask table MT is movable in a given direction (the so-called “scan direction”, e.g. the y direction) with a speed v, so that the projection beam PB is caused to scan over a mask image; concurrently, the substrate table WT is simultaneously moved in the same or opposite direction at a speed V=Mv, in which M is the magnification of the lens PL (typically, M=¼ or ⅕). In this manner, a relatively large target portion C can be exposed, without having to compromise on resolution.
Although certain specific embodiments of the present invention have been disclosed, it is noted that the present invention may be embodied in other forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A photolithography mask for optically transferring a pattern formed in the mask onto a substrate and for negating optical proximity effects. The mask includes a plurality of resolvable features to be printed on the substrate, and at least one non-resolvable optical proximity correction feature, where the non-resolvable optical proximity correction feature is a phase-edge.
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[0001] This invention relates to anchoring sinks in countertops through apertures which have been formed there to receive them. More particularly, it relates to utilizing an elongated stud anchored, as by welding, to the underside of a flange surrounding the sink and a locking link engaged on the body of the stud. When the link is forced away from the countertop, as by turning a bolt which extends from the link to engage the underside of the countertop, the stud, and the sink flange portion to which it is joined, are moved downwardly past the countertop, and the flange of the sink is drawn downwardly by the stud to a point where it is fastened against the upper side of the countertop.
BACKGROUND OF THE INVENTION
[0002] Sink anchoring systems are generally summed up in U.S. Pat. No. 4,613,995. Sink bowls are conventionally held in an opening in a countertop by way of mounting brackets spot-welded, for example, to the lower surface of the bowl flange overlapping the opening, the brackets being provided with apertures through which are passed fasteners, such as wood screws driven into the countertop material at the edge of the opening, or through the bottom surface of the countertop proximate the edge of the opening. The mounting brackets may be in the form of separate bracket elements welded at convenient locations, or in the form of a molding strip, the brackets being L-shaped in some installations and U-shaped in other installations. Other methods of securing a sink bowl in a countertop opening have been devised which avoid driving fasteners, such as wood screws, into the material of the countertop. Such alternate methods generally use clamping arrangements formed integrally with the mounting brackets, including threaded members passed through appropriate threaded apertures in the bracket engaging the surface of the countertop, generally the lower surface proximate the edge of the opening, and holding the sink bowl in position by pulling the bowl flange edge into engagement with the top surface of the countertop proximate the opening.
[0003] The fastening system in the '995 patent incorporates an upside down L-shaped angle-iron strip welded to the underside of the sink bowl flange. A C-shaped clamp has a top leg which nests into a runner along the toe of the angle-iron strip. The bottom leg of the C-shaped clamp is pierced to accommodate a threaded member whose head is below and outside of the C-shape of the clamp. A rim portion of a countertop aperture intrudes into the middle of the C-shape of the clamp, at which point the threaded member can be turned so that it will engage the underside of the rim portion. As the threaded member is turned and thrust against the rim portion, the top leg of the C-shaped clamp drags the L-shaped bracket, and the sink flange to which the bracket is welded, into firm contact with the upper side of the counter top rim portion.
[0004] Another fastening system is illustrated in U.S. Pat. No. 6,021,532, issued Feb. 8, 2000. In that system, too, a channel member is fastened to the underside of a perimeter flange around a sink. In the '532 patent the channel member has an inverted U-shaped cross section. The depending legs of the channel are formed with upwardly facing shoulder members which are situated inside the channel opposite each other. A pin with a conical head extends into the channel so that the underside of the shoulders of the cone engage the shoulder members on the channel legs. When the pin is drawn downwardly, it pulls the U-shaped channel, and the sink flange to which it is affixed, to engage the flange on the upper side of a countertop. The pin has a second conical head, opposite the head inside the channel, which is fixed in a base unit with an annular face. A series of flat surfaces which increase gradually in height around the annular face provide an increasing circumferential thickness of the base unit. The annular face engages the underside of the countertop adjacent the aperture for the sink, and when the base unit is turned, the pin with the conical heads has its upper end drawn down onto the shoulders of the channel, thereby drawing the sink flange to which the channel is attached down against the upper side of the countertop.
[0005] The present invention does not require the material or the tooling which the constructions in the above-described patents call for, and it also avoids the much more exact tolerances which the prior constructions demanded. The elements of the present invention are easier to handle and assemble, and they are faster to install.
SUMMARY OF THE INVENTION
[0006] The present invention is embodied in an assembly which includes a countertop that has a portion of its surface arranged for installing a sink. There is an aperture in that portion for the sink to be dropped into, and there is a rim portion of the countertop located around the aperture. A perimeter flange on the sink overlies the rim portion when the sink is disposed in the aperture. Studs depend from the sink's perimeter flange. Each stud has a first end secured to the perimeter flange, a distal end adjacent the underside of the countertop, and a body portion in between the ends. A link located between the stud and the rim portion of the countertop has a first end portion extending toward the underside of the countertop rim portion and a stud engagement portion disposed on the body portion of the stud. A displacement means located on the first end portion of the link is simultaneously moveable against the underside of the countertop rim portion and the first end portion of the link. When the displacement means is moved against these elements, the link moves the stud downwardly through the aperture passing it past the rim portion of the countertop and drawing the sink flange to which the stud is fastened into secure engagement with the upper side of the countertop rim portion.
[0007] From the foregoing, and from what follows, it will be apparent that the present invention solves a need for a less expensive way to fasten a sink securely in place in a countertop.
[0008] Accordingly, it is one of the objects of this invention to provide a sink clamping assembly in a countertop installation utilizing a stud affixed to and depending from the underside of a perimeter flange on the sink.
[0009] It is another object of this invention to provide a sink clamping assembly m a countertop installation in which a stud member depending from a flange on the sink is readily grasped around its midportion by a link which, when moved away from the countertop, pulls the stud through the aperture in which the sink is positioned and draws the flange on the sink against the upper side of the countertop.
[0010] It is another object of this invention to eliminate an expensive engagement means such as a welded rail or a welded track on the underside of the sink's perimeter flange and to provide an easier, less demanding engagement member attached to the flange.
[0011] It is another object of this invention to provide a sink flange and countertop engagement having less sophisticated, lower cost parts than prior combinations which have been offered.
[0012] Other objects and features of this invention will be apparent to those skilled in the practical art of installing and attaching sinks in countertops as well as to those skilled in the art of designing and manufacturing sink-to-countertop attachment mechanisms, especially after an examination of the following detailed description of the preferred embodiments of the present invention and of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a perspective view, partly in section and partly broken away, of a portion of a countertop to which a perimeter flange of a sink is secured on its upper side by a stud attached to the underside of the flange;
[0014] [0014]FIG. 2 is an elevational view, partly in section, of the sink flange and countertop assembly in FIG. 1 taken in the direction of arrows 2 - 2 in FIG. 1;
[0015] [0015]FIG. 3 is an enlarged view of a portion of FIG. 2 designated by the dotted line circle labeled FIG. 3 in FIG. 2;
[0016] [0016]FIG. 4 is an elevational view, partly in section, of a modified version of the sink flange and countertop assembly shown in FIG. 2;
[0017] [0017]FIG. 5 is a perspective view, partly in section, of an alternative embodiment of the invention shown in FIG. 4 utilizing a second form of linkage between the stud attached to the sink flange and the underside of the countertop;
[0018] [0018]FIG. 6 is a sectional view, partly broken away and enlarged, of a portion of the assembly shown in FIG. 5 taken in the direction of arrows 6 - 6 in FIG. 5;
[0019] [0019]FIG. 7 is a perspective view, partly in section, of an alternative embodiment of the invention shown in FIG. 5 utilizing a form of linkage threadably engaged upon the stud attached to the sink perimeter flange; and
[0020] [0020]FIG. 8 is a sectional view, partly broken away and enlarged of a portion of the assembly shown in FIG. 7 taken in the direction of arrows 8 - 8 in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The preferred embodiments of this invention shown in the accompanying drawings will now be described, it being understood that the preferred forms are illustrative and that the invention described herein is embodied in the claims which are appended hereto.
[0022] In FIG. 1 a countertop 10 has a rim portion 12 extending toward an aperture 14 in which a sink (not shown) may be installed. The upper side of the countertop rim portion is designated at 16 and the underside of the countertop rim portion is designated at 18 . The sink is provided with a perimeter flange 20 , part of which overlies the upper side of the countertop rim portion, so that when the flange rests on the countertop rim portion, the sink bowl is suspended in aperture 14 . A stud 22 is affixed, as by welding, to the underside 24 of perimeter flange 20 adjacent to the upper side 16 of the countertop rim portion. The first end 26 of the stud is affixed to the flange, the distal end 28 of the stud extends adjacent to the underside 18 of the countertop rim portion, and the body portion 30 of the stud is situated between first end 26 and the distal end 28 .
[0023] As shown in FIG. 1, a link 32 is located intermediate the underside 18 of the countertop rim portion and the stud 22 . The link includes a first end portion 34 which extends from the stud toward the underside of the countertop rim portion and also includes a stud engagement portion 36 which is slideably disposed on the body portion 30 of stud 22 . Particularly as shown in FIGS. 1-3, the stud engagement portion of the link 32 may be constructed of a flat strip of metal with a hole 38 through it and bent at a slight upward angle from the rest of the link. The hole 38 is slightly larger in diameter than the body portion 30 of the stud so that the stud engagement portion 36 can be slipped easily onto the stud's body portion 30 . When the link is tilted, as indicated by arrow 40 in FIG. 2, the edges 44 of the walls in the link around hole 38 engage and lock the link onto the stud's body portion 30 as shown in FIG. 3. Preferably, the stud is externally threaded, as illustrated, with threads 42 which the edges of the walls around hole 38 will readily and firmly engage when the link is tilted away from a horizontal orientation as shown in FIGS. 2 and 3.
[0024] A displacement means such as bolt 46 is engaged in an internally threaded aperture 48 formed in the first end portion 34 of the link. Bolt 46 is located so that when it is turned it will come into contact with the underside 18 of the countertop 10 . As the bolt is turned further on its threads and those in the walls of aperture 48 , it moves against the underside of the countertop and the first end portion 34 of link 32 simultaneously, forcing the link further and further away from the countertop and forcing the stud grasped by the link downwardly, moving it along past the rim portion 12 of the countertop. Such movement of the stud 32 draws the perimeter flange 20 of the sink into secure engagement with the upper side 16 of the countertop rim portion 12 .
[0025] If desired, the engagement of link 32 on stud 22 may be enhanced in the manner shown in FIG. 4. A nut or similar stop member 50 is threaded onto the distal end 28 of the bolt 22 and rotated until it is adjacent the stud engagement portion 36 of link 32 . If the walls 44 forming the hole 38 are spaced too far apart, so that the edges 44 cannot be counted upon to engage the body portion 30 of the stud 22 , the nut 50 can be relied upon to intercept and engage the link whenever the bolt 46 is manipulated to draw the stud downward and engage the sink flange 20 onto the countertop. It may also be preferable to use the nut 50 regularly in combination with the rest of the clamp elements shown in FIGS. 1-3 due to the fact that manipulating nut 50 can positively position link 32 and bolt 46 on the stud 22 to take up any slack in the chain of elements and insure that turning the bolt 46 accomplishes a secure flange engagement on the upper surface of the countertop rim portion.
[0026] A further embodiment of this invention is shown in FIG. 5. In this figure, the sink flange 20 , the stud 22 and the countertop rim portion 12 (with upper side 16 and underside 18 ) are the same elements illustrated in the preceding FIGS. 1-4. Link 52 , however, takes on a different form from that shown in the preceding figures. The body of link 52 includes a first or outer end portion 54 and an inner stud engagement portion 56 . The outer end portion 54 is circularly formed as a washer which can be rotated around the stud 22 . On one face of the washer, illustrated as the upper face, there is a circumferentially ascending surface portion 58 which may be formed as a radiating set of steps, as illustrated, or as an inclined ramp. Such a surface acts as a displacement means when the link 52 is rotated around stud 22 .
[0027] Link 52 includes a core portion 60 which is centrally located in link 52 and has a tubularly apertured section 62 for engaging the link on the body portion 30 of stud 22 . As illustrated in FIGS. 5 and 6, the tubularly apertured section 52 is not and need not be internally threaded for engagement on the stud 22 , and a nut such as nut 50 may be threaded onto stud 22 below the link 52 to hold the link at one point or another on the body portion of the stud. Tabs 64 or similar means easily grasped in a craftsman's fingers are attached to lower face 66 of link 52 so that the link can be easily assembled onto the stud and so that the link can be rotated around the stud without any need for a tool.
[0028] In use, link 52 is placed onto stud 22 and the nut 50 turned enough to bring the ascending surface portion 58 of the link into contact with the underside 18 of the countertop rim portion 12 . Then, by holding tabs 64 and rotating link 52 in the direction of arrows 68 , the displacement of the link and stud achieved by moving the ascending surface portion 58 against the underside 18 of the countertop rim portion draws the stud past the countertop rim portion and draws the sink flange 20 securely down onto the upper side 16 of the countertop rim portion.
[0029] The tubularly apertured section 62 of link 52 may also be internally threaded for obtaining a threaded engagement of the link on the stud 22 . Such an engagement is shown in FIGS. 7 and 8. The link 52 a is identical to link 52 except that the tubularly apertured section 62 is internally threaded and engages stud 22 as shown in FIG. 8. In that form, the link 52 a does not need to be supported by a nut 50 . Link 52 a is merely threaded onto threads 42 to engage it onto stud 22 and rotated until the displacement means 58 engages the underside surface 18 of the countertop rim portion 12 . Further rotation, as by forcing tabs 64 in the direction of arrows 68 , forces the displacement means 58 simultaneously against the underside 18 of the countertop and also against the first end portion 54 of the link for drawing the stud downwardly and pulling a perimeter flange of a sink (not shown) into secure engagement with the upper side of a countertop rim portion (also not shown).
[0030] From all of the foregoing it will be evident that, although particular forms of the invention have been illustrated and described, nevertheless various modifications can be made without departing from the true spirit and scope of the invention. Accordingly, no limitation is intended by the foregoing description, and its full breadth is intended to be covered by the following claims.
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An improved assembly is disclosed for clamping the perimeter flange of a sink snugly down upon a countertop where the sink is being installed. The assembly utilizes a stud extending downwardly from the underside of the perimeter flange and a link connected to the stud having a displacement member, such as a threaded bolt, which engages the underside of the countertop adjacent the hole in the countertop where the sink is located. As the displacement member is manipulated against the underside of the countertop, the link holding the displacement member draws the stud downwardly to pull the flange snugly against the upper face of the countertop adjacent the sink installation hole.
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TECHNICAL FIELD
[0001] This disclosure relates to a method of manufacturing a so-called grain oriented electrical steel sheet having crystal grains with {110} plane in accord with the sheet plane and <001> orientation in accord with the rolling direction, in Miller indices.
BACKGROUND
[0002] It is known that grain oriented electrical steel sheets having crystal grains in accord with {110}<001> orientation (hereinafter, “Goss orientation”) through secondary recrystallization annealing exhibit superior magnetic properties (e.g. see JP 540-15644B). As indices of magnetic properties of the grain oriented electrical steel sheets, magnetic flux density B 8 at a magnetic field strength of 800 A/m and iron loss (per kg) W 17/50 of the steel sheet when it is magnetized to 1.7 T in an alternating magnetic field with an excitation frequency of 50 Hz, are mainly used.
[0003] Further, it has been a common practice in manufacturing grain oriented electrical steel sheets to use precipitates called inhibitors to induce differences of grain boundary mobility during final annealing so that the crystal grains preferentially grow only in the Goss orientation.
[0004] For example, JP 540-15644B discloses a method of using MN and MnS, while JP 551-13469B discloses a method of using MnS and MnSe. Both have been put into practical use industrially.
[0005] Since those methods using inhibitors require a uniform and fine precipitate distribution of inhibitors as an ideal state, it is necessary to heat a slab before hot rolling to 1300° C. or higher. As such high temperature slab heating is performed, excessive coarsening occurs in the crystal structure of the slab. With such coarsening, the orientation of the slab structure tends to grow in {100}<011> orientation which is a stable orientation of hot rolling, which greatly impedes grain growth during secondary recrystallization, thereby leading to serious deterioration of magnetic properties.
[0006] For the purpose of reducing the above coarse slab structure, JP H03-10020A discloses a technique of obtaining uniformly recrystallized microstructures by performing high reduction rolling at a temperature range of 1280° C. or higher in the first pass of rough rolling, thereby facilitating generation of recrystallization nuclei from grain boundaries of a grains.
[0007] For the purpose of recrystallization of the surface layer of the hot rolled sheet, JP H02-101121A discloses a technique of performing hot rolling with a rolling reduction of 40% to 60% in a temperature range of 1050° C. to 1150° C. using the rolls having surface roughness of 4 μmRa to 8 μmRa, to increase the amount of shear strain in the surface layer of the hot rolled sheet.
[0008] Further, JP S61-34117A discloses a technique to grow only highly oriented secondary recrystallized grains, by subjecting a silicon steel slab containing 0.01 wt % to 0.06 wt % of C to high reduction rolling of 40% or more in the first pass of finish hot rolling, and afterward to light reduction rolling of 30% or less per 1 pass so that Goss orientation grains existing in the surface layer of the hot rolled sheet increase. The Goss orientation grains lead to the increased amount of Goss orientation grains in the surface layer after primary recrystallization annealing through a so called “structure memory mechanism”.
[0009] JP H03-10020A discloses high reduction rolling at a temperature of 1280° C. or higher in rough hot rolling. However, as a technical concept, this is originally high reduction rolling in an a single phase region, and there existed a problem that an (α+γ) dual phase is formed even at a temperature of 1280° C. or higher depending on compositions, so that sufficiently uniform recrystallized microstructures cannot be obtained.
[0010] Further, according to JP H02-101121A, shear strain in the surface layer of the hot rolled sheet increases by controlling finish hot rolling condition. However, recrystallization is hard to occur in the center layer in sheet thickness direction of a steel sheet where shear strain is difficult to be introduced, and there still remained a problem in facilitating recrystallization in the center layer.
[0011] Further, it is assumed that JP H02-101121A and JP S61-34117A mainly focus on high reduction rolling in a temperature range of high γ phase volume fraction. However, since the temperature range of the maximum γ phase volume fraction greatly varies depending on the material compositions, there was a problem that, when using certain compositions, high reduction rolling is performed in a temperature range out of the temperature range of maximum γ phase volume fraction, which results in an insufficient improving effect of magnetic properties.
SUMMARY
[0012] We discovered the relation between the addition amount of Si, C, and Ni which are known compositions in grain oriented electrical steel sheets, and the α single phase transition temperature (T α ) as well as the maximum γ phase volume fraction temperature (T γmax ). Further, we discovered that it is important to perform high reduction rolling at a temperature equal to or higher than (T α −100) ° C. which was obtained from the α single phase transition temperature in the first pass of the rough rolling process of hot rolling, and to perform high reduction rolling at a temperature range of (T γmax ±50)° C. obtained from the maximum γ phase volume fraction temperature in any one pass of the finish hot rolling process of hot rolling.
[0013] We also discovered that by performing the above hot rolling, ferrite grains in the hot rolled sheet are refined, and that fine and uniform generation of the γ phase provides refinement of the structure of the hot rolled steel sheet, and also that as the refinement of the structure of the hot rolled steel sheet proceeds, it becomes possible to better control the texture of the primary recrystallized sheet.
[0014] We thus provide a method of manufacturing a grain oriented electrical steel sheet using austenite (γ)-ferrite (α) transformation which develops excellent magnetic properties after secondary recrystallization by performing high reduction rolling at a predetermined temperature range based on the material compositions in the first pass of a rough rolling process and at least one pass of a finish rolling process during hot rolling.
[0015] In addition to the above technique, we achieve further improvement in the magnetic properties of the grain oriented electrical steel sheet by controlling the heating rate of the predetermined temperature range in the heating process of primary recrystallization annealing by performing magnetic domain refining treatment.
[0016] We thus specifically provide:
[0017] 1. A method of manufacturing a grain oriented electrical steel sheet, the method comprising:
[0018] heating a steel slab including by mass %
[0019] Si: 3.0% or more and 4.0% or less,
[0020] C: 0.020% or more and 0.10% or less,
[0021] Ni: 0.005% or more and 1.50% or less,
[0022] Mn: 0.005% or more and 0.3% or less,
[0023] Acid-Soluble Al: 0.01% or more and 0.05% or less,
[0024] N: 0.002% or more and 0.012% or less,
[0025] at least one element selected from S and Se in a total of 0.05% or less, and
[0026] the balance being Fe and incidental impurities;
[0027] then subjecting the slab to hot rolling to obtain a hot rolled steel sheet;
[0028] subjecting or not subjecting the steel sheet to subsequent hot band annealing;
[0029] then subjecting the steel sheet to cold rolling once, or twice or more with intermediate annealing performed therebetween to have a final sheet thickness;
[0030] then subjecting the steel sheet to primary recrystallization annealing and further secondary recrystallization annealing to manufacture a grain oriented electrical steel sheet,
[0031] wherein in a rough rolling process of the hot rolling, when the α single phase transition temperature calculated by the following equation (1) is defined as T α , a first pass of the rough rolling is performed at a temperature of (T α −100)° C. or higher with a rolling reduction of 30% or more, and
[0032] wherein in a finish rolling process of the hot rolling, when the maximum γ phase volume fraction temperature calculated by the following equation (2) is defined as T γmax , at least one pass of the finish rolling is performed in a temperature range of (T γmax ±50)° C. with a rolling reduction of 40% or more:
[0000] T α [° C.]=1383.98−73.29[% Si]+2426.33[% C]+271.68[% Ni] (1)
[0000] T γmax [° C.]=1276.47−59.24[% Si]+919.22[% C]+149.03[% Ni] (2)
[0000] where [% A] represents content of element “A” in steel (mass %).
[0033] 2. The method of manufacturing a grain oriented electrical steel sheet according to aspect 1, wherein the steel slab further includes by mass %, one or more of Sn: 0.005% or more and 0.50% or less, Sb: 0.005% or more and 0.50% or less, Cu: 0.005% or more and 1.5% or less, and P: 0.005% or more and 0.50% or less.
[0034] 3. The method of manufacturing a grain oriented electrical steel sheet according to aspect 1 or 2, wherein a heating rate from 500° C. to 700° C. in the primary recrystallization annealing is 50° C./s or more.
[0035] 4. The method of manufacturing a grain oriented electrical steel sheet according to any one of aspects 1 to 3, wherein the steel sheet is subjected to magnetic domain refining treatment at any stage after the cold rolling.
[0036] 5. The method of manufacturing a grain oriented electrical steel sheet according to any one of aspects 1 to 3, wherein the steel sheet after the secondary recrystallization is subjected to magnetic domain refining treatment by electron beam irradiation.
[0037] 6. The method of manufacturing a grain oriented electrical steel sheet according to any one of aspects 1 to 3, wherein the steel sheet after the secondary recrystallization is subjected to magnetic domain refining treatment by continuous laser irradiation.
[0038] 7. The method of manufacturing a grain oriented electrical steel sheet according to any one of aspects 1 to 6, wherein at least one pass of the finish rolling is performed in a temperature range of (T γmax ±50)° C. at a strain rate of 6.0 s −1 or more.
[0039] Since the method of manufacturing a grain oriented electrical steel sheet can control the texture of the primary recrystallized sheet so that the orientation of the product steel sheet is highly in accord with the Goss orientation, it becomes possible to manufacture the grain oriented electrical steel sheet having excellent magnetic properties compared to before, after secondary recrystallization annealing. In particular, the grain oriented electrical steel sheet can achieve excellent iron loss properties with iron loss W 17/50 after secondary recrystallization annealing of 0.85 W/kg or less, even with a thin steel sheet with a sheet thickness of 0.23 mm which is generally difficult to manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] Our steel sheets and methods will be further described below with reference to the accompanying drawings, wherein:
[0041] FIG. 1 is a graph showing the influence of the temperature and rolling reduction in the first pass of rough hot rolling and in the first pass of finish hot rolling on the magnetic properties of a final annealed steel sheet (Material No. 3);
[0042] FIG. 2 is a graph showing the influence of the temperature and rolling reduction in the first pass of rough hot rolling and in the first pass of finish hot rolling on the magnetic properties of another final annealed steel sheet (Material No. 15); and
[0043] FIG. 3 is a graph showing the influence of the temperature and rolling reduction in the first pass of rough rolling and in the first pass of finish rolling on the magnetic properties of another final annealed steel sheet (Material No. 20).
DETAILED DESCRIPTION
[0044] Unless otherwise specified, the indication of “%” regarding compositions of the steel sheet shall stand for “mass %”.
Si: 3.0% or More to 4.0% or Less
[0045] Si is an element that is extremely effective to enhance electrical resistance of steel and reduce eddy current loss which constitutes a part of iron loss. By adding Si to the steel sheet, electrical resistance monotonically increases until the content reaches 11%. However, when the content exceeds 4.0%, workability significantly decreases. On the other hand, if the content is less than 3.0%, electrical resistance becomes too small and good iron loss properties cannot be obtained. Therefore, the amount of Si is 3.0% or more to 4.0% or less.
C: 0.020% or More to 0.10% or Less
[0046] C is a necessary element to improve the hot rolled texture by using austenite-ferrite transformation during hot rolling and the soaking time of hot band annealing. However, when C content exceeds 0.10%, not only does the burden of decarburization treatment increase but the decarburization itself becomes incomplete, and becomes the cause of magnetic aging in the product steel sheet. On the other hand, if C content is less than 0.020%, the improving effect of the hot rolled texture is small, and it becomes difficult to obtain a desirable primary recrystallized texture. Therefore, the amount of C is 0.020% or more to 0.10% or less.
Ni: 0.005% or More to 1.50% or Less
[0047] Ni is an austenite forming element and therefore it is an element useful to improve the texture of a hot-rolled sheet and improving magnetic properties using austenite transformation. However, if Ni content is less than 0.005%, it is less effective in improving magnetic properties. On the other hand, if the content is over 1.50%, workability decreases and leads to deterioration of sheet threading performance, and also causes unstable secondary recrystallization and leads to deterioration of magnetic properties. Therefore, the amount of Ni is 0.005% to 1.50%.
Mn: 0.005% or More to 0.3% or Less
[0048] Mn is an important element in a grain oriented electrical steel sheet since it serves as an inhibitor in suppressing normal grain growth by MnS and MnSe in the heating process of secondary recrystallization annealing. If Mn content is less than 0.005%, the absolute content of the inhibitor will be insufficient and, therefore, the inhibition effect on normal grain growth will be insufficient. On the other hand, if Mn content exceeds 0.3%, not only will it be necessary to perform slab heating at a high temperature to completely dissolve Mn in the process of heating the slab before hot rolling, but the inhibitor will be formed as a coarse precipitate, and therefore the inhibition effect on normal grain growth will be insufficient. Therefore, the amount of Mn is 0.005% or more to 0.3% or less.
Acid-Soluble Al: 0.01% or More to 0.05% or Less
[0049] Acid-Soluble Al is an important element in a grain oriented electrical steel sheet since AlN serves as an inhibitor in suppressing normal grain growth in the heating process of secondary recrystallization annealing. If Acid-Soluble Al content is less than 0.01%, the absolute content of the inhibitor is insufficient, and therefore the inhibition effect on normal grain growth will be insufficient. On the other hand, if Acid-Soluble Al content exceeds 0.05%, AlN is formed as a coarse precipitate, and therefore inhibition effect on normal grain growth will be insufficient. Therefore, the amount of Acid-Soluble Al is 0.01% or more to 0.05% or less.
N: 0.002% or More to 0.012% or Less
[0050] N bonds with Al to form an inhibitor. However, if N content is less than 0.002%, the absolute content of the inhibitor will be insufficient, and therefore inhibition effect on normal grain growth will be insufficient. On the other hand, if the content exceeds 0.012%, holes called blisters will be generated during cold rolling, and the appearance of the steel sheet will be deteriorated. Therefore, the amount of N is 0.002% or more to 0.012% or less. Total of at least one element selected from S and Se: 0.05% or less
[0051] S and Se bond with Mn to form an inhibitor. However, if the content exceeds 0.05%, desulfurization and deselenization become incomplete in secondary recrystallization annealing which causes deterioration of iron loss properties. Therefore, the total amount of at least one element selected from S and Se is 0.05% or less. Further, although there is no particular lower limit for these elements, it is preferable to include them in an amount of about 0.01% or more in order to obtain their addition effect.
[0052] Although the basic components are as explained above, the following elements may also be added as necessary.
Sn: 0.005% or More to 0.50% or Less, Sb: 0.005% or More to 0.50% or Less, Cu: 0.005% or More to 1.5% or Less, and P: 0.005% or More to 0.50% or Less
[0053] Sn, Sb, Cu and P are useful elements to improve magnetic properties. However, if the content of each element is less than the lower limit value of each of the above ranges, improving effect of magnetic properties is poor, while if the content of each element exceeds the upper limit value of each of the above ranges, secondary recrystallization becomes unstable and magnetic properties deteriorate. Therefore, each element may be contained in the following ranges.
Sn: 0.005% or More to 0.50% or Less, Sb: 0.005% or More to 0.50% or Less, Cu: 0.005% or More to 1.5% or Less, and P: 0.005% or More to 0.50% or Less
[0054] A steel slab having the above composition is heated and subjected to hot rolling.
[0055] A major feature is that in the rough rolling process of the above hot rolling (also simply referred to as rough hot rolling in the present invention) and the finish rolling process (also referred to as finish hot rolling in the present invention), when defining the α single phase transition temperature and the maximum γ phase volume fraction temperature obtained from the addition amount of Si, C, and Ni as T α and T γmax respectively, high reduction rolling is performed with the surface temperature set to (T α −100)° C. or higher in the first pass of rough hot rolling, and high reduction rolling is performed with the surface temperature set to (T γmax ±50)° C. in at least one pass of the process of finish hot rolling.
[0056] Hereinbelow, reference will be made to experiments. Regarding each of the slabs of steel compositions shown in Table 1, thermal expansion coefficient in the heating process was measured using Formastor dilatometer, and T α was obtained from the change in its slope. That is, since the atomic packing factor is lower in a phase (bcc structure) compared to γ phase (fcc structure), it is possible to confirm transition of a single phase from the sharp change in thermal expansion coefficient.
[0000]
TABLE 1
T α [° C.]
T γmax [° C.]
Si
C
Ni
Mn
sol. Al
N
S
Se
(Measured
(Measured
No.
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
Value)
Value)
1
3.0
0.02
0.005
0.08
0.02
0.01
0.01
0.02
1159
1099
2
3.0
0.02
0.2
0.08
0.03
0.01
0.01
0.02
1278
1158
3
3.0
0.02
0.4
0.09
0.02
0.01
0.01
0.02
1343
1181
4
3.0
0.05
0.005
0.08
0.03
0.01
0.01
0.02
1316
1162
5
3.0
0.05
0.2
0.08
0.03
0.01
0.01
0.02
1359
1181
6
3.0
0.05
0.4
0.08
0.03
0.01
0.01
0.02
1396
1195
7
3.0
0.08
0.005
0.09
0.02
0.01
0.01
0.02
1372
1181
8
3.0
0.08
0.2
0.09
0.03
0.01
0.01
0.02
1402
1195
9
3.0
0.08
0.4
0.08
0.03
0.01
0.01
0.02
1429
1205
10
3.5
0.02
0.2
0.08
0.02
0.01
0.01
0.02
1193
1106
11
3.5
0.02
0.4
0.08
0.03
0.01
0.01
0.02
1302
1159
12
3.5
0.05
0.005
0.09
0.03
0.01
0.01
0.02
1263
1121
13
3.5
0.05
0.2
0.09
0.03
0.01
0.01
0.02
1322
1157
14
3.5
0.05
0.4
0.08
0.02
0.01
0.01
0.02
1371
1180
15
3.5
0.08
0.005
0.09
0.03
0.01
0.01
0.02
1336
1157
16
3.5
0.08
0.2
0.08
0.03
0.01
0.01
0.02
1374
1178
17
3.5
0.08
0.4
0.08
0.02
0.01
0.01
0.02
1410
1195
18
4.0
0.02
0.4
0.08
0.03
0.01
0.01
0.02
1242
1118
19
4.0
0.05
0.005
0.08
0.03
0.01
0.01
0.02
1192
1048
20
4.0
0.05
0.2
0.09
0.03
0.01
0.01
0.02
1273
1115
21
4.0
0.05
0.4
0.09
0.03
0.01
0.01
0.02
1337
1155
22
4.0
0.08
0.005
0.08
0.02
0.01
0.01
0.02
1292
1117
23
4.0
0.08
0.2
0.08
0.02
0.01
0.01
0.02
1340
1150
24
4.0
0.08
0.4
0.08
0.03
0.01
0.01
0.02
1384
1175
[0057] Further, regarding T γmax , a thermodynamic calculation software (Thermo-Calc) was used to estimate the temperature where the component reaches the maximum γ phase volume fraction. Then, a simulated thermal cycle tester was used to perform soaking treatment for 30 minutes in the range of ±30° C. of the estimated temperature with an increment of 5° C., and then rapid cooling was performed to freeze the microstructure. Regarding the steel sheet microstructure for each temperature, microstructure observation was performed using an optical microscope, to measure the pearlite fraction in the range of approximately 130 μm×100 μm, and a mean value of 5 views was defined as γ phase volume fraction.
[0058] Then, the relations between test temperatures and measurement results of γ phase volume fraction were plotted, and the maximum value of the γ phase volume fraction was obtained by a curved approximation of the plots, and the temperature of the maximum value was defined as T γmax .
[0059] The results of T γmax obtained by the above procedures are shown in Table 1. Based on the results of the same table, the relations of the addition amount of Si, C and Ni, and T α and T γmax are obtained from multiple regression calculation, and they are expressed by equations (1) and (2):
[0000] T α [° C.]=1383.98−73.29[% Si]+2426.33[% C]+271.68[% Ni] (1)
[0000] T γmax [° C.]=1276.47−59.24[% Si]+919.22[% C]+149.03[% Ni] (2)
[0000] where [% A] represents content of element “A” in steel (mass %).
[0060] Next, experiments of changing hot rolling conditions regarding slabs of the steel compositions shown in Nos. 3, 15 and 20 of Table 1 were conducted. The values obtained by equations (1) and (2) were used as T α and T γmax . Regarding material No. 3, T α =1321° C. and T γmax =1177° C. Regarding material No. 15, T α =1323° C. and T γmax =1144° C. Regarding material No. 20, T α =1266° C. and T γmax =1116° C.
[0061] Each slab shown in Table 1 was heated to a temperature of 1400° C., subjected to rough hot rolling and finish hot rolling with various conditions regarding temperature and rolling reduction of the first pass, and then the steel sheet was subjected to hot rolling until reaching sheet thickness of 2.6 mm thick, and then subjected to hot band annealing at 1050° C. for 40 seconds. Then, the steel sheet was subjected to the first cold rolling until reaching a sheet thickness of 1.7 mm thick and then subjected to intermediate annealing at 1100° C. for 60 seconds. Further, the steel sheet was subjected to cold rolling until reaching a sheet thickness of 0.23 mm thick, and then the steel sheet was subjected to primary recrystallization annealing combined with decarburization annealing at 800° C. for 120 seconds. Then, an annealing separator mainly composed of MgO was applied to the surface of the steel sheet, and the steel sheet was subjected to secondary recrystallization annealing combined with purification annealing at 1150° C. for 50 hours to obtain a test piece under each condition.
[0062] FIGS. 1 to 3 show the magnetic properties of material Nos. 3, 15 and 20 in table 1. FIGS. 1 to 3 show that good magnetic properties can be obtained by performing the first pass of rough rolling at a temperature of (T α −100)° C. or higher with a rolling reduction of 30% or more, and the first pass of finish hot rolling at a temperature of (T γmax ±50)° C. with a rolling reduction of 40% or more.
[0063] Although the upper limit of the temperature of the first pass of rough hot rolling is not specified, considering air cooling after high temperature slab heating, a temperature of around 1350° C. is preferable. Further, the upper limit of rolling reduction is preferably around 60% in terms of the bite angle. Further, rough hot rolling is performed with the total pass of around 2 to 7 passes. The temperature and the rolling reduction from the second pass and after are not particularly limited and the temperature may be around (T α −150)° C. or higher, and the rolling reduction may be around 20% or more.
[0064] On the other hand, the upper limit of the rolling reduction of finish hot rolling is preferably around 80% in terms of the bite angle. Further, finish rolling is performed with the total pass of around 4 to 7 passes. We found that performing finish hot rolling with a rolling reduction of 40% or more in a temperature range of (T γmax ±50)° C. even at any pass of the second pass and after would lead to the desired effect. Therefore, in the finish hot rolling process, it is sufficient to perform at least one pass of finish rolling in the temperature range of (T γmax ±50)° C. with a rolling reduction of 40% or more.
[0065] By performing rough hot rolling and finish hot rolling satisfying the above conditions, an improving effect on texture such as mentioned above is obtained, and good magnetic properties can be obtained in the product steel sheet. Further, by performing one pass of finish hot rolling in a temperature range of (T γmax ±50)° C. at a strain rate of 6.0 s −1 or more, refinement of the γ phase during finish hot rolling becomes prominent, and improving effect of the texture of the primary recrystallized sheet and improving effect of magnetic properties of the secondary recrystallized sheet becomes prominent.
[0066] Further, the microstructure of the hot rolled sheet can be improved by performing hot band annealing, if necessary. Hot band annealing at this time is preferably performed under the conditions of soaking temperature of 800° C. or higher and 1200° C. or lower and soaking duration of 2 seconds or more and 300 seconds or less.
[0067] With a soaking temperature of hot band annealing of lower than 800° C., the microstructure of the hot rolled sheet is not completely improved and non-recrystallized parts remain. Therefore, a desirable microstructure may not be obtained. On the other hand, if the soaking temperature is over 1200° C., dissolution of AlN, MnSe and MnS proceeds, the inhibition effect of inhibitor in the secondary recrystallization process becomes insufficient, and secondary recrystallization is suspended accordingly, resulting in deterioration of magnetic properties. Therefore, soaking temperature of hot band annealing is preferably 800° C. or higher and 1200° C. or lower.
[0068] Further, if the soaking duration is less than 2 seconds, non-recrystallized parts remain because of the short high-temperature holding time, and a desirable microstructure may not be obtained. On the other hand, if the soaking duration is over 300 seconds, dissolution of AlN, MnSe and MnS proceeds, the inhibition effect of inhibitor in the secondary recrystallization process becomes insufficient, so that secondary recrystallization is suspended, resulting in deterioration of magnetic properties.
[0069] Therefore, soaking duration of hot band annealing is preferably 2 seconds or more and 300 seconds or less.
[0070] After hot band annealing or without hot band annealing by subjecting the steel sheet to cold rolling once, or twice or more with intermediate annealing performed therebetween until reaching the final sheet thickness, it is possible to obtain our grain oriented electrical steel sheet.
[0071] The conditions for intermediate annealing may be in accordance with conventionally known conditions. Preferably, soaking temperature is 800° C. or higher and 1200° C. or lower and soaking duration is 2 seconds or more and 300 seconds or less. In the cooling process after intermediate annealing, it is preferable to perform rapid cooling with a cooling rate from 800° C. to 400° C. of 10° C./s or more and 200° C./s or less.
[0072] If the above soaking temperature is lower than 800° C., non-recrystallized microstructures remain, and therefore it becomes difficult to obtain a microstructure of uniformly-sized grains in the microstructure of the primary recrystallized sheet and a desirable growth of secondary recrystallized grains cannot be achieved, thereby leading to deterioration of magnetic properties. On the other hand, if the soaking temperature is over 1200° C., dissolution of AlN, MnSe and MnS proceeds, the inhibition effect of inhibitor in the secondary recrystallization process becomes insufficient, and secondary recrystallization is suspended, which may result in deterioration of magnetic properties.
[0073] Therefore, soaking temperature of intermediate annealing before final cold rolling is preferably 800° C. or higher and 1200° C. or lower.
[0074] Further, if the soaking duration is less than 2 seconds, non-recrystallized parts remain because of the short high-temperature holding time, and it becomes difficult to obtain a desirable microstructure. On the other hand, if the soaking duration is over 300 seconds, dissolution of AlN, MnSe and MnS proceeds, the inhibition effect of inhibitor in the secondary recrystallization process becomes insufficient, so that secondary recrystallization is suspended, resulting in deterioration of magnetic properties.
[0075] Therefore, soaking duration of intermediate annealing before final cold rolling is preferably 2 seconds or more and 300 seconds or less.
[0076] Further, in the cooling process after intermediate annealing before final cold rolling, if the cooling rate from 800° C. to 400° C. is less than 10° C./s, coarsening of carbides becomes more likely to proceed, and the texture improving effect from the subsequent cold rolling to primary recrystallization annealing decreases, and magnetic properties are more likely to deteriorate. On the other hand, if the cooling rate from 800° C. to 400° C. is over 200° C./s, hard martensite phase is more easily generated, and a desirable microstructure cannot be obtained in the microstructure of the primary recrystallized sheet, thereby leading to deterioration of magnetic properties.
[0077] Therefore, the cooling rate from 800° C. to 400° C. in the cooling process after intermediate annealing before final cold rolling is preferably 10° C./s or more and 200° C./s or less.
[0078] By setting the rolling reduction in final cold rolling to 80% or more and 92% or less, it is possible to obtain an even better texture of the primary recrystallized sheet.
[0079] Steel sheets rolled until reaching final sheet thickness by final cold rolling are preferably subjected to primary recrystallization annealing at a soaking temperature of 700° C. or higher and 1000° C. or lower. In this case, the primary recrystallization annealing may be performed in, for example, wet hydrogen atmosphere to obtain the effect of decarburization of the steel sheet.
[0080] If the soaking temperature in primary recrystallization annealing is lower than 700° C., non-recrystallized parts remain, and a desirable microstructure may not be obtained. On the other hand, if the soaking temperature is over 1000° C., secondary recrystallization of Goss orientation grains may occur.
[0081] Therefore, primary recrystallization annealing is preferably performed at a temperature of 700° C. or higher and 1000° C. or lower.
[0082] By performing common primary recrystallization annealing satisfying the above conditions, texture improving effect such as mentioned above is achieved. By performing primary recrystallization annealing where the heating rate from 500° C. to 700° C. until reaching soaking temperature of primary recrystallization annealing is 50° C./s or more, it is possible to obtain an even higher S orientation ({1 2 4 1}<0 1 4>) intensity or Goss orientation intensity of textures of primary recrystallized sheets and hence it becomes possible to increase the magnetic flux density of the steel sheet after secondary recrystallization and decrease the recrystallized grain size to improve iron loss properties.
[0083] Regarding the temperature range of primary recrystallization annealing, since an object of primary recrystallization annealing is to cause recrystallization by performing rapid heating in the temperature range corresponding to recovery of microstructure after cold rolling, the heating rate from 500° C. to 700° C. corresponding to the recovery of microstructure is important and it is preferable that the heating rate of this range is defined. Specifically, if the heating rate in the aforementioned temperature range is less than 50° C./s, recovery of the microstructure in the temperature cannot be sufficiently suppressed and, therefore, the heating rate is preferably 50° C./s or more. Although there is no upper limit for the above heating rate, it is preferably 300° C./s from the limitation of facilities.
[0084] Further, primary recrystallization annealing is normally combined with decarburization annealing and should be performed in an appropriate oxidizing atmosphere (e.g. P H2O /P H2 >0.1). Regarding the above range of 500° C. to 700° C. where a high heating rate is required, there may be situations where due to limitations of facilities and the like it is difficult to introduce oxidizing atmosphere. However, in the light of decarburization, the oxidizing atmosphere in the vicinity of 800° C. is important. Therefore, there would be no problem even if the temperature range of 500° C. to 700° C. is a range of P H2O /P H2 0.1.
[0085] If it is difficult to perform these annealing procedures, a separate decarburizing annealing process may be provided.
[0086] It is also possible to perform nitriding treatment of 150 ppm to 250 ppm of N in steel after completion of primary recrystallization annealing and before beginning of secondary recrystallization annealing. To do so, known techniques of performing heat treatment in NH 3 atmosphere, adding nitride in annealing separators, changing the atmosphere of secondary recrystallization annealing to nitriding atmosphere may be applied after primary recrystallization annealing.
[0087] Then, if necessary, an annealing separator mainly composed of MgO can be applied on the steel sheet surface, and then secondary recrystallization annealing can be performed. Annealing conditions of the secondary recrystallization annealing are not particularly limited, and conventionally known annealing conditions may be applied. Further, by making the annealing atmosphere a hydrogen atmosphere, it is also possible to obtain the effect of purification annealing. Then, after an insulating coating applying process and a flattening annealing process, a desired grain oriented electrical steel sheet is obtained. There is no particular provision regarding the manufacturing conditions of the insulating coating applying process and the flattening annealing process, and they may be performed in accordance with conventional manners.
[0088] A grain oriented electrical steel sheet manufactured by satisfying the above conditions have an extremely high magnetic flux density as well as low iron loss properties after secondary recrystallization.
[0089] However, achieving the high magnetic flux density, means that the crystal grains were allowed to preferentially grow only in orientations in the vicinity of the Goss orientation during the secondary recrystallization process. Since it is known that the closer to the Goss orientation the secondary recrystallized grains are, the more the growth rate of secondary recrystallized grains increases, an increase in magnetic flux density indicates that secondary recrystallized grain size is potentially coarse. This is advantageous in terms of reducing hysteresis loss, yet may be disadvantageous in terms of reducing eddy current loss. To advantageously solve such an offsetting problem for the ultimate goal of reducing iron loss, it is possible to perform magnetic domain refining treatment in the present invention.
[0090] By performing magnetic domain refining treatment, the increase in eddy current loss caused by coarsening of secondary recrystallized grain size is improved, and together with reduction in hysteresis loss, it is possible to obtain extremely good iron loss properties, even better than those of the aforementioned examples of the grain oriented electrical steel sheets. Both of conventionally known heat resistant and non-heat resistant magnetic domain refining treatment methods may be applied. In particular, by performing magnetic domain refining treatment using an electron beam or a continuous laser to the steel sheet surface after secondary recrystallization, it is possible to allow the magnetic domain refining effect to spread to the inner part in the sheet thickness direction of the steel sheet, leading to even lower iron loss properties compared to other magnetic domain refining treatment such as etching.
EXAMPLES
Example 1
[0091] Slabs of steel compositions shown in Table 2 were heated at a temperature of 1420° C., then subjected to the first pass of rough hot rolling with a rolling reduction of 40% at 1280° C., then the steel sheet was subjected to the first pass of finish hot rolling with a rolling reduction of 50% at 1180° C., and then subjected to hot rolling until reaching a sheet thickness of 2.6 mm. Then, the steel sheet was subjected to hot band annealing for 40 seconds at 1050° C. Then, the steel sheet was subjected to cold rolling until reaching a sheet thickness of 1.6 mm, intermediate annealing for 80 seconds at 1080° C., cold rolling until reaching a sheet thickness of 0.23 mm, and then to primary recrystallization annealing combined with decarburization for 120 seconds at 820° C. Then, an annealing separator mainly composed of MgO was applied on the steel sheet surface, and then secondary recrystallization annealing combined with purification was performed for 50 hours at 1150° C.
[0092] T α and T γmax calculated from equations (1) and (2) and the results of magnetic measurement of the final annealed sheets are shown in Table 2:
[0000] T α [° C.]=1383.98−73.29[% Si]+2426.33[% C]+271.68[% Ni] (1)
[0000] T γmax [° C.]=1276.47−59.24[% Si]+919.22[% C]+149.03[% Ni] (2)
[0000] where [% A] represents content of element “A” in steel (mass %).
[0000]
TABLE 2
Product Sheet-
Magnetic
Properties
Si
C
Ni
Mn
sol. Al
N
S
Se
T α
T γmax
W 17/50
B 8
No.
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[° C.]
[° C.]
[W/kg]
[T]
Remarks
1
3.2
0.04
0.01
0.08
0.02
0.01
0.01
0.02
1249
1125
0.87
1.92
Comparative
Example
2
3.4
0.07
0.2
0.08
0.03
0.01
0.01
0.02
1359
1169
0.83
1.94
Inventive
Example
3
3.3
0.08
0.18
0.09
0.02
0.01
0.01
0.02
1385
1181
0.84
1.94
Inventive
Example
4
3.6
0.05
0.005
0.08
0.03
0.01
0.01
0.02
1243
1110
0.88
1.91
Comparative
Example
5
3.1
0.06
0.31
0.08
0.03
0.01
0.01
0.02
1387
1194
0.82
1.95
Inventive
Example
6
3.7
0.05
0.4
0.08
0.03
0.01
0.01
0.02
1343
1163
0.79
1.95
Inventive
Example
7
3.4
0.03
0.42
0.09
0.02
0.01
0.01
0.02
1322
1165
0.81
1.94
Inventive
Example
8
3.6
0.06
0.2
0.09
0.03
0.01
0.01
0.02
1320
1148
0.80
1.94
Inventive
Example
[0093] Table 2 shows that a material subjected to high reduction rolling in a temperature range of (T α −100)° C. or higher in the first pass of rough hot rolling, and high reduction rolling in a temperature range of (T γmax ±50)° C. in the first pass of finish hot rolling, was provided with excellent magnetic properties. On the other hand, regarding materials of Nos. 1 and 4, it is assumed that the reason why excellent magnetic properties were not obtained is that, due to the fact that the temperature of the first pass of finish hot rolling is higher than the temperature range of maximum γ phase volume fraction which is calculated from the compositions, recrystallized grain refinement of ferrite grains as well as uniform generation of the γ phase was insufficient.
[0094] From the above results, it is understood that a grain oriented electrical steel sheet with excellent magnetic properties can be obtained by calculating T, and T γmax using equations (1) and (2) based on the steel slab compositions, and performing high reduction rolling of 30% or more in a temperature range of (T α −100)° C. or higher in the first pass of rough hot rolling, and performing high reduction rolling of 40% or more in a temperature range of (T γmax ±50)° C. in the first pass of finish hot rolling.
Example 2
[0095] Slabs of steel compositions shown in Table 3 were heated at a temperature of 1420° C., then subjected to the first pass of rough hot rolling with a rolling reduction of 40% at 1280° C., then the steel sheet was subjected to the first pass of finish hot rolling with a rolling reduction of 50% at 1180° C., and then subjected to hot rolling until reaching a sheet thickness of 2.6 mm. Then, the steel sheet was subjected to hot band annealing for 40 seconds at 1050° C. Then, the steel sheet was subjected to cold rolling until reaching a sheet thickness of 1.8 mm, intermediate annealing for 80 seconds at 1080° C., cold rolling until reaching a sheet thickness of 0.27 mm, and then to primary recrystallization annealing combined with decarburization for 120 seconds at 820° C. Then, an annealing separator mainly composed of MgO was applied on the steel sheet surface, and then secondary recrystallization annealing combined with purification was performed for 50 hours at 1150° C.
[0096] T α and T γmax calculated from equations (1) and (2) and the results of magnetic measurement of the final annealed sheets are shown in Table 3.
[0000]
TABLE 3
Si
C
Ni
Mn
sol. Al
N
S
Se
No.
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[mass. %]
1
3.4
0.06
0.15
0.08
0.03
0.01
0.01
0.02
2
3.5
0.07
0.20
0.09
0.02
0.01
0.01
0.02
3
3.3
0.08
0.10
0.08
0.02
0.01
0.01
0.02
4
3.4
0.06
0.17
0.08
0.02
0.01
0.01
0.02
5
3.5
0.06
0.31
0.08
0.03
0.01
0.01
0.02
Product Sheet-
Magnetic
Properties
Sn
Sb
Cu
P
Tα
Tγmax
W 17/50
B 8
No.
[mass. %]
[mass. %]
[mass. %]
[mass. %]
[° C.]
[° C.]
[W/kg]
[T]
Remarks
1
tr
tr
tr
tr
1321
1153
0.86
1.96
Inventive
Example
2
0.15
tr
tr
tr
1352
1163
0.85
1.95
Inventive
Example
3
tr
0.031
tr
tr
1363
1169
0.85
1.96
Inventive
Example
4
tr
tr
0.1
tr
1327
1156
0.84
1.95
Inventive
Example
5
tr
tr
tr
0.012
1357
1170
0.85
1.95
Inventive
Example
[0097] Table 3 shows that a material subjected to high reduction rolling in a temperature range of (T α −100)° C. or higher in the first pass of rough hot rolling, and high reduction rolling in a temperature range of (T γmax ±50)° C. in the first pass of finish hot rolling, was provided with excellent magnetic properties.
[0098] From the above results, it is understood that a grain oriented electrical steel sheet with excellent magnetic properties can be obtained by calculating T, and T γmax from equations (1) and (2) based on the steel slab compositions, and performing high reduction rolling of 30% or more in a temperature range of (T α −100)° C. or higher in the first pass of rough hot rolling, and performing high reduction rolling of 40% or more in a temperature range of (T γmax ±50)° C. in the first pass of finish hot rolling.
Example 3
[0099] The above mentioned Examples 1 and 2 are results of performing primary recrystallization annealing with a heating rate from 500° C. to 700° C. of 20° C./s. Samples prepared by performing cold rolling under conditions of No. 2 (inventive example) of Example 1 until reaching a sheet thickness of 0.23 mm were used with the heating rate from 500° C. to 700° C. in primary recrystallization annealing being the values shown in Table 4, to further conduct a test of changing the method of magnetic domain refining treatment.
[0100] Etching grooves having a width of 150 μm, depth of 15 μm, rolling direction interval of 5 mm were formed in transverse direction (direction orthogonal to the rolling direction) on one side of the steel sheet subjected to cold rolling until reaching a sheet thickness of 0.23 mm. The steel sheet was continuously irradiated on one side with an electron beam in the transverse direction after final annealing under the conditions of an acceleration voltage of 100 kV, irradiation interval of 5 mm, beam current of 3 mA. A laser was continuously irradiated in the transverse direction on one side of the steel sheet after final annealing under the conditions of beam diameter of 0.3 mm, output of 200 W, scanning rate of 100 m/s, irradiation interval of 5 mm.
[0101] The measurement results of magnetic properties are shown in Table 4.
[0000]
TABLE 4
Primary Re-
crystallization
Magnetic Properties
Annealing
(After Magnetic
Heating Rate
Magnetic
Domain Refining)
(500-700° C.)
Domain
W 17/50
B 8
No.
[° C./s]
Refining
[W/kg]
[T]
Remarks
2-a-0
20
—
0.83
1.94
Inventive
Example
2-a-1
20
Etching
0.72
1.90
Inventive
Example
2-a-2
20
Electron Beam
0.69
1.94
Inventive
Example
2-a-3
20
Continuous
0.70
1.94
Inventive
Laser
Example
2-b-0
40
—
0.81
1.95
Inventive
Example
2-b-1
40
Etching
0.70
1.91
Inventive
Example
2-b-2
40
Electron Beam
0.67
1.94
Inventive
Example
2-b-3
40
Continuous
0.67
1.94
Inventive
Laser
Example
2-c-0
100
—
0.76
1.95
Inventive
Example
2-c-1
100
Etching
0.66
1.91
Inventive
Example
2-c-2
100
Electron Beam
0.60
1.95
Inventive
Example
2-c-3
100
Continuous
0.60
1.95
Inventive
Laser
Example
[0102] Table 4 shows that as the heating rate from 500° C. to 700° C. during primary recrystallization annealing increases, good iron loss properties are obtained. Further, it is also shown that, regarding all of the heating rates, extremely good iron loss properties are obtained by performing magnetic domain refining treatment.
Example 4
[0103] Examples 1, 2, and 3 are results of conducting experiments in a temperature range of (T γmax ±50)° C. with a strain rate of 8.0 s −1 in the first pass of finish hot rolling. Regarding a material of No. 3 (inventive example) of Example 1, an experiment of changing the strain rate of only one pass of finish hot rolling was performed.
[0104] Using a rolling reduction and a rolling speed such as shown in Table 5, the material was subjected to at least one pass of finish hot rolling at 1150° C. which corresponds to (T γmax ±50)° C. under the controlled strain rate, and then the steel sheet was subjected to hot rolling until reaching a sheet thickness of 2.0 mm thick. Then, the steel sheet was subjected to hot band annealing for 60 seconds at 1100° C. Further, the steel sheet was subjected to cold rolling until reaching a sheet thickness of 0.23 mm thick, and then subjected to primary recrystallization annealing combined with decarburization for 120 seconds at 820° C. Then, an annealing separator mainly composed of MgO was applied on the steel sheet surface, and then secondary recrystallization annealing combined with purification was performed for 50 hours at 1150° C. The results of magnetic measurement of the final annealed sheets are shown in Table 5.
[0000]
TABLE 5
Conditions for Finish Hot Rolling
First Pass
Second Pass
Pass which is
Rolling
Rolling
Strain
Rolling
Rolling
Strain
the Subject of
Temp.
Reduction
Rate
Rate
Temp.
Reduction
Rate
Rate
No.
the Invention
[° C.]
[%]
[mpm]
[s −1 ]
[° C.]
[%]
[mpm]
[s −1 ]
3-a-1
First Pass
1150
40
70
6.0
1100
35
150
12.0
3-a-2
First Pass
1150
50
70
6.8
1095
35
150
12.0
3-a-3
First Pass
1150
50
150
14.3
1095
35
180
14.4
3-a-4
First Pass
1150
70
70
7.9
1085
35
150
12.0
3-a-5
First Pass
1150
70
150
16.9
1085
35
180
14.4
3-b-1
Second Pass
1200
40
70
6.0
1150
40
150
12.8
3-b-2
Second Pass
1200
40
70
6.0
1150
50
150
14.3
3-b-3
Second Pass
1200
40
70
6.0
1150
50
220
21.0
3-b-4
Second Pass
1200
40
70
6.0
1150
70
150
16.9
3-b-5
Second Pass
1200
40
70
6.0
1150
70
220
24.8
3-c-1
Third Pass
1250
50
70
6.7
1190
45
150
13.6
3-c-2
Third Pass
1250
50
70
6.7
1190
45
150
13.6
3-c-3
Third Pass
1250
50
70
6.7
1190
45
150
13.6
3-c-4
Third Pass
1250
50
70
6.7
1190
45
150
13.6
3-c-5
Third Pass
1250
50
70
6.7
1190
45
150
13.6
Conditions for Finish Hot Rolling
Third Pass
Rolling
Rolling
Strain
Magnetic Properties
Temp.
Reduction
Rate
Rate
W 17/50
B 8
No.
[° C.]
[%]
[mpm]
[s −1 ]
[W/kg]
[T]
Remarks
3-a-1
1070
30
250
18.5
0.84
1.93
Inventive
Example
3-a-2
1060
30
250
18.5
0.83
1.94
Inventive
Example
3-a-3
1060
30
290
21.4
0.80
1.95
Inventive
Example
3-a-4
1040
30
250
18.5
0.82
1.94
Inventive
Example
3-a-5
1040
30
290
21.4
0.79
1.95
Inventive
Example
3-b-1
1100
30
250
18.5
0.81
1.94
Inventive
Example
3-b-2
1090
30
250
18.5
0.81
1.94
Inventive
Example
3-b-3
1090
30
320
23.7
0.79
1.95
Inventive
Example
3-b-4
1075
30
250
18.5
0.80
1.94
Inventive
Example
3-b-5
1075
30
320
23.7
0.78
1.95
Inventive
Example
3-c-1
1150
40
250
21.3
0.81
1.94
Inventive
Example
3-c-2
1150
50
250
23.8
0.80
1.93
Inventive
Example
3-c-3
1150
50
360
34.3
0.78
1.95
Inventive
Example
3-c-4
1150
70
250
28.2
0.79
1.95
Inventive
Example
3-c-5
1150
70
360
40.6
0.79
1.96
Inventive
Example
[0105] Table 5 shows that good iron loss properties are obtained by performing at least one pass of finish hot rolling at the strain rate of 6.0 s −1 or more in a temperature range of (T γmax ±50)° C.
|
A method of manufacturing a grain oriented electrical steel sheet uses austenite (γ)-ferrite (α) transformation which develops excellent magnetic properties, uses T α calculated from equation (1) and performs the first pass of rough hot rolling at a temperature of (T α −100)° C. or higher with a rolling reduction of 30% or more, and further uses T γmax calculated from equation (2) and performs any one pass of finish hot rolling in a temperature range of (T γmax ±50)° C. with a rolling reduction of 40% or more:
T α [° C.]=1383.98−73.29[% Si]+2426.33[% C]+271.68[% Ni] (1)
T γmax [° C.]=1276.47−59.24[% Si]+919.22[% C]+149.03[% Ni] (2)
where [% A] represents content of element “A” in steel (mass %).
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns plants for the production of metal articles through the feeding of molten metal under pressure from a holding furnace to a die positioned on a surface of a press located on the furnace.
2. Description of the Related Art
At present many metal articles, for example the rims of vehicle wheels, are produced through the forced injection of molten metal into a die. Molten metal is usually kept in holding furnaces. A hydraulic press is positioned on top of the holding furnace and, on a lower plane of the press, a die is provided which communicates with the bottom of the holding furnace through a vertical duct. The furnace is pressurized with compressed air so that the molten metal is conveyed upward along the duct until reaching the die and filling it.
Molten metal is periodically introduced into the holding furnace through an appropriate opening provided with a door. Since the furnace is pressurized with compressed air, the door must ensure a perfect seal. For this purpose, the door is provided with a gasket made of a suitable heat-resistant material, which, however, wears out due to repeated use and must be periodically replaced.
At present, the doors of holding furnaces comprise a simple panel hinged to the furnace, which is lifted either for the introduction of new molten metal into furnace itself or for the replacement of the gasket. These doors present a series of drawbacks, since the opening and closing mechanism exerts an asymmetrical pressure on the gasket and does not ensure a perfect seal, thus making it necessary to change the gasket frequently. Furthermore, due to such opening and closing systems, maintenance operations on the door and/or on the charging hole and/or the gasket are neither quick, nor simple to carry out.
SUMMARY OF THE INVENTION
The subject of the present invention is a new automatic door for molten metal holding furnaces which is provided with a double opening/closing and tilting mechanism for the replacement of the gaskets and/or the maintenance of the door and the charging hole. The new door for holding furnaces simplifies the opening and closing operations, ensures easy and precise maintenance of the door and/or the charging hole and also allows the gasket of the door to be easily changed, and furthermore no special external equipment is required to open, close or tilt the door.
The new automatic door comprises a fixed plate with charging and inspection hole integral with the furnace itself, a moveable closing panel with replacement gasket, two rotary guides, two parallel lever systems that press the closing panel against the furnace mouth, two adjusting mechanisms, a hydraulic cylinder that provides for the sliding movement of the closing panel and two hydraulic cylinders operating the lever systems that press the closing panel.
BRIEF DESCRIPTION OF THE DRAWINGS
The following is just an example, among many, of a practical embodiment of the new automatic door, whose description refers to the attached drawings, wherein:
FIG. 1 is a front view of the new door;
FIG. 2 is a horizontal section along line A—A;
FIG. 3 is a vertical section along line B—B; and
FIG. 4 is a vertical section along line C—C.
FIGS. 5 and 6 show further views of the new door.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A plate ( 1 ) with a charging hole ( 1 . 1 ) and structure ( 1 . 2 ) constitutes the mouth of the furnace. The hole ( 1 . 1 ) provided on the plate makes it possible to reach and/or inspect the inside of the furnace. The structure ( 1 . 2 ) of the plate ( 1 ) serves as support for the other components of the automatic door and in particular it mounts two supports ( 1 . 21 ) positioned at the sides of the charging hole ( 1 . 1 ) and two vertical wings ( 1 . 22 ) positioned on the upper part of the plate ( 1 ). Each one of the two supports ( 1 . 21 ) positioned at the sides of the charging hole ( 1 . 1 ) is provided with one of the two adjusting mechanisms ( 2 ) that substantially comprise a drilled sliding element ( 2 . 1 ) that slides to approach and move away from the plate ( 1 ) and can be locked as desired at intermediate distances from the plate ( 1 ).
Each one of two rotary guides ( 3 ) is constituted by a generically rectangular plate ( 3 . 1 ) provided with an elongated slot ( 3 . 2 ) which is parallel to the substantially vertical side of the plate ( 3 . 1 ). Each guide ( 3 ) has its upper end ( 3 . 3 ) hinged or pivotally mounted to a vertical wing ( 1 . 22 ) of the plate ( 1 ) and is longer than the distance between the wings ( 1 . 22 ) and the lower edge of the charging hole ( 1 . 1 ) of the plate ( 1 ). The upper ends ( 3 . 3 ) of the two guides ( 3 ) are joined by a cross element ( 4 ) that serves as a mounting base for a hydraulic cylinder ( 5 ) that ensures the sliding movement of a closing panel ( 6 ).
The lower ends ( 3 . 4 ) of the two guides ( 3 ) are connected to the two lateral supports ( 1 . 21 ) of the plate ( 1 ) by means of a pressure lever systems ( 7 ). Each pressure lever system ( 7 ) comprises two connecting rods ( 7 . 1 , 7 . 2 ) hinged to each other. One of the connecting rods ( 7 . 1 ), which is further from the plate ( 1 ), is hinged to the adjusting mechanism ( 2 ) described above, while the other connecting rod ( 7 . 2 ), which is nearer to the plate ( 1 ), is hinged to the lower end ( 3 . 4 ) of the adjacent rotary guide ( 3 ).
The two hydraulic cylinders ( 7 . 3 ) that press the door against the hole ( 1 ) are connected to the upper vertical wings ( 1 . 22 ) of the plate ( 1 ) and to a common hinge point ( 7 c ) between the two connecting rods ( 7 . 1 , 7 . 2 ) of the pressure lever system ( 7 ).
Each retraction of the two hydraulic cylinders ( 7 . 3 ) causes a rotating movement of the two connecting rods ( 7 . 1 , 7 . 2 ) that form an acute angle, moving the lower end ( 3 . 4 ) of the rotary guides ( 3 ) away from the plate ( 1 ). Each extension of the two hydraulic cylinders ( 7 . 3 ) causes a rotating movement of the two connecting rods ( 7 . 1 , 7 . 2 ) that form an obtuse or straight angle, reducing the distance between the lower end ( 3 . 4 ) of the rotary guides ( 3 ) and the plate ( 1 ).
The closing panel ( 6 ) that constitutes the actual opening and closing door comprises a panel made of a suitable material with appropriate thickness, provided on opposite sides with four pins ( 6 . 1 , 6 . 2 ), two for the right side and two for the left side, which slide in the elongated slots ( 3 . 2 ) of the rotary guides ( 3 ). The two upper pins ( 6 . 2 ) are fixed, while the two lower pins ( 6 . 1 ) can be removed from the closing panel ( 6 ).
The surface of the closing panel ( 6 ) that faces the plate ( 1 ) is equipped with an appropriate gasket ( 6 . 5 ). A coupling point, a ring or a drilled plate ( 6 . 3 ) is provided near the lower edge of the closing panel ( 6 ). The closing panel ( 6 ) can be provided with a hole with a plug ( 6 . 4 ), in such a way as to permit a visual check of the inside of the furnace, with no need to open it.
The hydraulic cylinder ( 5 ) is mounted to the cross element ( 4 ) that joins the upper ends ( 3 . 3 ) of the rotary guides ( 3 ) and is parallel to the rotary guides ( 3 ). In particular, the body ( 5 . 1 ) of the cylinder ( 5 ) is positioned on the side of the cross element ( 4 ) that is opposite the rotary guides ( 3 ), while the sliding rod ( 5 . 2 ) of the cylinder ( 5 ) is positioned between the rotary guides ( 3 ), connected to the upper edge of the closing panel ( 6 ). The connection between the sliding rod ( 5 . 2 ) of the cylinder ( 5 ) and the closing panel ( 6 ) is such as to ensure a rapid release of the cylinder ( 5 ) from the closing panel ( 6 ), with a perpendicular movement with respect to the plane of the closing panel ( 6 ).
The movement of the rod ( 5 . 2 ) of the hydraulic cylinder ( 5 ) causes the translation of the closing panel ( 6 ) from a lower position in which it covers the hole ( 1 . 1 ) of the plate ( 1 ) completely to a higher position in which it leaves the hole ( 1 . 1 ) of the plate ( 1 ) completely open.
All the hydraulic cylinders ( 7 . 3 , 5 ) of the new automatic door are controlled by appropriate solenoid valves that properly convey a flow of pressurized fluid coming from an appropriate pump. An electronic/electromechanical unit controls the operation of the solenoid valves, the pump and the various operating and safety sensors during the opening, closing and servicing of the new automatic door.
When the door must be opened, the cylinders ( 7 . 3 ) are retracted, so that the lower ends ( 3 . 4 ) of the rotary guides ( 3 ) move away from the plate ( 1 ) and, successively, the cylinder ( 5 ) is also retracted to move the closing panel ( 6 ) upwards and permit free access to the hole ( 1 . 1 ) of the plate ( 1 ) that constitutes the access to the furnace.
When the door must be closed, the cylinder ( 5 ) is extended to move the closing panel ( 6 ) downwards until it is positioned before the hole ( 1 . 1 ) of the plate ( 1 ) and, successively, the cylinders ( 7 . 3 ) are extended, so that the lower ends ( 3 . 4 ) of the rotary guides ( 3 ) approach the plate ( 1 ), pressing the closing panel ( 6 ) and the relevant gasket ( 6 . 5 ) against the hole ( 1 . 1 ) of the plate ( 1 ) and thus closing the furnace.
Due to the successive pressures exerted by the closing panel ( 6 ) against the hole ( 1 . 1 ) of the plate ( 1 ), the thickness of the gasket ( 6 . 5 ) of the closing panel ( 6 ) is gradually reduced and it becomes necessary to act on the adjusting mechanisms ( 2 ) positioned on the lateral supports ( 1 . 21 ) of the plate ( 1 ).
When it is necessary to carry out maintenance operations on the closing panel ( 6 ), for example to replace the gasket ( 6 . 5 ) when it is worn, the closing panel ( 6 ) is moved away from the hole ( 1 . 1 ) of the plate ( 1 ) by retracting the cylinders ( 7 . 3 ). The rod ( 5 . 2 ) of the cylinder ( 5 ) is released from the closing panel ( 6 ) and the lower pins ( 6 . 1 ) of the closing panel ( 6 ) are removed (FIG. 5 ).
Successively, a winch or bridge crane is coupled to the coupling point, ring or drilled plate ( 6 . 3 ) provided near the lower edge of the closing panel ( 6 ) and the winch or bridge crane is operated, rotating the closing panel ( 6 ) completely, in such a way as to make its inner surface, which is generally pressed against the charging hole ( 1 . 1 ), fully visible (FIG. 6 ). To prevent the heat still present in the furnace from being dispersed and/or any object from falling inside the furnace, it is advisable to position a temporary wall or door on the charging hole of the furnace.
In order to prevent the fluid circulating in the hydraulic cylinder ( 5 ) and in the cylinders ( 7 . 3 ) from overheating due to the high temperature present immediately outside the furnace, the hydraulic circuits that operate the cylinder ( 5 ) and cylinders ( 7 . 3 ) are provided with double connections for the recirculation of the operating fluid, which is kept under pressure and conveyed in such a way as to make it pass through a suitable cooler. In this way, by keeping the fluid temperature within the prescribed limits, it is possible to avoid the boiling of the fluid and any pressure variation of the same, which would make the operation of the cylinder ( 5 ) and cylinders ( 7 . 3 ) imprecise or even impossible.
The description is sufficient to enable one skilled in the art to realize the invention, consequently, in the final application, variations may be made without prejudicing the substance of the innovative concept. Therefore, with reference to the above description and the enclosed drawings, the following claims are put forth.
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A door for molten metal holding furnaces which includes a fixed plate with charging and inspection hole provided with two supports positioned at the sides of the charging hole and with two vertical wings positioned on an upper part of the plate and two guides are hinged to the two vertical wings and directed downwards, beyond a lower edge of the charging hole. A closing panel with gasket is equipped with lateral pins that are housed in the guides for making the closing panel slide along the guides. One or more pressure mechanisms act on lower ends of the guides and rotate the guides so as to bring the closing panel in contact with the plate and press the panel against the hole or to move it away from the plate.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to the field of dishwashers. More particularly, this invention relates to a single piece frame and support member for the tub of a dishwasher.
[0002] A typical dishwasher includes a tub having an open front leading to an interior washing compartment. A door pivotally mounts in a sealable manner over the front opening. Various means have been provided for supporting the tub on a floor or supporting surface. Heretofore tub frame and support means have typically included a plurality of separate component parts that must be welded or fastened together with mechanical fasteners, such as screws, rivets, or the like. Fabrication and assembly of these component parts requires considerable time and effort. It is desirable to minimize the number of component parts, movements, operations, and fasteners that are necessary to assemble the tub support frame, as well as to mount the tub and the door thereto. The component parts must also be assembled in a rather precise manner or distortion of the tub occurs. If the tub walls are not square with each other at the front opening, the door may have difficulty properly sealing the opening.
[0003] Therefore, a primary objective of the present invention is the provision of an improved frame and support system for a dishwasher tub.
[0004] A further objective of the present invention is the provision of a single piece tub frame and support member that requires no screws, rivets or other mechanical fasteners for its fabrication.
[0005] Another objective of the present invention is the provision of a single piece tub frame and support member that elevates the bottom wall of the tub and wraps around the top wall and opposite side walls of the tub to maintain squareness therebetween.
[0006] A further objective of the present invention is the provision of a method and means for dishwasher tub and support assembly that is economical, efficient in use, and which results in a reliable and durable assembly.
[0007] These and other objectives will be apparent from the drawings, as well as from the description and claims that follow.
SUMMARY OF THE INVENTION
[0008] The single piece tub support and frame for a dishwasher has a unitary support member that includes a pair of laterally spaced U-shaped upright end portions and an intermediate inverted U-shaped upright portion. The dishwasher tub attaches to the intermediate portion, which fits over the top and sides of the dishwasher tub rearwardly adjacent the front flange portion thereof. When the U-shaped end portions clear the bottom wall of the tub, they resiliently spring inward into supporting positions under the bottom wall. The unitary support member greatly reduces the number of components required, reduces manufacturing time and cost, and maintains the tub in its designed shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] [0009]FIG. 1 is a right rear perspective view of a dishwasher tub mounted on the single piece support-frame of the present invention.
[0010] [0010]FIG. 2 is a right side elevation view of the dishwasher tub and support frame of FIG. 1.
[0011] [0011]FIG. 3 is a front elevation view of the dishwasher tub and support frame of FIG. 1.
[0012] [0012]FIG. 4 is a perspective view of the unitary support frame of this invention.
[0013] [0013]FIG. 5 is a top plan view of the support frame of FIG. 3.
[0014] [0014]FIG. 6 is a front elevation view of the support frame of FIG. 3.
[0015] [0015]FIG. 7 is a right side elevation view of the support frame of FIG. 3.
[0016] [0016]FIG. 8 is a cross-sectional view taken along line 8 - 8 in FIG. 7 and illustrates an embodiment wherein square tubing forms the support frame.
[0017] [0017]FIG. 8A is cross-sectional view similar to FIG. 7, but shows an alternate embodiment wherein a U-shaped channel member forms the support frame.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] FIGS. 1 - 3 illustrate a dishwasher tub-and frame combination 10 that has a tub 12 supported by a single piece frame and support member 14 according to the present invention. The tub 12 includes a top wall 16 , opposite side walls 18 , 20 , and a bottom wall 22 . The tub 12 has a back wall 23 and an open front 24 . In the preferred embodiment, the tub 12 is formed of lightweight stainless steel or molded from a plastic material, such as polypropylene, but the materials of the tub can be varied without detracting from the invention.
[0019] The tub 12 has a front flange portion 26 for receiving a portion of a door (not shown) that pivotally mounts to the frame and support member 14 at a pair of laterally spaced hinge brackets 28 . The front flange portion 26 has a substantially vertical faceplate 30 . A recessed substantially vertical surface 32 extends parallel to the faceplate 30 and partially around the perimeter of the open front 24 of the tub 12 . More particularly, the surface 32 extends along the top wall 16 and the side walls 18 , 20 . A guide rib or flange 34 protrudes from the top wall 16 and the opposite side walls 18 , 20 generally parallel to the recessed surface 32 and offset therefrom in the direction of the back tub wall 23 . Thus, a channel, slot or groove 36 is formed in the tub 12 between the guide rib or flange 34 and the front flange portion 26 . The front flange portion 26 and the groove 36 preferably extend perpendicular or square to the bottom wall 22 of the tub 12 .
[0020] Referring to FIGS. 4 - 8 , a single piece of elongated bar stock forms the support member 14 . Preferably the bar stock is tubular and has a square transverse cross-section 38 , as shown in FIG. 8, or an open channel extending longitudinally therein and a U-shaped transverse cross-section 38 A, as shown in FIG. 8A. The preferred materials include steel or aluminum alloys, but the materials can be varied without distracting from the invention. A forming operation results in the support member 14 having a plurality of bends that define several identifiable portions.
[0021] In general, the portions of the support member 14 include a pair of laterally spaced upright U-shaped end portions 40 L, 4 R and an intermediate portion 42 that has an inverted U-shape. The end portions 40 L, 40 R each have an upright front leg 44 L or 44 R, an upright rear leg 46 L or 46 R and a substantially horizontal bottom rail 48 L or 48 R respectively connecting the legs. The U-shaped end portions 40 L, 40 R preferably extend parallel to each other and reside in substantially vertical planes.
[0022] The intermediate portion 42 has a top rail 50 and side rails 52 L, 52 R. The exact profile of the inverted U-shaped intermediate portion 42 preferably closely conforms to the outer profile of the tub 12 . In the usual case of a rectangular tub, the top rail 50 extends horizontally and the rails 52 L, 52 R extend vertically. The side rails 52 L, 52 R are parallel to each other and perpendicular to the top rail 50 .
[0023] The side rails 52 L, 52 R are perpendicular to the U-shaped end portions 40 L, 40 R respectively. The top rail 50 is also perpendicular to the U-shaped end portions 40 L, 40 R. Thus, the intermediate portion 42 as a whole is perpendicular to and square with the end portions 40 L, 40 R. The lower ends of the vertical rails 52 L, 52 R can extend straight down and be directly joined to the front legs 44 L, 44 R respectively, or optional transition portions or rails 54 L, 54 R can angle downwardly and rearwardly to provide an indirect connection and recess the end portions 40 L, 40 R rearwardly from the rails 52 L, 52 R.
[0024] The unitary support member 14 has a plurality of holes 56 , 58 , 62 , 64 , 66 , that are preferably punched, pierced, or drilled during the forming operation. Longitudinally spaced holes 56 extend vertically through the bottom rails 48 L, 48 R of the U-shaped end portions 40 L, 40 R to receive threaded bolts 68 for leveling the tub 12 . Holes 58 extend through the intermediate portion 42 of the support member 14 . Holes 62 extend laterally into the lower-ends of the vertical rails 52 L, 52 R, preferably just above the transition portions 54 L, 54 R when those portions exist. Holes 64 extend into the front legs 44 L, 44 R of the end portions 40 L, 40 R. Holes 66 extend into the rear legs 46 L, 46 R of the end portions 40 L, 40 R.
[0025] In use, the support member 14 attaches to the tub 12 in a quick, simple and easy manner. Although the support member 14 is substantially rigid, by design it has some resilient deformability. The worker can pull the end portions 40 L, 40 R or the lower ends of the intermediate portion 42 farther apart to slip them over the width of the top wall 16 . Then the worker moves the member 14 toward the front flange portion 26 and the bottom wall 20 of the tub 12 until the U-shaped end portions 40 L, 40 R clear the bottom wall 20 . At that point, the end portions 40 L, 40 R resiliently spring back inward into a supporting position under the bottom wall 20 or optional pads 69 attached thereto. The inverted U-shaped intermediate portion 42 will then be securely disposed in the groove 36 .
[0026] The worker secures the tub 12 to the support member 14 primarily by installing conventional fastening means 70 , such as screws in the holes 58 . A conventional door seal 72 (FIGS. 2 and 3) mounts on the recessed surface 32 and covers the heads of the screws 70 . Cabinet mounting brackets 74 , 76 are also attached to the top rail 50 by the screws 70 . Door mounting brackets 28 attach to the lower ends of the intermediate portion 42 using holes 62 , just above the transition portions 54 L, 54 R. The optional angled transition portions 54 L, 54 R, also allow a toe plate 78 to be recessed rearwardly with respect to the front flange 26 of the dishwasher 10 . Conventional fastening means 80 , such as screws, attach the toe plate 78 at the holes 64 in the front legs 44 L, 44 R of the end portions 40 L, 40 R. An optional rear support cross member 82 laterally interconnects the rear legs 46 L, 46 R of the end portions 40 L, 40 R to provide additional rigidity to the frame and provide a means for securing the rear legs 46 L, 46 R to the pads 69 .
[0027] The single piece support member 14 can be formed in a single forming operation, thereby eliminating a number of machining operations for separate components parts and the sub-assembly thereof. Furthermore, the support member 14 has the added benefit of insuring the squareness of the tub 12 while supporting it. The front flange portion 26 of the tub is directly secured to the intermediate portion 42 of the support member 14 . By supporting the tub 12 at the front flange portion 26 , door seal problems have been substantially reduced or eliminated altogether.
[0028] Thus, it can be seen that the present invention at least satisfies its stated objectives.
[0029] In the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, these are used in a generic and a descriptive sense only and not for the purposes of limitations. Changes in the form and the proportional parts as well as in the substitution of equivalence are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims.
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A single piece tub support and frame for a dishwasher has a unitary support member that includes a pair of laterally spaced U-shaped upright end portions and an intermediate inverted U-shaped upright portion. The intermediate portion fits over the top and sides of the dishwasher tub rearwardly adjacent the front flange portion thereof. When the U-shaped end portions clear the bottom wall of the tub, they resiliently spring inward into supporting positions under the bottom wall. The unitary support member greatly reduces the number of components required, reduces manufacturing time and cost, and maintains the tub in its designed shape.
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BACKGROUND OF THE INVENTION
The invention relates to a nozzle means for an air conditioning installation or the like for the ventilation of rooms, having a mounting frame with an opening and a nozzle pivotably mounted therein, which has an extension with a contour substantially closing the opening.
A nozzle means of the aforementioned type is disclosed in, for example, DE-OS No. 31 24 876. The known nozzle means has a nozzle pivotably inserted in a mounting frame and which over most of its axial extension has a diameter which is much smaller than the diameter of an opening of the mounting frame. The nozzle is held in the mounting frame, in that it is fixed to a cup which partly surrounds it and is held in the opening of the mounting frame, the latter having a frame-like ring flange adapted to the cup shape and directed outwards from the plane of its cover plate. This ring flange holds the cup, so that the nozzle can be correspondingly pivoted. This construction is not only complicated, but as a result of the complicated swivel mounting of the nozzle fault-prone, so that problems can occur during pivoting. Moreover, unless the nozzles are separately secured, they can move out of a set position, while an additional securing means is complicated due to the ball guide and possibly disfigures the mounting frame.
The aim underlying the present invention essentially resides in providing a nozzle means of the aforementioned type, which offers possibilities of much more varied use due to the advantageous construction from the manufacturing and material standpoints.
SUMMARY OF THE INVENTION
In the case of a nozzle means of the aforementioned type, according to the present invention the extension is a widened extension region constructed in one piece with the nozzle. Whereas in the known nozzle means it is necessary to provide, apart from the mounting frame and the actual nozzle, an additional nozzle-surrounding cup, as well as optionally a counter-mounting part, while the mounting frame also had to be constructed in a complicated manner, the inventive nozzle means only comprises the nozzle and the mounting frame. Thus, the nozzle is itself constructed in one piece and extended in such a way that the extension region largely covers the mounting frame opening, but the nozzle can still be adequately pivoted or swivelled.
Whereas, in the prior art it was necessary to directly mount the cup, according to a further development of the present invention the nozzle is articulated in the extension region by two swivel holders fixed to the frame. Thus, compared with the pivoting possibilities with the cup mounting limited by the proportion of the cup with respect to the overall ball, this construction permits a greater swivel or pivoting angle than was possible with the pivoting nozzle according to the prior art. Due to the greater pivoting possibilities, there is the advantage of covering a much larger surface than was the case in the prior art. Another advantage is that in the invention only one nozzle body has to be used, whereas, with the known pivotable nozzles two bodies were provided and consequently there was a risk of suspended matter penetrating and becoming deposited between the bodies, so that the nozzle would not then function in a completely satisfactory manner.
According to a further development of the present invention up to just below the cover plate of the mounting frame, the nozzle has a much smaller diameter than the opening and is only then extended to the contour substantially corresponding to the mounting frame opening. In the basic position in the extended region below the frame, the nozzle contour is located within a cup contour closing the opening and formed round the centre of the pivot axis. Thus, despite the one-piece construction of the overall swivel nozzle and the ensuring of its pivoting possibility in the mounting frame while substantially covering the opening of the latter in all swivelling positions, it is still ensured that the actual nozzle region tapering towards its front end is sufficiently long to achieve an adequate nozzle effect and, in particular, an optimum projecting range. It is possible to shorten the conical portion in known manner in a plane at right angles to the nozzle axis and in the front region thereof, so that for a given injection pressure the nozzle can be adapted to the desired throughput quantity and/or pipe width. In particular, the nozzle starts to widen from its region having a smaller diameter than that of the mounting frame opening at a distance from the plane of the mounting frame cover plate which corresponds substantially to the vertical spacing of the swivel axis from the cover plate.
The swivel holders are constructed as angle brackets arranged on the cover frame and are either welded or constructed in one piece with the cover frame.
According to a further development of the present invention a whirl-producing grid is inserted in the inner part of the nozzle and, in particular, in an inlet frame constructed thereon. The rotation produced by the grid is increased by passing through the conical nozzle region, so that there is a reduction in the projecting range compared with a construction without a grid. If there is not only to be a permanent setting of the nozzle alignment and instead it can be modified after installation, e.g. as a function of whether hot or cold air is to be supplied, then the nozzle can be connected to a motor pivot drive for pivoting its pivot axis or shaft. If the nozzle is e.g. located in the upper region of a wall, e.g. on introducing cold air it can be pivoted into an upper position, whereas, on supplying hot air is can be pivoted into a downwardly directed position. In the upper position, the outflowing cold air jet engages with the ceiling and is guided by the latter until the air has distributed in such a way that it no longer causes a draft in the room. However, on introducing the air, it is possible to have a high throughput quantity and a high discharge speed and consequently a large projecting range into the room. In the downwardly directed position, heated air can be directly supplied to the desired point, without drafts occurring. If necessary, it is also possible to juxtapose several similar nozzles in a duct, e.g. by a common holding frame.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to a non-limitative embodiment and the attached drawings, wherein show:
FIG. 1, a sectional view through the nozzle means according to the invention; and
FIG. 2, a view from below in accordance with arrows II--II of FIG. 1, whereby as a result of symmetry only half the nozzle means is shown.
DETAILED DESCRIPTION OF THE INVENTION
The inventive nozzle means generally designated by the reference numeral 1 has a mounting frame generally designated by the reference numeral 2, which is circular symmetrical in the represented embodiment. The mounting frame 2 has a cover plate 3 and a ring flange 4 on its outer circumference. By the mounting frame 2, the nozzle means 1 can be installed in the manner apparent from FIG. 1 in an opening generally designated by the reference numeral 6 in a ceiling or wall 7, with the angular position of the frame 2 therein, particularly in the case of the represented circular configuration being selectable in a random, appropriate manner.
In the cover plate 3, the mounting frame 2 has a circular opening generally designated by the reference numeral 8, through which extends the actual nozzle 9. Nozzle generally designated by the reference numeral 9 is substantially constituted by a nozzle casing generally designated by the reference numeral 11 from the same material as mounting frame 2, preferably metal, which can be varnished, but can also be made from plastic. Nozzle jacket 11 has a conical nozzle portion 12, which tapers towards its outer end generally designated by the reference numeral 13 and can be optionally be cutoff for modifying the throughput quantity and/or range of the nozzle for a given injection pressure in a plane 14 at right angles to nozzle axis 16, as shown with respect to the nozzle 9 in the drawings by the part indicated in broken line manner.
To the conical nozzle portion 12 is connected a shoulder-like extension 17 which, with respect to the conical configuration in the represented basic position, starts at a distance from cover plate 3 of mounting frame 2 roughly corresponding to the vertical spacing of the pivot point 18 of the nozzle 9 relative to the mounting frame 2. The diameter of the widening or extending shoulder region 17 in the plane of cover plate 3 is slightly smaller than the diameter of opening 8 of the mounting frame 2 and which is e.g. 1 to 3 mm. To the shoulder region 17 is connected a substantially cylindrical extension region of nozzle casing 11, whose diameter roughly corresponds to the diameter of opening 8 of mounting frame 2. In the illustrated embodiment is connected to the extension region 19 by a further small shoulder 21, an inlet frame 22 having a constant diameter, which is constructed in one piece with the further nozzle regions and the cut off.
Angle brackets are fixed as pivot holders generally designated by the reference numeral 23 to the inside of cover plate 3 of mounting frame 2, e.g. when using metal for both the mounting frame 2 and brackets or holdus 23. The latter can also be constructed in such a way that during the manufacture of mounting frame 2, flaps are left when punching out the opening 8 in the opening region and they are subsequently bent out of the plane of cover plate 3 with a leg 24 thereof inwards into the frame 2. When made from plastic, instead of being welded the angle brackets or holders 23 can also be jointly injection moulded in one piece onto frame 2. In the illustrated embodiments the angle brackets or holders 23 are provided in the leg 24, in the same way as nozzle 9 in extension region 19 with diagonally facing holes, through which pass rivets 27, by which the nozzle 9 is pivotable articulated to the mounting frame 2 about the pivot axis 18 defined by the rivets 27.
When the plastic is used, the above construction can be replaced by the leg 24 and/or nozzle 9 having projections with undercuts through radially extending noses provided on the tip thereof and which engage in a hole 26 of the other part until its circumferential edge overcomes the undercut, so that in this way the nozzle 9 is pivotably held in the frame 2. As a result of its elasticity, the plastic legs 24 can pivot back during assembly, so after the attachments have entered the openings of the other part, the legs 24 can also closely engage therewith.
The nozzle 9 can be pivoted into positions generally designated by the reference numerals 9' and 9" indicated by dot-dash lines in FIG. 1. Due to the inventive construction, the pivot region is larger than in the case of a nozzle 9 held directly in the mounting frame opening 8 by a cup part, in the case of an identical positioning of the fictional pivot axis, because, at least in the simple, one-piece construction, the cup cannot extend beyond a hemisphere and, consequently, its pivot region is limited. Moreover, the inventive construction is simpler and less costly than known constructions, so that it can, in many cases, be used more advantageously than previously. As a result of its described contour and particularly the fact that the widened shoulder region 17 and extension region 19 are set back towards the edge of opening 8 with respect to the contour of a fictional cup formed around the pivot axis 18, the nozzle 9 has good projecting characteristics, particularly over long distances.
In the inlet frame 22 of FIG. 1 is provided a whirl-producing grid 26 having sheet-metal guides or webs 27 inclined in the direction of axis 16. Through the choice of the slope of the sheet-metal guide 27, it is possible to adjust the intensity and whirling effect of the air jet passing out of the nozzle 9 and, consequently, the projection range within wide limits.
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In a nozzle for an air conditioning installation or the like for ventilating rooms, having a mounting frame with an opening and a nozzle pivotably mounted therein and which has an extension part with a contour substantially closing the opening, the extension part is a widened extension region constructed in one piece with the nozzle, which leads to manufacturing advantages and wider possibilities of use.
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This invention relates to biarylalkylimidazole derivatives and their non-toxic salts, to processes for their preparation, to pharmaceutical compositions containing at least one of these derivatives and to their use as α 2 -adrenergic receptor blocking and anti-depressant agents.
BACKGROUND OF THE INVENTION
It is known that α-adrenergic receptors are subdivided into α 1 and α 2 receptors essentially on the basis of their response to specific agonist and antagonist agents. The α 2 receptors are located at the noradrenergic nerve endings where such receptors are involved in the release of noradrenaline. The α 2 receptors are also present in various tissues as, for example, in the pancreas, in blood platelets, in adipose tissues, in blood vessels and in the brain.
Blocking agents for α 2 adrenergic are of therapeutic interest for the treatment of ailments of the central nervous system, such as depressive illness and cerebral aging, for treatment of some cardiac deficiencies and asthma and for the prophylactic and curative treatment of ailments in which platelet hyper-aggregability is involved such as migraine and thrombotic ailments. Further, α 2 blocking agents are of value as diuretic and anorexigenic agents and for the treatment of metabolic troubles such as diabetes and obesity, as well as of certain forms of hypertension and of sexual inadequacies.
Although non-selective α-adrenergic blocking agents such as yohimbine and rauwolscine have been known for several years, few classes of compounds are known which provide selective α 2 blocking activity. One of these classes, for example, comprises imidazoline derivatives of 2,3-dihydrobenzofuran such as disclosed in GB Pat. No. 2,102,422. Another class comprises imidazoline derivatives of 1,4-benzodioxan, such as disclosed in EP Pat. Appl. 092,328 and GB Pat. No. 2,068,376 of which 2-[2-(1,4-benzodioxanyl)]-2-imidazoline hydrochloride (Idazoxan hydrochloride) seems the compound of most interest. Another class of compounds comprises 2-[(1,4-benzodioxan-2-yl)alkyl]imidazoles such as described by J. M. Caroon, et al., J. Med. Chem., 25, 666-670 (1982). A further class of compounds comprises 4(5)-(phenylalkylimidazoles, 4(5)-(phenylalkanoyl)-imidazoles and 4(5) [(phenyl)hydroxyalkyl]imidazoles, such as described in EP Pat. Appl. 034,473. Also European patent application No. 86870010.5 describes certain compounds as having α 2 adrenergic receptor blocking activity, namely, 4(5)-(biphenylalkyl)imidazoles, 4(5)-(biphenylalkenyl)imidazoles and 4(5)-[(biphenyl)hydroxyalkyl]imidazoles. U.S. Pat. No. 4,281,141 discloses 4-[2,2,2,-(phenyl)(pyridyl)(cyano)ethyl]imidazole derivatives as having activity as fungicides.
Lilly U.S. Pat. No. 4,605,661 to Hirsch et al shows 4(5)-(2,2-diarylethyl)imidazoles as aromatase enzyme inhibitors useful for treatment of estrogen dependent disorders. In particular, the compound 4(5)-(2,2-diphenylethyl)imidazole is described. There is no mention, however, of any specific pyridylethylimidazole compound.
BRIEF DESCRIPTION OF THE INVENTION
A new class of imidazole derivatives having selective and useful α 2 -adrenergic receptor blocking activity is provided by 4(5)-(biarylethyl)imidazole derivatives and pharmaceutically acceptable acid addition salts thereof having at least one aryl group which is an aromatic heterocyclic group. Pharmaceutical compositions containing as active ingredient at least one of these 4(5)-(biarylethyl)imidazoles or an acid addition salt thereof, as well as methods for the preparation of these compounds and their use as pharmaceuticals also fall within the scope of this invention.
DETAILED DESCRIPTION OF THE INVENTION
Compounds having α 2 -adrenergic receptor blocking activity comprise a class of biarylethylimidazole derivatives of general Formula I ##STR1## wherein each of Ar 1 and Ar 2 independently represents an aromatic heterocyclic group selected from the group consisting of a furan group, a thiophene group, a pyrrole group, an N-alkyl pyrrole group, an N-phenyl-pyrrole group, an imidazole group, and a pyridyl group, any one of which groups may be optionally substituted by one or two linear or branched alkyl or alkoxy groups having one to three carbon atoms; and wherein at least one of Ar 1 and Ar 2 , but not both, may represent a phenyl group or a phenyl group substituted by one or two halogen atoms such as fluorine, chlorine or bromine, or by one or two trifluoromethyl radicals, or by alkyl or alkoxy groups having one to three carbon atoms, with the proviso that at least one of the Ar 1 and Ar 2 is an aromatic heterocyclic group, and with the further proviso that where Ar 1 or Ar 2 represents a pyridyl group, said pyridyl group must be selected from meta-pyridyl and para-pyridyl.
The terms "meta-pyridyl" and "para-pyridyl" refer to pyridyl radicals which, when selected as Ar 1 or Ar 2 groups of formula I, are attached to the --CH-- moiety of formula I through a pyridyl ring carbon atom which is located, respectively, at the "meta" and "para" positions relative to the pyridyl ring nitrogen atom.
Also included in this invention are the corresponding optically pure isomers and racemic or non-racemic mixtures of the isomers of the derivatives of Formula I, the possible tautomers of the derivatives, as well as the non-toxic acid addition salts of any of these foregoing compounds formed with pharmaceutically acceptable acids.
A preferred class of derivatives comprises compounds of Formula I in which each of Ar 1 and Ar 2 represents an aromatic heterocyclic group independently selected from a furan, a thiophene, a pyrrole, an N-alkyl-pyrrole, an N-phenyl-pyrrole, an imidazole, a meta-pyridyl and a para-pyridyl group optionally substituted by one or two halogen atoms or by one or two alkyl or alkoxy groups having one to three carbon atoms.
Another preferred class of compounds of the invention comprises derivatives corresponding to general Formula I wherein at least one of Ar 1 and Ar 2 represents a meta-pyridyl group or a para-pyridyl group optionally substituted by one or two alkyl or alkoxy groups having one to three carbon atoms.
A particularly preferred class of derivatives within general Formula I is that class in which Ar 1 represents a meta-pyridyl group or a para-pyridyl group, optionally substituted by one or two alkyl or alkoxy groups having one to three carbon atoms, and in which Ar 2 represents a phenyl group optionally substituted by one or two trifluoromethyl radicals, or by one or two halogen atoms, or by one or two alkyl or alkoxy groups having one to three carbon atoms.
A more particularly preferred class of derivatives comprises compounds of Formula I in which Ar 1 represents a meta-pyridyl group or a para-pyridyl group and Ar 2 represents a phenyl group, specific examples of which are the following compounds:
______________________________________4(5)-[2-phenyl-2-(4-pyridinyl)-ethyl]-imidazole and4(5)-[2-phenyl-2-(3-pyridinyl)-ethyl]-imidazole.______________________________________
Compounds of Formula I may be in the form of a salt of addition with a pharmaceutically utilizable acid, either an inorganic acid such as hydrochloric acid, sulphuric acid or phosphoric acid, or an appropriate organic acid such as an aliphatic, cycloaliphatic, aromatic, araliphatic, heterocyclic, carboxylic or sulphonic acid, such as formic, acetic, propionic, succinic, glycolic, gluconic, lactic, malic, tartaric, citric, ascorbic, glucuronic, maleic, fumaric, pyruvic, aspartic, glutamic, benzoic, anthranilic, p-hydroxybenzoic, salicylic, phenylacetic, mandelic, embonic, methanesulphonic, ethanesulfonic, pantothenic, toluene-sulphonic, sulphanilic, cyclohexylaminosulphonic, stearic, alginic, β-hydroxybutyric, malonic, galactaric or galacturonic acid.
The compounds of formula I can possess one or more asymmetric carbon atoms and are thus capable of existing in the form of different, pure optical isomers as well as in the form of racemic or non-racemic mixtures thereof. All these forms fall within the scope of the present invention. The optical isomers can be obtained by resolution of the racemic mixtures according to conventional processes, for example by formation of diastereoisomer salts by treatment with optically active acids, such as tartaric, diacetyltartaric, dibenzoyltartaric and ditoluoyltartaric acid, and separation of the mixture of diastereoisomers, for example, by crystallization or chromatography followed by liberation of the optically active bases from these salts. The optically active compounds according to Formula I can likewise be obtained by utilizing optically active starting materials.
The present invention also covers pharmaceutical compositions containing, as active ingredient, at least one compound of the general Formula I or its salt of addition with a pharmaceutically utilizable acid, in the presence or absence of a suitable excipient.
These compositions are prepared in such a manner that they can be administered by oral, rectal, parenteral or local route. The compositions can be solids, liquids or gels and be utilized, according to the administration route, in the form of powders, tablets, lozenges, coated tablets, capsules, granulates, syrups, suspensions, emulsion solutions, suppositories or gels. These compositions can likewise comprise another therapeutic agent having an activity similar to or different from that of the compounds of the invention.
The compounds according to the invention are in general endowed with selective α 2 -blocking properties. Consequently, these compounds can be of major interest in the treatment of depressive and degenerative diseases of the central nervous system.
The compounds of the invention may be prepared according to several processes which are part of the present invention and are described below. In the case where these processes give rise to the production of new intermediate compounds, these as well as the processes serving for their preparation likewise form part of the present invention.
Procedure 1
Compounds of Formula I may be obtained by synthesis of the imidazole group from an appropriate starting material. Several methods are known for carrying out the synthesis of the imidazole group, such as described by H. Bredereck, et al. Angewandte Chemie, 71, 759-764 (1959) and by M. R. Grimmett Advances in Heterocyclic Chemistry, Ed. A. R. Katritsky and A. J. Boulton, Academic Press, Vol. 12, 104-137 (1970) and Vol. 27, 242-269 (1980), and in EP patent application No. 86870010.5.
1.1:
According to a first procedure, the compounds of Formula I are obtained by condensation of a carbonyl derivative of Formula IIa or IIb, the carbonyl group of which may be latent, for example in the form of an acetal or thiocetal, whether cyclic or not, with a nitrogen-containing reagent III, followed if appropriate by a complementary conversion according to Scheme 1.1.a, below. ##STR2##
In this Scheme 1.1.a:
A represents the group (Ar 1 )(Ar 2 )CH--CH 2 -- wherein Ar 1 and Ar 2 have the meanings defined above, or a group which easily can be transformed by known methods into the group (Ar 1 )(Ar 2 )CH--CH 2 --,
Z represents a hydroxy radical, an oxo radical, an amino group, halogen atom or an alkanoyloxy radical,
W represents a substituent which is easily substituted by a hydrogen atom, for example, by hydrolysis, hydrogenation, desulphurization, hydrogenolysis, diazotization or oxidation, such as a mercapto or amino group,
and the reagent III represents a suitable nitrogen derivative or a combination of two compounds at least one of which is a suitable nitrogen derivative, such as, for example, formamide or formamidine usually applied in the form of an acid addition salt, in the presence or absence of ammonia, or cyanamide, guanidine, an alkaline or ammonium thiocyanate, or formaldehyde in the presence of ammonia. Hereinafter the symbols A, Z, W, Ar 1 and Ar 2 always possess the values as defined above, except where explicitlyy indicated otherwise. The choice of the reagent III and of the experimental conditions takes place according to the nature of the group Z of the molecule IIa or IIb. For example in the case where Z represents an atom of halogen or an oxo-, hydroxyl, alkanoyloxy or amino radical, the synthesis of a compound of Formula I is effected by condensation of the compound I or IIb with formamide which is often likewise used as solvent, or with formamidine or an acid addition salt thereof, at elevated temperature, under an inert atmosphere or advantageously under an atmosphere of ammonia and under elevated pressure. A very practical variant of this process consists in preparing the α-halocarbonyl derivative of formula IIa or IIb (Z=halogen) in situ, for example by bromination of a carbonyl derivative of formula Va or Vb, ##STR3## in formamide, followed by its condensation with formamide by heating the reaction mixture.
Another variant consists in generating an α-amino-carbonyl derivative of formula IIa or IIb (Z=NH 2 ) in situ, by catalytic reduction in formamide, of an oxime of formula VIa or VIb ##STR4## which can easily be obtained for example by conversion of a carbonyl derivative of formula Va or Vb into a nitroso compound according to known methods, and followed by its condensation with formamide by heating of the reaction mixture. The condensation proceeds easily by mixing the reagents IIa or IIb and formamide in a suitable solvent such as an alcohol, in the presence of ammonia and/or a strong base such as an alcoholate of an alkaline, the reaction medium advantageously being heated. Another way to transform an α-aminocarbonyl derivative of formula IIa or IIb (Z=NH 2 ) into a compound of Formula I consists in the condensation of the compound IIa or IIb with potassium thiocyanate followed by the complementary conversion of the intermediate IV (W=SH) formed (cf. Scheme 1.1). The condensation is effected easily by heating a mixture of the two reagents in a solvent such as water and the intermediate IV (W=SH) is then converted into a derivative of Formula I, for example by oxidation. This can be done for example by treating the intermediate IV in aqueous medium with nitric acid at a moderate temperature. Another variant of this process for preparing the imidazole group consists in condensing an enamine of formula VII with an amidine VIIIa or an N-chloro-amidine VIIIb in accordance with Scheme 1.1.b ##STR5## The condensation takes place in an inert atmosphere under anhydrous conditions. In the case of an amidine, the condensation takes place in the presence of an equimolar quantity of bromine, in an inert solvent such as dichloromethane and advantageously in the presence of an organic base such as triethylamine or pyridine. The intermediate aminoimidazoline IX is deaminated into a derivative of Formula I, either already in situ under the applied reaction conditions, or by heating the intermediate IX in the presence of triethylamine hydrochloride or pyridine hydrochloride.
1.2:
Another procedure for the preparation of the imidazole group starts from an appropriate heterocyclic derivative. According to this method, the compounds of Formula I are obtained starting from an imidazoline of formula X in accordance with Scheme 1.2.a. ##STR6## wherein A has the values defined above, and P' represents hydrogen or a protective group P such as an alkyloxymethyl, benzloxymethyl, dialkoxymethyl, trimethylsilylmethyl, [2-(trimethylsilyl)ethoxy]methyl, trityl, vinyl, benzyl, N,N-dialkylaminosulphonyl, 2-chloroethyl, 2-phenylsulphonylethyl, diphenyl methyl or [(bis-trifluoromethyl)-(4-chlorophenoxymethoxy)] methyl radical, which after the transformation of the imidazoline group into an imidazole group can easily be substituted by hydrogen.
The transformation of the imidazoline X is effected either by means of an appropriate oxidizing reagent, such as manganese dioxide in an inert solvent such as acetone, at a moderate temperature or by dehydrogenation, carried out at an elevated temperature (150° C.) in an inert solvent with the aid of an appropriate catalyst, such as a catalyst based upon nickel, platinum or palladium and optionally in the presence of a co-reagent such as copper oxide or sulphur. The protective group P can be substituted by hydrogen by various known methods selected as a function of the nature of P, such as:
(a) by acidolysis in aqueous or non-aqueous medium by means of an acid such as a halogenated hydracid, acetic acid, trifluoroacetic acid, sulphuric acid, at a temperature which can vary from room temperature to reflux temperature,
(b) by treatment with tetra-n butylammonium fluoride in THF at room temperature,
(c) by treatment with sodium hydride in dimethyl formamide at room temperature, followed by hydrolysis,
(d) by catalytic hydrogenation (hydrogenolysis), or
(e) by treatment of sodium hydride, followed by hydrolysis and reaction at elevated temperature with sodium acetate in acetonitrile.
Another procedure according to this method involves converting an oxazole derivative of Formula XII into a immidazole derivative of Formula I by heating the oxazole XII in the presence of ammonia or advantageously in the presence of formamide, according to Scheme 1.2.b. in which A has the meanings defined above. ##STR7##
Compounds of Formula I can be made according to the above Procedure I by formation of the imidazole group as the end stage of the preparation which is carried out on a substrate of formulae IIa, IIb, IV, Va, Vb, VIa, VIb, VII, IX, X, XI and XII in which A represents the group
(Ar.sup.1)(Ar.sup.2)CH--CH.sub.2 --,
as well as by the formation of the imidazole group on a substrate of Formula IIa, IIb, IV, Va, Vb, VIa, VIb, VII, IX, X, XI and XII in which the group A represents a group which can be transformed into (Ar 1 )(Ar 2 )CH--CH 2 -- group by methods such as by the procedures 2.1 to 2.5 described hereafter.
Procedure 2
According to a second process, the compounds of the invention can be obtained by the condensation of an imidazole derivative with a suitable substrate. A first procedure, illustrated by Scheme 2.1, consists in substituting the group L of a compound of formula XIII by the imidazole group which is usually reacted in the form of an organolithiated derivative of formula XIV. ##STR8##
In Scheme 2.1, L represents an easily substitutable radical such as a halogen atom, e.g., chlorine, bromine or iodine, an O-tosyl group or an O-mesyl group. P represents a protective group as defined above, and R 1 represents hydrogen or a group substituable by hydrogen, such as a phenylthio or alkylthio group. Hereinafter the radicals R 1 , L and P possess the values as defined previously, unless otherwise explicitly stipulated. The organolithium derivative XIV is prepared by lithiation of an N 1 -protected imidazole and substituted in the 2 position by a group R 1 , provided that R 1 does not represent hydrogen, or by means of n-butyl lithium at low temperature, under an inert atmosphere and in an inert solvent such as diethyl ether or tetrahydrofuran (THF). The substitution of the L group of compound XIII proceeds by addition of this compound at low temperature, in solution in an appropriate solvent such as THF, anhydrous diethyl ether or a saturated hydrocarbon, to the solution of the lithiated reagent XIV. After reaction, the mixture is brought to room temperature, treated by a protic solvent such as water, and acidified to supply either the desired derivative of Formula I directly or the intermediate of Formula XV which by deprotection is converted into a compound of Formula I. The protection of the imidazole group in the 2 position by a R 1 group, being a phenylthio or alkylthio group, is effected for example by lithiation of an N-protected imidazole, followed by a reaction with an alkyl disulphide or a phenyl disulphide under conditions similar to those described for the substitution of the imidazole group in the 4 position. The protection of the nitrogen of the imidazole group is effected by treatment of the imidazole in the presence of a base in a solvent such as dimethyl formamide or 1,2-dichloroethane in the presence of a phase transfer catalyst, with a reagent of formula P--L, P and L being defined above. The deprotection of the imidazole group is then carried out. The radical R 1 , being an alkylthio or phenylthio group, is substituted by hydrogen, for example, by desulphurization by means of hydrogen at elevated temperature in the presence of a catalyst such as Raney nickel. The radical P is substituted by hydrogen by various methods selected as a function of the nature of P as indicated above the Procedure 1.2.
2.2:
According to a second procedure, the derivatives of Formula I are obtained by condensation of an organometallic derivative of imidazole, usually applied in the form of a organolithiated derivative XIV, with a carbonyl derivative of formula XVI or XVII followed by a deprotection and possibly a complementary conversion, in accordance with Scheme 2.2. ##STR9## The experimental conditions of the condensation and the deprotection are the same as those described in Procedure 2.1. Any complementary conversion to obtain a derivative of formula I from the intermediates XVIII and XIX can be effected in one or more steps from deprotected, partially deprotected or protected intermediates, according to methods selected as a function of the nature of the intermediate obtained, as for example:
(a) by dehydration of XVIII followed by hydrogenation of the intermediate alkene obtained,
(b) by substitution of the hydroxyl radical by a halogen atom, by means of an halogenating agent such as for example PBr 5 or SOCl 2 , and conversion of the intermediate alkyl halide by hydrogenolysis, into a compound of formula I,
(c) by hydrogenolysis,
(d) by reduction of an intermediate of formula XIX.
2.3:
According to a third procedure, the derivatives of formula I are obtained by condensation of an organometallic derivative of formula XX with an halogenated or carbonyl derivative of formula XXI, such as a ketone, an aldehyde, an ester or an acid halide, according to Scheme 2.3. ##STR10##
In Scheme 2.3, M represents an alkali metal such as lithium, sodium or potassium or a radical containing a metal atom such as magnesium, zinc, copper or titanium, as for example MgCl or MgBr. D represents a halogenated or carbonyl group such as ##STR11## wherein
L represents an atom of chlorine, bromine or iodine,
Im represents the imidazole group of formula ##STR12## protected by a radical P in the 1-position and a radical R 1 in the 2-position; and
Ar 1 , Ar 2 , P and R 1 have the meanings previously defined.
The preparation of the organometallic derivative XX is effected in a conventional manner, either by transmetallation, or by acid-base reaction of the compound (AR 1 )(Ar 2 )CH 2 with a strong base such for example as butyl lithium or sodium amide. The condensation is effected by opposing the reagents XX and XXI under experimental conditions similar to those stated above in Procedures 2.1 and 2.2 for the condensation of an organolithiated derivative with a halogenated or carbonyl derivative.
2.4:
A fourth procedure of this preparation method of derivatives of Formula I involves in the condensation of an organometallic derivative of Formula XXIV with an halogenated or carbonyl derivative of Formula XXV followed by conversion of the intermediate XXVI, XXVII or XVIII into a derivative I according to Scheme 2.4. ##STR13##
In this diagram, E represents a halogenated and/or carbonyl group of formula ##STR14##
Ar' represents an Ar 1 or Ar 2 group defined above, R 4 represents a C 1 -C 3 alkyl group and M, L and Im have the values previously defined. The preparation of the organometallic derivative XXIV and its condensation with compound XXV are effected in accordance with methods similar to those described above for processes 2.1. to 2.3.
2.5:
A fifth variant of the method involves in condensing a carbonyl derivative XXIX with an appropriate imidazole derivative XXI or XXX and the reduction of the intermediate XXXI into a compound of Formula I according to Scheme 2.5. ##STR15##
In Scheme 25., D represents the group ##STR16## φ represents a phenyl group, and Ar' and Im possess the values defined above. The condensation of the carbonyl derivative XXIX with compound D-Im is effected by heating these derivatives in an inert solvent such as dimethoxyethane, in the presence of activated titanium, obtained by reaction of metallic lithium with titanium trichloride in an inert solvent. The condensation of the carbonyl derivative XXIX with the phosphorus ylide XXX is effected under anhydrous conditions, optionally with slight heating, by mixing the reagents in dimethyl sulphoxide, followed by hydrolysis of the reaction medium. The ylide itself is obtained by treatment of the corresponding alkyltriphenyl-phosphonium halide with a strong base such as sodium hydride in anhydrous dimethyl sulphoxide. The hydrogenation of intermediate XXXI into a derivative of Formula I is carried out in conventional ways, e.g. by treatment of XXXI in an inert solvent with hydrogen optionally at elevated pressure and in the presence of a suitable hydrogenation catalyst. The deprotection of the imidazole group Im is carried out according to a method described above for Procedure 2.1.
The selection of the process for preparation of derivatives of Formula I, of the reagents and of the experimental conditions is effected in such manner as to keep intact the part of the substrate which does not participate in the envisaged transformation or conversion. The functional groups of the substrate-reagent pairs in each of the Schemes 2.1. to 2.5. are interchangeable and these process-variants, which are carried out under the same experimental conditions as those described for the Procedures 2.1. to 2.5., are technically equivalent with the Procedures 2.1 to 2.5.
If the derivatives of Formula I are present in the form of a free base they can be transformed into an acid addition salt by treatment with the corresponding acid. If the derivatives of Formula I are present in the form of salts of addition with acids, they can be transformed into free bases or into salts of addition with other acids.
Some detailed examples of preparation of the derivatives according to the invention are given below with the purpose of illustrating the particular characteristics of the processes according to the invention.
EXAMPLE 1
Synthesis of 4(5)-[2-phenyl-2-(4-pyridyl)-ethyl]-imidazole (5) ##STR17##
(a) Synthesis of 4(5)-hydroxymethylimidazole (hydrochloride) (1).
An autoclave of 500 ml content was charged with ca. 150 ml anhydrous, liquid ammonia, 31.2 g (300 moles) formamidine acetate and 27 g (300 mmoles) 1,3-dihydroxyacetone and heated to 70°-90° C. (pressure 40-50 bars) for about 6 hours. Then heating was stopped and the mixture was stirred overnight (temp. about 50° C.). The mixture was cooled to ambient temperature and the ammonia was evaporated under a current of nitrogen. The crude product obtained was dissolved in 210 ml isopropanol and gaseous HCl was added to the solution until a pH value of about 2 was reached. The precipitate was filtered off and washed with hot isopropanol (210 ml). To the combined isopropanol solutions, diethylether was added and (1) was allowed to crystallize. After filtration of the crystals, a second and a third crop of (1) were isolated from the mother liquid by concentration. Compound (1) is obtained as an off-white solid (MP: 103.3° C.).
(b) Synthesis of 1-trityl-4-hydroxymethyl-imidazole (2).
To a solution of 26.2 g (195 mmoles) (1) in 200 ml dimethylformamide (DMF) were added under nitrogen atmosphere 68 ml triethylamine and then 61.3 g (220 mmoles) tritylchloride dissolved in 500 ml DMF. After 2 hours stirring at room temperature the mixture was poured into 3.2 l ice-water and the solid obtained was filtered and washed with water and finally with diethylether. The crude product was recrystallized from 1150 ml hot dioxane yielding (2) in the form of an off-white solid (MP: 217.5° C.).
(c) Synthesis of 1-trityl-4-chloromethyl-imidazole (3).
To a solution of 2 g of 1-trityl-4-hydroxymethyl-imidazole (2) and 0.83 ml triethylamine in 25 ml anhydrous benzene these was dropwise added 0.41 ml of thionyl chloride. After 45 minutes of stirring at room temperature, the gas evolution has ceased. Then the precipitate was filtered and washed with benzene. The combined organic solutions were evaporated under reduced pressure. The residue was crystallized from dioxane yielding compound (3) used as such in the next stage.
(d) Synthesis of 1-trityl-4-[2-phenyl-2-(4-pyridinyl)ethyl]-imidazole (4).
Under nitrogen atmosphere a 100 ml flask was charged with 50 ml liquid ammonia, a small piece of sodium and a few crystals of Fe(NO 3 ) 3 . Then about 0.25 g (11 mmol) sodium metal was added and the mixture was stirred at ca. -70° C. for 0.5 hours. Then, under stirring, and at about -70° C. 1.69 g (10 mmoles) of phenyl-(4-pyridinyl)methane dissolved in 5 ml anhydrous ether are added in 10 minutes. After stirring for 0.5 hours the mixture was allowed to warm up to the boiling temperature of ammonia and 3.21 g (9 mmoles) of (3) dissolved in 20 ml anhydrous THF was added dropwise. The mixture was allowed to warm up to room temperature while ammonia evaporated. To the residue 30 ml water was added and the mixture was extracted with methylene chloride. Then the methylene chloride was evaporated from the dried, combined solutions yielding crude derivative (4) used as such in the next stage.
(e) Synthesis of 4(5)-[2-phenyl-2-(4-pyridinyl)-ethyl]imidazole (5).
The crude derivative (4) obtained in the foregoing step was hydrolysed by treatment with 20 ml of 90% acetic acid at reflux temperature for 5 minutes. The solvent was evaporated and the residue was treated with aqueous NaHCO 3 and extracted with methylene chloride. The crude product, obtained after evaporation of the solvent from the dried and combined methylene chloride solutions, was purified by crystallization from diethylether, toluene and ethylacetate. Compound (5) was obtained as a white solid (MP: 151.7° C.).
______________________________________Elemental analysis C H N______________________________________C.sub.16 H.sub.15 N.sub.3 (0.14H.sub.2 O) % calculated 76.3 6.1 16.7 % found 76.4 6.1 16.7______________________________________ H.sub.2 O content (KarlFisher): 1.02%
EXAMPLE 2
Synthesis of 4(5)-[2-phenyl-2-(3-pyridinyl)-ethyl]imidazole (7). ##STR18##
Starting from (phenyl)-(3-pyridinyl)methane, intermediate (6) was prepared according to the same procedure as described in Example 1d. Then the crude intermediate (6) was hydrolysed with 20 ml of 90% acetic acid at reflux temperature for 5 minutes. The solvent was then evaporated, the residue was heated with hexane to remove the excess of phenyl-(3-pyperidinyl)methane and then recrystallized from diethyl ether, toluene and ethylacetate. Compound (7) was obtained as an off-white solid (MP: 138.4° C.).
______________________________________Elemental analysis C H N______________________________________C.sub.16 H.sub.15 N.sub.3 % calculated 77.1 6.1 16.9 % found 76.8 6.1 16.8______________________________________
EXAMPLE 3
Synthesis of 4(5)-[2-phenyl-2-(2-pyridyl)-ethyl]-imidazole (9) ##STR19##
(a) Synthesis of 4(5)-hydroxymethylimidazole hydrochloride (1).
In a 2 liter pressure vessel, there were charged 81 g of formamidine acetate (0.78 mole), 70 g of 1,3-dihydroxyacetone (0.78 mole) and 400 ml of liquid ammonia. The vessel was heated at 70° C. with stirring during 2 hours and then kept 16 hours at room temperature (pressure reached: ±40 bars). Ammonia was then blown out and the residual oil was dissolved in 500 ml methanol, decolorized at reflux temperature with active coal, filtered, evaporated and enough toluene was added to distill off water in the reaction vessel azeotropically. The residue was dissolved in 150 ml methanol and gaseous HCl was bubbled into this solution to reach an acidic pH. The methanol was evaporated and the solid residue was triturated at reflux temperature in 400 ml of acetonitrile. The suspension was cooled and filtered and the resulting product was used in the following step.
(b) Synthesis of 1-trityl-4-hydroxymethylimidazole (2).
To a reaction vessel containing a solution of 30.9 g of (1) (0.23 mole) and 75 ml triethylamine in 150 ml of anhydrous dimethylformamide at 0° C. under nitrogen, there was charged 71.6 g of chlorotriphenylmethane (0.26 mole). The reaction mixture was stirred for 16 hours at room temperature and then poured into 1.2 l of water and extracted with chloroform (3×500 ml). The combined organic phases were washed with water, dried over magnesium sulfate and evaporated under reduced pressure. The residue was dispersed in 1 liter ether. Compound (2) crystallized as a white solid which was filtered, washed with ether and used as such in the next stage.
(c) Synthesis of 1-trityl-4-chloromethylimidazole (3).
Into a solution of 2 g of (2) and 0.83 ml of triethylamine in 25 ml of anhydrous benzene, there was added dropwise 0.41 ml of thionyl chloride. After 45 minutes of stirring at room temperature, gas evolution ceased and the precipitate was filtered and washed with benzene. The combined organic phases were evaporated under reduced pressure. The residue was crystallized from dioxane yielding compound (2) which was used as such in the next stage.
(d) Synthesis of 1-trityl-4-[2-phenyl-2-(2-pridyl)ethyl]-imidazole (8).
To a vessel kept under a nitrogen atmosphere, there were charged 2.26 g of 2-benzyl pyridine (13.4 mmoles) dissolved in 20 ml anhydrous THF at 0° C. To this solution, there was added dropwise 8 ml of 1.6 M butyl lithium solution (12.8 mmoles). The solution appeared to be red in color and a precipitate formed after one hour. The reaction mixture was cooled at -5° C. and then 4 g of (3) (11.2 mmoles) dissolved in 40 ml of THF was added in small portions until the solution has completely discolored. At that point, a white precipitate formed and 20 ml of a saturated aqueous solution of NH 4 Cl was added. Enough ethyl acetate was added to dissolve all the solid and the mixture was then decanted, the organic layer dried in MgSO 4 and evaporated. The white solid was crystallized from toluene yielding compound (8).
(e) Synthesis of 4(5)-[2-phenyl-2-(2-pyridyl)-ethyl]imidazole (9).
A reaction vessel containing 4 g of (8) (8 mmoles) was heated to reflux condition for 1 minute in 25 ml 90% acetic acid. The solution was evaporated and then saturated aqueous Na 2 CO 3 was added. The mixture was extracted with 3×25 ml of CH 2 Cl 2 and the combined organic layers were dryed on K 2 CO 3 and evaporated. The residual oil obtained was dissolved in 200 ml anhydrous ether and HCl gas was bubbled into the solution. A solid formed which was filtered and washed with ether. The hygroscopic solid was directly dissolved in methanol (10 ml), neutralized with saturated aqueous Na 2 CO 3 and extracted with 3×20 ml ethyl acetate. After drying on of the combined organic solutions with MgSO 4 the solvent was evaporated and an oil was obtained which solidified on standing. This solid was crystallized from toluene to yield compound (9) (MP: 108° C.).
______________________________________Elemental analysis C H N______________________________________C.sub.16 H.sub.15 N.sub.3 % calculated 77.08 6.06 16.85 % found 77.29 6.22 16.78______________________________________
Table 1 below lists the derivatives of the invention described in the foregoing examples as well as the other derivatives of Formula I prepared according to the processes described above. The C,H,N- elemental analyses for these compounds confirmed the theoretical elemental make-up, and their structures were verified by NMR-spectroscopy and mass spectrometry.
TABLE 1______________________________________ ##STR20## ##STR21##Formula I Comparison Compound ("CC")Compounds of Invention of EP Patent Appl. #86870010.5Com-pound Melting Recrystalli-No. Ar.sup.1 Ar.sup.2 Point (°C.) zation solvent______________________________________ ##STR22## ##STR23## 151.7 AcOEt*2 ##STR24## ##STR25## 138.4 AcOEt3 ##STR26## ##STR27## 108 toluene______________________________________ *AcOEt: ethyl acetate.
The acute toxicity of the compounds of the present invention was studied after oral administration to mice. The products to be tested, suspended in a 1% tragacanth gum mucilage, were administered by means of an intragastric probe to groups of three male mice which had fasted since the preceding day. The doses tested are a function of the effect observed and can vary from 3,000 to 3 mg/kg or less. The mortality was recorded for 15 days. The lethal dose for 50% of the animals (LD 50 ) was calculated according to the method of J. Litchfield and F. Wilcoxon, J. Pharmacol. Exp. Ther., 96, 99 (1949) and expressed in mg/kg. Results are shown in Table IV. The effect of the products on the behavior of the animals was observed during a 5-to-6 hour period after the treatment indicated above and after 24 hours, using a method derived from that of S. Irwin, described by R. A. Turner, Screening Methods in Pharmacology, Chapter 3, pages 22-34, Academic Press, 1965. If anomalies were noted, the observation was prolonged and smaller doses were tested. The compounds of the present invention have been subjected to a series of in vitro and in vivo tests to determine their biological activity and therapeutic utility. The essential activity of importance resides in the α 2 receptor antagonistic activity. Such activity indicates therapeutic activity for indications of disorders of the central nervous system, e.g., depression, mental disorders and epilepsy. In addition, the compounds show low or insignificant affinity for α 1 receptor sites as indicated by in-vitro receptor binding assays. This property indicates an additional benefit of selectivity, particularly with respect to diminished cardiovascular side effects. The results of these biological tests are summarized in Tables II, III and IV. The tests were carried out as described below.
Table II summarizes the binding activities for α 1 and α 2 adrenergic receptors of the compounds tested. The activity of the compounds according to the invention with respect to binding of the α-adrenergic receptors was determined in vitro according to a method derived from the works of B. R. Rouot, et al., Life Sci., 25, 769 (1979) of D. U'Prichard, et al., Mol. Pharmacol., 13, 454 (1977) and of P. Greengrass, et al., European J. Pharmacol., 55, 323, 1979. This method measures the binding to the receptor on rat brain homogenates by marking by means of a specific tritiated ligand placed in competition with the product to be tested. In the present case the binding, to the α 1 -adrenergic receptors was measured by use of 1.6 nM of H-WB 4101 (WB) and 0.2 nM --H--prazosin (PRA). The binding to the α 2 -adrenergic receptors was determined by uses of 0.7 nM of 3 H-p-aminoclonidine (PAC). The non-specific binding was determined by use of 1,000 nM of phentolamine. Results are given in Table II with columns 2 and 3 expressed in terms of percentage of inhibition of the specific binding at 10 -7 molar and 10 -6 molar compound concentration. The results indicate that the compounds according to the invention have very low affinity for the α 1 receptors since the percentage of inhibition of the specific binding on the α 1 receptors was generally low. The high percentage of inhibition of the specific binding of the α 2 -adrenergic receptors presented by the compounds tested, as shown in column 3, indicates that the compounds according to the invention, in particular compounds No. 1 and 2, exhibit a high affinity for α 2 receptors in the in vitro binding assay.
TABLE II__________________________________________________________________________BIOLOGICAL DATA : α-Receptor Binding Activities. Column 2 % Column 3 % Inhibition of the specific Inhibition of the specific binding for α.sub.1 receptor at binding for α.sub.2 receptor atColumn 1 compd. conc. 10.sup.-6 M compd. conc. 10.sup.-7 MCompound No..sup.a Ligand WB.sup.c Ligand PRA.sup.d Ligand PAC.sup.e__________________________________________________________________________1 2 14 912 7 10 943 0 -- 40"CC".sup.b 21 27 89__________________________________________________________________________ .sup.a Compound number corresponds to the compound number defined in Tabl I. .sup.b Comparison Compound "A" is shown in EP Patent Appl. #86870010.5. .sup.c Ligand .sup.3 H--WB4101. .sup.d Ligand .sup.3 H--prazosin. .sup.e Ligand .sup.3 H--paminoclonidine.
In Table III, columns 2 and 3 show the pKi values (pKi=-log inhibition constant) for respecively the α 1 receptor (ligand 3 H-prazosin) and the α 2 receptor (ligand 3 H-p-aminoclonidine), calculated according to the equation of Cheng and Prusoff: ##EQU1## wherein: Ki represents the inhibition constant;
IC 50 represents the concentration of the test compound providing 50% inhibition of the specific binding;
K D represents the dissociation constant of the 3 H-ligand in the test mixture
[L*] represents the concentration of the 3 H-ligand in the test mixture.
Comparison of the affinity to the α-receptors of the compounds of the invention with the Comparison Compound disclosed in EP patent application 86 870010.5 demonstrates that the compounds of the invention, although showing α 2 receptor activity rather similar to the disclosed Comparison Compound, show much less affinity for α 1 receptors than the Comparison Compound. Thus, the selectivity of the α 1 /α 2 adrenergic receptor affinity of the compounds of the invention, expressed by the ratio Kiα 1 /Kiα 2 and displayed in column 4 of Table III, was considerably higher than the selectivity of the Comparison Compound.
TABLE III______________________________________BIOLOGICAL DATA: Selectivity of α.sub.1 /α.sub.2Receptor Affinity Column 2 Column 3 Column 4 α.sub.1 receptor α.sub.2 receptor Selectivity ofColumn 1 Ki value.sup.c Ki value.sup.c α.sub.1 /α.sub.2Compound ligand PRA.sup.d ligand PAC.sup.e affinityNo..sup.a (.10.sup.-6 M) (.10.sup.-9 M) (Ki.sub.αl /Ki.sub.α2)______________________________________1 13.4 4.6 29002 2.6 4.8 5403 -- 73 --"CC".sup.b 0.66 7.8 85______________________________________ Legend: .sup.a Compound number corresponds to the compound number defined in Tabl I. .sup.b Comparison compound shown in EP Patent Appl. #86870010.5. ##STR28## .sup.d ligand .sup.3 H--prazosin. .sup.e ligand .sup.3 H--paminoclonidine.
Such high selective activity of the compounds of the invention constitutes a significant technical advantage over the Comparison Compound and increases considerably the pharmaceutical utility of the invention compounds.
Preferred compounds of the invention are characterized by the requirement that in Formula I where Ar 1 or Ar 2 represents a pyridyl group, then the pyridyl group must be attached at th meta- or para- positions of the pyridyl group. The significance of the meta-/para- pyridyl type compounds over ortho-pyridyl compounds is demonstrated in Table III. Compounds 1 and 2, respectively, are the para- and meta-pyridyl derivatives. Compound 3 is the ortho-pyridyl derivative. As shown in Column 3 of Table III, the α 2 -receptor binding affinity for the aminoclonidine ligand is fifteen times higher for the para- and meta-pyridyl type compounds than for the ortho-pyridyl compound. Therefore, Compounds 1 and 2 would be expected to be active in vivo for treatment of depression and other CNS disorders in humans at correspondingly lower doses than Compound 3.
In Table IV, columns 3 and 4 summarize the in vitro activities of the compounds evaluated in a guinea pig ileum model. Column 5 summarizes the α 2 antagonistic effects of the compounds in an in vivo animal model. The α 2 antagonistic and α 2 agonistic activities of the compounds according to the invention were determined upon isolated organs according to a model described by G. Drews, Br. J. Pharmaco., 64, 293-300 (1978). This model was based upon the principle that the stimulation of the cholinergic nervous transmissions of the guinea pig ileum causes the liberation of acetyl choline, which in turn causes contractions of the ileum. The stimulation of the α 2 -adrenergic receptors inhibits the activity of the cholinergic nerves and consequently reduces all responses due to the latter. Thus the contractions of the ileum induced by electric stimulation are inhibited by clonidine, an α 2 agonist, in proportion to the dose. This inhibition was selectively displaced by α 2 antagonists and not by α 1 antagonists. The method used can be summarized as follows. Three dose-response curves to clonidine were established at an interval of 60 minutes. Two concentration of the test product were added succesively 10 minutes before the realization of the second and third clonidine curves. Next, after washing, a dose-response curve was established with the tested product. The dose-response curves were calculated as a percentage of the maximum inhibition obtained for the first curve. In this system the products having an α 2 antagonistic activity displaced the dose-response curve to clonidine. The α 2 antagonist activity, expressed in pA 2 value shown in column 3 of Table IV, was calculated according to J. M. Van Rossum, Arch. Int. Pharmacodyn., 143, 299-300 (1963). A reduction of the contractions induced by the tested product alone indicated an α 2 agonist effect. This activity was expressed in pD 2 values (=-log ED 50 : the negative logarithm of the concentration of the product giving 50% of the maximum inhibition obtained with clonidine). The higher the pA 2 value, the higher the α 2 antagonist activity; the higher the pD 2 value, the higher the α 2 agonist activity.
Results of these tests, expressed as pA 2 and pD 2 values, are given in Table IV and indicate that the compounds of the present invention have high α 2 antagonist activity and insignificant α 2 agonist activity.
TABLE IV__________________________________________________________________________BIOLOGICAL DATA. Column 5 Open field test % inhibition ofColumn 1 Column 2 Column 3 α.sub.2 Column 4 α.sub.2 clonidine hypomobilityCompound No..sup.a LD.sub.50 (mg/kg) antagonist activity pA.sub.2 agonist activity pD.sub.2 Locomotion Rearing__________________________________________________________________________1 90 802 ±1753 130 7.3 4"CC".sup.b 155 8.3 5.5 100 100__________________________________________________________________________ .sup.a Compound number corresponds to the compound number defined in Tabl I. .sup.b Comparison Compound shown in EP Patent Appl. #86870010.5.
The activity of the compounds of the invention on the central nervous system was demonstrated in an in vivo study of clonidine-induced depression of locomotor activity. This study involved clonidine α 2 agonist effects on central control of locomotor activity. Clonidine inhibits locomotor activity and rearing activity in the mouse. In this "open field" test, mice were pretreated with the compounds of the present invention at a dose of 3 mg/kg p.o. (n=4 to 8), one hour prior to intraperitoneal administration of clonidine in solution (150 μg/kg, i.p.). Ninety minutes after the clonidine administration the animals were placed in a rectangular "open field" of 47×53 cm, having a floor divided into 36 boxes of about 8×9 cm. The number of boxes through which the animal goes in 3 minutes and the number of rearing episode were noted. The compounds were evaluated for their ability to antagonize the effect of clonidine and the results are given in Table IV, column 5. Among the compounds of the invention, compound No. 1 was very active in this test, since it highly antagonizes clonidine-induced depression of locomotor and rearing activity.
In man, the compounds according to the invention can be administered by various routes and in various galenic forms. Thus, the compounds will be administered, for example, one to three times per day orally, at doses varying from 0.5 mg to 300 mg. Some examples of galenic forms are given below in which the derivative according to the invention, being the active compound, is designated "Active". Examples of active compounds are the following derivatives: 4(5)-[2phenyl-2-(4-pyridinyl)-ethyl]-imidazole 4(5)-[2-phenyl-2-(3-pyridinyl)-ethyl]-imidazole.
______________________________________Tablets.a. Active 25 mgmicrocrystalline cellulose 100 mgpregelatinized starch 50 mgcolloidal silicon oxide 1 mgmagnesium stearate 2 mgb. Active 200 mgpolyvinylpyrrolidone 7.5 mgmaize starch 50 mglactose 50 mgmicrocrystalline cellulose 50 mgmagnesium stearate 2.5 mgHard gelatin capsulesa. Active 10 mgpregelatinized starch 188.5 mgcolloidal silicium dioxide 0.5 mgmagnesium stearate 1 mgb. Active 25 mgcorn starch 25 mgpolyvinylpyrrolidone 2.5 mgmicrocrystalline cellulose 30 mgpregelatinized starch 117 mgcolloidal silicium dioxide 0.5 mgInjectionA 5 mgsodium chloride 8 mgpurified water ad 1 mlTopic - transdermal formA 5 gpolyacrylic acid 1 gsodium hydroxide ad pH 6.5purified water ad 100 gDropsA 5 gphosphate buffer ad pH 6.5socium saccharinate 0.5 gpurified water ad 100 mlRectal formA 50 mgPolysorbate 80 20 mgWitepsol ad 2 g______________________________________
"Polysorbate 80" is a poly-oxyethylene(20)-sorbitan monooleate and "Witepsol" is a mixture of mono, di and triglycerides of mixed C 10 -C 18 fatty acids.
Although this invention has been described with respect to specific embodiments, the details of these embodiments are not to be construed as limitations. Various equivalents, changes and modifications may be made without departing from the spirit and scope of this invention, and it is understood that such equivalent embodiments are part of this invention.
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Certain 4(5)-(biarylethyl)imidazole derivatives are selectiv3 α 2 -adrenergic receptor blockers and are useful as anti-depressant agents.
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TECHNICAL FIELD
[0001] The present invention relates to an X-ray imaging apparatus which images a specimen, and a wavefront measuring apparatus which measures a transmitted wavefront of the specimen.
BACKGROUND ART
[0002] An X-ray has high transparency in various materials, and can achieve imaging with high spatial resolution. For these reasons, the X-ray is used for a nondestructive inspection of an object or a body as industrial utilization, X-raying as medical utilization, and the like.
That is, by the X-ray in the above utilization, a contrast image is formed by using a difference of absorption in a case where the X-ray transmits through an object or a living body, due to constituent elements and density differences of the object or the living body. It should be noted that such a process is called an X-ray absorption contrast method.
[0004] However, since an X-ray absorption capability of a light element is very small, it is difficult by the X-ray absorption contrast method to perform imaging of living soft tissue which consists of carbon, hydrogen, oxygen and the like being constituent elements of the living body, or a soft material.
[0005] On the other hand, in order to provide a method which can clearly perform imaging of even tissue consisting of light elements, a research for a phase contrast method using a phase difference of X-rays has been performed since 1990's.
[0006] Here, as one of various kinds of phase contrast methods, there is the method which is described in PTL 1.
[0007] The method described in PTL 1 is one kind of a method which is called a phase shift method. More specifically, in this method, an X-ray which was transmitted through a specimen is irradiated to a diffraction grating, and an intensity distribution (called as a self-image, hereinafter) which arises at a position away from the diffraction grating by a specific distance is imaged as a moiré fringe.
Then, phase information of an X-ray which transmitted through the specimen is obtained on the basis of three or more images which are obtained by scanning the moiré fringe as moving the diffraction grating. At this time, a differential wavefront in one direction is obtained. Therefore, in order to retrieve a wavefront shape, it is generally necessary to a differential wavefront in a direction perpendicular to the above direction.
[0010] Incidentally, a phase retrieval method which has been known as a Fourier transform method is disclosed in PTL 2.
In this method, a Fourier transform is first performed to the self-image which consists of the fringe components in the mutually perpendicular directions arisen by using a two-dimensional diffraction grading, whereby a frequency map is obtained. Next, the peripheries of two peaks corresponding to the mutually perpendicular fringe components on the obtained frequency map are cut out, an inverse Fourier transform is performed to such respective cut-out regions, and the phases of the respective regions are calculated.
[0013] Incidentally, two phase distribution maps thus obtained respectively form differential wavefronts in the mutually perpendicular directions, and a wavefront retrieval process is performed based on these wavefronts, whereby two-dimensional wavefront retrieval is achieved from one interference image.
CITATION LISTS
Patent Literatures
[0014] PTL 1: U.S. Pat. No. 7,180,979
PTL 2: Japanese Pat. No. 4,323,955
Non Patent Literature
[0016] NPL 1: Mitsuo Takeda et al., J. Opt. Soc. Am., Vol. 72, Issue 1 (1982)
SUMMARY OF INVENTION
Technical Problem
[0017] In the method disclosed in PTL1, at least the three images are necessary to obtain the differential wavefront in one direction, and the differential wavefronts in the mutually perpendicular directions are necessary to retrieve the wavefront shape.
For these reasons, at least the six images are necessary in the imaging process, thereby increasing an X-ray radiation dose, and prolonging a measuring time. Thus, such matters become problems in case of applying the above-described method to a medical diagnostic apparatus.
[0019] On the other hand, a phase contrast image which is obtained in the method described in PTL 2 has a problem in a point that components which are caused by a transmissivity distribution of a specimen and uneven illumination of a light source are included in addition to a differential phase. For this reason, it is impossible to correctly measure a phase distribution which transmitted through the specimen.
[0020] In consideration of the above-described problems, the present invention aims to provide an X-ray imaging apparatus which measures an X-ray phase image of a specimen, in which the X-ray imaging apparatus enables to two-dimensionally retrieve a wavefront as suppressing an influence of a transmissivity distribution of the specimen and uneven illumination of a light source, by utilizing images the number of which is smaller than that in the method disclosed in PTL 1 and with spatial resolution which is higher than that in the method disclosed in PTL 2.
Solution to Problem
[0021] In one aspect of the present invention, an X-ray imaging apparatus, which images a specimen, comprises: an X-ray source; a diffraction grating configured to diffract an X-ray from the X-ray source; an X-ray detector configured to detect the X-ray diffracted by the diffraction grating; and a calculator configured to calculate phase information of the specimen on the basis of an intensity distribution of the X-ray detected by the X-ray detector, wherein the calculator obtains a spatial frequency spectrum from the plural intensity distributions, and calculates the phase information from the obtained spatial frequency spectrum.
[0022] Other aspects of the present invention will be clarified in the following exemplary embodiments of the present invention.
Advantageous Effects of Invention
[0023] According to the present invention, it is possible to achieve high-accurate X-ray phase image measurement which can eliminate a noise due to uneven illumination to a specimen and/or uneven transmission of the specimen and improve spatial resolution.
[0024] Further, it is possible to measure a transmitted wavefront on the conditions that the number of imaging operations is less than that in the phase shift method, spatial resolution is higher than that in the conventional Fourier transform method, and an error in the measured wavefront due to an uneven transmissivity of the specimen and uneven illumination of the light source is reduced.
[0025] Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0026] [ FIG. 1 ] FIG. 1 is a block diagram for describing a constructive example of an X-ray imaging apparatus according to a first embodiment and an example 1 of the present invention.
[0027] [ FIG. 2 ] FIG. 2 is a diagram for describing a checked phase grating of the X-ray imaging apparatus according to the example 1 of the present invention.
[0028] [ FIG. 3 ] FIG. 3 is a flow chart indicating a wavefront measuring process to be performed by a calculator according to the example 1 of the present invention.
[0029] [ FIGS. 4A , 4 B, 4 C, 4 D, 4 E, 4 F, 4 G and 4 H] FIGS. 4A , 4 B, 4 C, 4 D, 4 E, 4 F, 4 G and 4 H are diagrams for describing intensity distributions and frequency spectra in a case where a phase modulation grating which has checks respectively having a phase difference π/2 is used, in the example 1 of the present invention.
[0030] [ FIG. 5 ] FIG. 5 is a diagram for describing a frequency spectrum cut-out region in a case where the present invention is not applied.
[0031] [ FIG. 6 ] FIG. 6 is a diagram for describing a frequency spectrum cut-out region in the example 1 of the present invention.
[0032] [ FIGS. 7A , 7 B, 7 C, 7 D, 7 E, 7 F, 7 G and 7 H] FIGS. 7A , 7 B, 7 C, 7 D, 7 E, 7 F, 7 G and 7 H are diagrams for describing intensity distributions and frequency spectra in a case where a phase modulation grating which has checks respectively having a phase difference π is used, in the example 1 of the present invention.
[0033] [ FIGS. 8A , 8 B, 8 C, 8 D, 8 E, 8 F, 8 G and 8 H] FIGS. 8A , 8 B, 8 C, 8 D, 8 E, 8 F, 8 G and 8 H are diagrams for describing intensity distributions and frequency spectra in a case where an intensity modulation grating of a mesh pattern is used, in the example 1 of the present invention.
[0034] [ FIG. 9 ] FIG. 9 is a block diagram for describing a constructive example of an X-ray imaging apparatus according to an example 2 of the present invention.
[0035] [ FIGS. 10A , 10 B, 10 C, 10 D, 10 E, 10 F, 10 G, 10 H, 10 I, 10 J, 10 K, 10 L, 10 M and 10 N] FIGS. 10A , 10 B, 10 C, 10 D, 10 E, 10 F, 10 G, 10 H, 10 I, 10 J, 10 K, 10 L, 10 M and 10 N are diagrams for describing intensity distributions and frequency spectra in a case where a phase modulation grating which has a manufacturing error and has checks respectively having a phase difference π is used, in an example 3 of the present invention.
[0036] [ FIGS. 11A , 11 B, 11 C, 11 D, 11 E, 11 F, 11 G and 11 H] FIGS. 11A , 11 B, 11 C, 11 D, 11 E, 11 F, 11 G and 11 H are diagrams for describing intensity distributions and frequency spectra in a case where a diffraction grating which has periodicity in one direction, in an example 4 of the present invention.
[0037] [ FIG. 12 ] FIG. 12 is a diagram for describing a frequency spectrum cut-out region in the example 4 of the present invention.
[0038] [ FIG. 13 ] FIG. 13 is a block diagram for describing a constructive example of a wavefront measuring apparatus according to an example 5 of the present invention.
DESCRIPTION OF EMBODIMENTS
[0039] Hereinafter, exemplary embodiments of the present invention will be described.
First Embodiment
[0040] As a first embodiment, a constructive example of an X-ray imaging apparatus to which the present invention is applied will be described with reference to FIG. 1 .
[0041] FIG. 1 illustrates an X-ray source 1 which radiates an X-ray, an X-ray 2 which is radiated by the X-ray source 1 , a specimen 3 which is to be imaged and measured by the X-ray imaging apparatus, and a diffraction grating 4 which periodically modifies a phase or intensity of an incident X-ray in two directions which are perpendicular to each other.
[0042] Further, FIG. 1 illustrates an X-ray detector 5 which detects an intensity distribution which arises by a Talbot effect based on the X-ray which transmitted through (or was reflected on) the diffraction grating, a diffraction grating moving unit 6 which changes an in-plane position of the diffraction grating 4 , and a calculator 7 which calculates a differential wavefront and a transmitted wavefront from an image which has been imaged by the X-ray detector 5 .
[0043] Namely, the X-ray imaging apparatus according to the present embodiment includes the X-ray source 1 , the diffraction grating 4 , the diffraction grating moving unit 6 , the X-ray detector 5 , and the calculator 7 .
[0044] More specifically, the calculator 7 includes a spectrum calculation means which obtains a spatial frequency spectrum of a difference between two imaging intensity distributions obtained by using the diffraction grating moving unit 6 and the X-ray detector 5 , a spectrum separation means which cuts out, from the spatial frequency spectrum obtained by the spectrum calculation means, a frequency component in a period of the imaging intensity distribution, and a differential phase calculation means which calculates a differential phase distribution by performing an inverse Fourier transform to the frequency component obtained by the spectrum separation means.
[0045] Hereinafter, the present embodiment will further be described in detail. In the above constitution, the diffraction grating 4 is disposed immediately before or immediately after the specimen 3 to function so that the X-ray which transmitted through the diffraction grating 4 forms the periodic intensity distribution on the X-ray detector 5 .
[0046] More specifically, the diffraction grating 4 can be constituted by a phase modulation grating which consists of an X-ray transmission member of which the thickness periodically changes, an intensity modulation grating which has periodically arranged openings, or the like.
[0047] In order to obtain a clear intensity distribution, a distance Z 1 between the diffraction grating 4 and the X-ray detector 5 satisfies an expression (1) of Talbot condition as indicated below.
[0000] (1/ Z 0 )+(1/ Z 1 )=(1/ N )×(λ/ d 2 ) (1)
[0048] In the above expression (1), Z 0 indicates a distance between the X-ray source 1 and the diffraction grating 4 , λ is a wavelength of the X-ray, and d indicates a grating period of the diffraction grating 4 .
Further, N is a real number which is expressed as n/2-¼ (n is a natural number) in a case where a phase modulation grating which has checks respectively having a phase difference π/2 is used, a real number which is expressed as n/4-⅛ in a case where a phase modulation grating which has checks respectively having a phase difference π is used, and a real number which is expressed as n in a case where an intensity modulation grating of a mesh pattern is used.
[0050] If an inclination of the wavefront changes according to the transmission of the X-ray through the specimen 3 , the radiation direction of the X-ray changes. Thus, the intensity distribution on the X-ray detector moves.
[0051] Generally, it is possible to obtain an inclination of the transmitted wavefront (called the differential wavefront, hereinafter) on the specimen 3 , by utilizing a Fourier transform method to an intensity distribution image obtained by the X-ray detector. Here, since the detail of the Fourier transform method is described in NPL 1, only an outline thereof will be described here.
[0052] That is, in a frequency spectrum which is obtained by performing a two-dimensional Fourier transform to an intensity distribution, there arise peaks which correspond to a frequency (called a carrier frequency, hereinafter) of a fundamental period component of the intensity distribution (called a carrier fringe, hereinafter) and numerous its harmonic components. Then, the periphery of one of the two peaks which respectively correspond to the perpendicular carrier frequencies is cut out, and such a cut-out component is moved to the center.
Further, an inverse Fourier transform is performed to the moved component, and a phase component thereof is obtained, whereby it is possible to obtain a differential wavefront in one direction of a wavefront to be measured.
[0054] To retrieve the wavefront, it is necessary to integrate the obtained differential wavefront in a differential direction. However, in general, a change of a wavefront in the direction perpendicular to the differential direction cannot be calculated only by such a process. Namely, it is possible to solve such a problem by performing the same process as described above to the other of the two peaks and thus obtaining the differential wavefronts in the perpendicular two directions.
[0055] In the present embodiment, the diffraction grating 4 is moved within a plane by the diffraction grating moving unit 6 , whereby the frequency spectrum of a difference between the two images which are imaged as moving a carrier fringe of the intensity distribution by a half period.
[0056] Incidentally, how to obtain the frequency spectrum of the difference between the relevant two images will be briefly described hereinafter. Namely, a subtraction between the two images is first performed, and the Fourier transform may be performed to such an obtained difference image. Alternatively, the Fourier transform is first performed to the two images to calculate the frequency spectra of the respective images, and then a subtraction may be performed between the calculated frequency spectra.
[0057] Particularly, in the present embodiment, since the diffraction grating is moved within the plane, the intensity distribution is moved by half of its period. Here, the intensity distribution is imaged before and after the movement.
Then, the difference between the two images thus obtained is calculated by the calculator, and the Fourier transform method is applied to the calculated difference image, whereby the inclination of the transmitted wavefront on the specimen is obtained.
[0059] Since uneven illumination to the specimen or uneven transmission of the specimen produces the same pattern respectively in the two images, it is possible to eliminate an influence of the uneven illumination and/or the uneven transmission by obtaining the difference between these images.
Further, it is also possible to eliminate a peak of a second harmonic of a carrier which restricts spatial resolution in the wavefront measurement by the Fourier transform method, thereby improving the spatial resolution.
[0061] As described above, according to the present embodiment, it is possible to achieve high-accurate X-ray phase image measurement which can eliminate a noise due to the uneven illumination to the specimen and/or the uneven transmission of the specimen and improve the spatial resolution.
Second Embodiment
[0062] Subsequently, as a second embodiment, a wavefront measuring apparatus to which the first embodiment is applied will be described.
[0063] In the present embodiment, the constitution of the first embodiment is applied to the wavefront measuring apparatus which inspects a shape and an internal property of an optical element on the basis of a measured result of a transmitted wavefront.
[0064] Namely, the wavefront measuring apparatus according to the present embodiment includes a light source, a diffraction grating which periodically modifies a phase or an intensity of the a light ray irradiated from the light source, and a moving unit which changes an in-plane position of the diffraction grating. Further, the wavefront measuring apparatus includes an imaging device which obtains an intensity distribution which arises by a Talbot effect due to the light ray transmitting through or reflected on the diffraction grating, or an intensity distribution of a moiré fringe which arises by further disposing a shielding member. Furthermore, the wavefront measuring apparatus is constituted to have a calculator which obtains a differential phase distribution of the light ray transmitting through the specimen disposed between the light source and the diffraction grating or between the diffraction grating and the imaging device, and thus measure the transmitted wavefront of the specimen. Here, it should be noted that the moving unit can be provided by the diffraction grating moving unit in the first embodiment and the calculator can be provided by the calculator in the first embodiment.
[0065] As described above, according to the present embodiment, it is possible to measure the transmitted wavefront on the conditions that the number of imaging operations is less than that in the phase shift method, the spatial resolution is higher than that in the conventional Fourier transform method, and an error in the measured wavefront due to an uneven transmissivity of the specimen and uneven illumination of the light source is reduced.
EXAMPLES
[0066] Hereinafter, examples of the present invention will be described.
Example 1
[0067] As an example 1, a constructive example of the X-ray imaging apparatus will be described with reference to FIG. 1 .
[0068] In the X-ray imaging apparatus of this example, the X-ray 2 radiated by the X-ray source 1 reaches the X-ray detector 5 through the specimen 3 and the diffraction grating 4 .
[0069] Here, the diffraction grating 4 is the phase modulation grating which modulates the phase of the incident X-ray by π/2 or π or the intensity modulation grating which modulates the intensity of the incident X-ray.
[0070] If the phase modulation grating is used, the relevant phase modulation grating is made by silicon of which the X-ray transmissivity is large and which is well workable. On the other hand, if the intensity modulation grating is used, the relevant intensity modulation grating is made by gold of which the X-ray transmissivity is small.
[0071] Initially, a case where the phase modulation grating of the phase difference π/2 is used as the diffraction grating will be described.
[0072] Namely, the phase modulation grating of the phase difference π/2 in which the portions that the phases of the transmission X-ray are relatively different from others by π/2 are two-dimensionally and periodically arranged by periodically changing the thickness of the silicon is formed.
[0073] FIG. 2 is a diagram which is obtained by viewing one portion of the diffraction grating in this example from the side of the light source.
[0074] That is, the thickness of the diffraction grating is made to have differences so that a transmission phase of a portion 41 having hatched lines is different from a transmission phase of a portion 42 not having hatched lines by π/2. Further, these portions are two-dimensionally arranged with a period d.
[0075] FIG. 3 is a flow chart indicating a wavefront measuring process to be performed in this example.
[0076] In a step 110 , the X-ray detector is arranged so that the distance Z 1 between the diffraction grating and the X-ray detector satisfies the expression (1) in case of N=¼, whereby a clear intensity distribution image arises on the X-ray detector.
[0077] In a step 120 , the intensity distribution is obtained by the X-ray detector, and the obtained intensity distribution is set as an intensity distribution 1 .
[0078] FIGS. 4A , 4 B and 4 C respectively illustrate the position state of the diffraction grating 4 at this time, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector.
[0079] In a step 130 , the intensity distribution is moved by ½ of the period by moving, with the diffraction grating moving unit 6 , the diffraction grating 4 in the vertical or horizontal direction by a half period, i.e., ½ of the period d illustrated in FIG. 2 .
[0080] In a step 140 , the intensity distribution is again obtained by the X-ray detector, and the obtained intensity distribution is set as an intensity distribution 2 .
[0081] FIGS. 4D , 4 E and 4 F respectively illustrate the position state of the diffraction grating 4 at this time, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector.
[0082] Here, it should be noted that FIGS. 4C and 4F seem the same because light and shade are represented on the drawing sheet according to the magnitudes of the absolute values of the frequency spectra. Namely, a sign of the carrier peak being the peak corresponding to the carrier fringe in FIG. 4C is reversed in regard to that in FIG. 4F .
[0083] On the other hand, since the peak at the center of the frequency spectrum corresponds to the component which arises from uneven illumination to the specimen and uneven transmission of the specimen but does not arise from movement of the carrier, a sign of the peak is unchanged. For this reason, it is possible to eliminate the peak at the center by obtaining a difference between the intensity distribution 1 and the intensity distribution 2 . In a step 150 , the frequency spectrum of the difference between the intensity distributions before and after the movement of the diffraction grating is obtained.
[0084] FIG. 4G illustrates the difference between the intensity distributions before and after the movement of the diffraction grating.
[0085] FIG. 4H illustrates the frequency spectrum of the difference between these intensity distributions. Here, it can be understood that the peak at the center has disappeared.
[0086] Incidentally, it is needless to say that, in case of calculating the frequency spectrum of the difference between the intensity distributions before and after the movement of the diffraction grating, it is possible to first calculate the frequency spectra of the intensity distributions 1 and 2 and then calculate the difference between the calculated frequency spectra.
[0087] In a step 160 , a region near the carrier frequency is cut out. Here, if the region to be cut out (called the cut-out region) is made large, spatial resolution of the differential phase distribution to be calculated in a later step improves.
[0088] However, in order to reduce an influence of peak other than the carrier peak, the cut-out region is restricted to be within the intermediate line between the carrier peak and the peak other than the carrier peak.
[0089] FIG. 5 is a diagram for describing the cut-out region in a case where the present invention is not applied, that is, in a case where the difference between the intensity distributions is not obtained. As illustrated in the drawing, cut-out regions 340 and 341 are a maximum region as the cut-out regions in the two directions perpendicular to each other as centering on the carrier frequency.
[0090] If it is assumed that a pixel size of the X-ray detector is P, an absolute value of a spatial frequency capable of being expressed (called an expressible spatial frequency) is restricted to be equal to or lower than a Nyquist frequency, i.e., within a range of ±1/2P.
Further, the expressible spatial frequencies are restricted inside the intermediate line between carrier peaks 310 and a peak 320 at the center and inside intermediate line between carrier peaks 311 and a peak 320 . For this reason, the maximum cut-out region is inside the two squares which have the peaks 310 and 311 as the respective centers, of which each side is ½√2P, and which incline by 45°.
[0092] On the other hand, FIG. 6 is a diagram for describing the cut-out region in a case where the present invention is applied. As illustrated in the drawing, cut-out regions 350 and 351 are a maximum region as the cut-out regions in the two directions perpendicular to each other as centering on the carrier frequency.
[0093] Since the peak at the center has disappeared, the cut-out region can be increased up to the intermediate line between the adjacent carrier peaks.
Therefore, the maximum cut-out region is inside the erected two squares which have the peaks 310 and 311 as the respective centers, and of which each side is ±1/2P.
[0095] Since the area of the cut-out regions 350 and 351 in FIG. 6 is twice the area of the cut-out regions 340 and 341 in FIG. 5 , the frequency components which can be retrieved in FIG. 6 are large accordingly, whereby it is possible to resultingly obtain an X-ray phase image of which the spatial resolution is high.
[0096] In a step 170 , the spatial frequency spectrum which has been cut out is moved to the original point, and an inverse Fourier transform is performed.
[0097] In a step 180 , a phase component of a complex distribution obtained in the step 170 is calculated. Since the calculated phase has been generally convoluted into 0 to 2π, the differential phase distribution is obtained by performing phase unwrapping. Further, if the differential phase is integrated so that the obtained differential phases in the two directions perpendicular to each other are simultaneously satisfied, the phase distribution of the X-ray which transmitted through the specimen, i.e., the transmitted wavefront, can be obtained as need arises.
[0098] Incidentally, as another method of obtaining the phase distribution, there may be a method of fitting the differential phase to a differential function sequence which is obtained by differentiating a function sequence such as a Zernike polynomial or the like to a periodicity direction of the carrier fringe.
Further, if the sum of the intensity distributions 1 and 2 is obtained as need arises, information indicating X-ray transmission of the specimen can be obtained because the carrier peak disappears.
[0100] Subsequently, a case where the phase modulation grating of the phase difference π is used as the diffraction grating will be described. However, the process which is the same as that to be performed in the above-described case where the phase modulation grating of the phase difference π/2 is used will be omitted.
[0101] In the step 130 , the diffraction grating is moved so that the intensity distribution on the X-ray detector is deviated in both the vertical and horizontal directions by a half period. The distance by which the diffraction grating is moved is 1/√2 of the case where the phase modulation grating of the phase difference π/2 is used, and the direction in which the diffraction grating is moved is the direction which inclines by 45° from the case where the phase modulation grating of the phase difference π/2 is used.
[0102] FIGS. 7A , 7 B and 7 C respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, in the case where the phase modulation grating of the phase difference π is used.
[0103] FIGS. 7D , 7 E and 7 F respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, after the diffraction grating was moved.
[0104] FIG. 7G illustrates the difference between the intensity distributions before and after the movement of the diffraction grating, and FIG. 7H illustrates the difference between the frequency spectra before and after the movement of the diffraction grating.
[0105] As well as the case where the phase modulation grating of the phase difference π/2 is used, since unnecessary peaks other than the carrier peak disappear, a difference in the calculated differential phase distribution is recued.
[0106] Moreover, since the unnecessary peaks disappear, it is possible to make the cut-out region of the frequency spectrum in the step 160 large, whereby it is possible to resultingly obtain the X-ray phase image of which the spatial resolution is high.
[0107] Further, a case where an intensity modulation grating having a mesh pattern is used as the diffraction grating will be described. However, the process which is the same as that to be performed in the above-described case where the phase modulation grating of the phase difference π/2 is used will be omitted.
[0108] In the step 130 , the diffraction grating is moved so that the intensity distribution on the X-ray detector is deviated in both the vertical and horizontal directions by a half period. Namely, if it is assumed that the period of the diffraction grating is d as illustrated in FIG. 8A , the diffraction grating is moved in both the vertical and horizontal directions by d/2.
[0109] FIGS. 8A , 8 B and 8 C respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, in a case where the intensity modulation grating which includes transmission portions and shielding (or light shielding) portions is used.
[0110] FIGS. 8D , 8 E and 8 F respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, after the diffraction grating was moved. Incidentally, in FIGS. 8 A and 8 D, the black portions indicate the shielding portions respectively.
[0111] FIG. 8G illustrates the difference between the intensity distributions before and after the movement of the diffraction grating, and FIG. 8H illustrates the difference between the frequency spectra before and after the movement of the diffraction grating. As well as the case where the phase modulation grating of the phase difference π/2 is used, since unnecessary peaks other than the carrier peak disappear, a difference in the calculated differential phase distribution is recued.
[0112] Moreover, since the unnecessary peaks disappear, it is possible, as well as the case where the phase modulation grating of the phase difference π/2 is used, to make the cut-out region of the frequency spectrum in the step 160 large, whereby it is possible to resultingly obtain the X-ray phase image of which the spatial resolution is high.
Example 2
[0113] As an example 2, a constructive example of the X-ray imaging apparatus which is different from that in the example 1 will be described with reference to FIG. 9 .
[0114] In this example, only portions which are different from the example 1 will be described.
[0115] It should be noted that this example is effective to reduce a size of the X-ray imaging apparatus in which a Talbot interference is used.
[0116] Here, to reduce the size of the X-ray imaging apparatus, it is necessary to reduce the period d of the diffraction grating so that the distances Z 0 and Z 1 in the expression (1) become small.
Therefore, since the period of the intensity distribution is approximately equal to or less than the existing pixel of the X-ray detector, it is impossible to retrieve the wavefront by the Fourier transform method. Consequently, a moiré fringe is formed by a shielding member which has a period slightly different from the period of the intensity distribution by the Talbot interference, and the wavefront is retrieved based on a distortion of the intensity distribution enlarged to the moiré fringe.
[0119] In this example, a shielding member 8 which has a period slightly different from the period of the intensity distribution is disposed immediately before the X-ray detector 5 , thereby forming the moiré fringe and thus obtaining the intensity distribution of the moiré fringe.
[0120] More specifically, since the distortion has arisen in the moiré fringe based on the phase distribution of the X-ray which transmitted through the specimen 3 , the differential phase distribution or the phase distribution of the X-ray which transmitted through the specimen 3 is obtained according to the procedure of FIG. 3 same as that in the example 1.
[0121] Unlike the example 1, second imaging corresponding to the step 130 is performed as moving the period of the moiré fringe by a half period.
[0122] Here, to move the distribution of the moiré fringe on the X-ray detector, it may move the diffraction grating 4 within the plane of the diffraction grating.
Otherwise, it may move the shielding member 8 within the plane of the making member.
[0124] According to the steps 140 to 180 , even if the size of the apparatus is small, it is possible to measure the wavefront on which an error in the measured wavefront due to an uneven transmissivity of the specimen and uneven illumination of the light source has been reduced.
Further, if it is designed that the region to be cut out from the spatial frequency spectrum becomes maximum as illustrated in FIG. 6 , the spatial resolution of the calculated differential phase distribution or the calculated phase distribution is maximized.
Example 3
[0126] As an example 3, a constructive example of the X-ray imaging apparatus which is different from those in the examples 1 and 2 will be described with reference to FIGS. 10A to 10N .
[0127] In this example, only portions which are different from the examples 1 and 2 will be described.
[0128] In this example, with respect to the checked phase modulation grating which has the phase difference π and is used as the diffraction grating, even if the phase difference is deviated from π due to a defect in manufacturing or the checks are deformed, it enables to eliminate a noise due to uneven illumination to the specimen and/or uneven transmission of the specimen, and it enables to measure the transmitted wavefront of the specimen with a high degree of accuracy on the condition that the spatial resolution has been improved.
[0129] If the phase difference of the phase modulation grating having the phase difference π is deviated from π due to the defect in manufacturing and/or if the checks in the periodic structure are deviated from rectangles, zero-dimensional light which does not exist ideally is generated.
Then, if the zero-dimensional light is generated, an interference between the zero-dimensional light and plus and minus one-dimensional light arises. Thus, an intensity distribution of a lower frequency is generated, whereby an error arises in the phase calculation by the Fourier transform method.
[0131] FIGS. 10A , 10 B and 10 C respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, in a case where the phase modulation grating of the phase difference π in which the periodic structure thereof has been deviated from the checks due to the defect in manufacturing is used.
[0132] Here, it can be understood that, in the frequency spectrum of FIG. 10C , a frequency spectrum which does not exist in the frequency spectrum of FIG. 7C in the case where a defect in manufacturing does not arises exists.
[0133] The spectrum which arises due to the defect in manufacturing of the diffraction grating cannot be eliminated by the difference spectrum of which the obtaining procedure is indicated in FIG. 3 . Thus, in this example, a differential phase distribution is calculated based on four imaging intensity distributions obtained by moving the intensity distribution on the X-ray detector.
[0134] As well as FIGS. 7D , 7 E and 7 F, FIGS. 10D , 10 E and 10 F respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, in a case where the diffraction grating is moved.
[0135] Incidentally, the diffraction grating is moved so that the intensity distribution on the X-ray detector is deviated in the periodic vertical and horizontal directions by a half period.
[0136] FIGS. 10G , 10 H and 10 I respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, in a case where the diffraction grating is moved by the movement amount same as that in the movement of the diffraction grating indicated in FIG. 10D and in the direction perpendicularly changed by 90° from that in the movement of the diffraction grating indicated in FIG. 10D .
[0137] FIGS. 10J , 10 K and 10 L respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, in a case where both the movement of the diffraction grating indicated in FIG. 10D and the movement of the diffraction grating indicated in FIG. 10G are performed.
[0138] Here, if it is assumed that the imaging intensity distribution corresponding to FIG. 10B is IA, the imaging intensity distribution corresponding to FIG. 10E is IB, the imaging intensity distribution corresponding to FIG. 10H is IC, and the imaging intensity distribution corresponding to FIG. 10K is ID, then the intensity distribution corresponding to IA−IB−IC+ID is indicated in FIG. 10M .
[0139] In this regard, the imaging intensity distributions respectively indicated by IA to ID are the imaging intensity distributions which are obtained as indicated below.
[0140] That is, a moving unit is constituted by a first moving unit which can change the in-plane position of the diffraction grating so as to move the period of the intensity distribution in both the perpendicular two periodicity directions by ½, and a second moving unit which changes the position of the diffraction grating or the shielding member in the same plane as that of the first moving unit, in the direction perpendicular to that of the first moving unit, and by the same distance as that of the first moving unit.
[0141] Then, the imaging intensity distribution IA is obtained without using the moving unit, and the imaging intensity distribution IB is obtained by using only the first moving unit.
Further, the imaging intensity distribution IC is obtained by using only the second moving unit, and the imaging intensity distribution ID is obtained by using the first moving unit and the second moving unit.
[0143] FIG. 10N indicates the frequency spectrum which is obtained by performing the two-dimensional Fourier transform to the intensity distribution indicated in FIG. 10M . It can be understood from this drawing that the spectrum which arose due to the defect in manufacturing of the diffraction grating has been eliminated.
[0144] In this example, as described above, with respect to the intensity distribution which is obtained by the expression (IA−IB−IC+ID) in which the imaging intensity distributions respectively obtained at the four diffraction grating positions are added/subtracted, the differential phase distribution or the phase distribution is calculated on the basis of the frequency spectrum obtained by the two-dimensional Fourier transform.
[0145] Here, the calculation of the phase at this time is performed according to the steps 160 , 170 and 180 respectively described in the example 1.
[0146] According to this example, since the spectrum which arises due to the defect in manufacturing of the diffraction grating is eliminated, it is possible to increase accuracy of the phase calculation in the Fourier transform method.
[0147] In the above-described examples 1 to 3, the diffraction grating, the shielding member or the X-ray detector is disposed so that the period of the intensity distribution or the intensity distribution of the moiré fringe has the size being 2√2 times the pixel size of the X-ray detector and the periodicity direction of the relevant intensity distribution inclines from the pixel arrangement of the X-ray detector by 45°.
Further, the spectrum separation means in the calculator is constructed to be able to cut out, from the spatial frequency spectrum obtained by the Fourier transform, the rectangular region which includes the frequencies from the zero frequency to the Nyquist frequency, respectively in the perpendicular two periodicity directions of the pixel arrangement of the X-ray detector. By doing so, since the maximum frequency region centering on the carrier peak is cut out, the spatial resolution of the calculated differential phase distribution is maximized.
Example 4
[0149] As an example 4, a constructive example of the X-ray imaging apparatus which is different from those in the above examples 1 to 3 will be described with reference to FIGS. 11A to 11H and FIG. 12 .
[0150] In this example, only portions which are different from the examples 1 to 3 will be described. Incidentally, although the diffraction grating which has periodicity in the two directions is used as the diffraction grating in the examples 1 to 3, the phase modulation grating or the intensity modulation grating which has periodicity in one direction is used in this example.
[0151] The diffraction grating having periodicity in one direction has an advantage that manufacturing is easier than the diffraction grating having periodicity in two directions.
[0152] FIGS. 11A , 11 B and 11 C respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, in a case where the phase modulation grating which periodically modifies the phase in one direction by π/2 is used.
[0153] FIGS. 11D , 11 E and 11 F respectively illustrate the position state of the diffraction grating, the intensity distribution on the X-ray detector, and the frequency spectrum obtained by performing the two-dimensional Fourier transform to the intensity distribution on the X-ray detector, after the diffraction grating was moved so as to deviate the intensity distribution on the X-ray detector in the horizontal direction having periodicity by a half period.
[0154] FIG. 11G illustrates the difference between the intensity distributions before and after the movement of the diffraction grating, and FIG. 11H illustrates the difference between the frequency spectra before and after the movement of the diffraction grating.
[0155] As illustrated in FIG. 11H , since unnecessary peaks other than the carrier peak have been eliminated, a difference in the differential phase distribution is recued.
[0156] Here, the differential phase distribution is calculated from the difference spectrum illustrated in FIG. 11H according to the steps 160 , 170 and 180 .
[0157] When the period of the intensity distribution is four times the size of the pixel of the X-ray detector and the periodicity direction of the intensity distribution coincides with the arrangement direction of the pixels of the X-ray detector, the spatial resolution of the differential phase distribution to be calculated is maximized.
[0158] FIG. 12 illustrates the frequency spectrum at this time. As illustrated in the drawing, a peak 620 at the center and a peak 630 corresponding to a second harmonic of the carrier peak have been eliminated by the difference of the imaging intensity distribution obtained after the movement of the diffraction grating. Thus, a region 640 which is a hatched-line rectangular region and based on a carrier peak 610 can be cut out.
[0159] This region, that is, the frequency region which includes frequencies from a zero frequency to a Nyquist frequency in the periodicity direction of the intensity distribution and includes the overall frequency region between the Nyquist frequencies in the direction perpendicular to the periodicity direction of the intensity distribution is maximum as the region to be cut out as centering on the carrier peak. Thus, the spatial resolution of the calculated differential phase distribution is maximized.
[0160] Even in the case where the phase modulation grating of the phase difference π or the phase modulation grating is used, the differential phase distribution in which the error has been reduced can be calculated based on the two imaging intensity distributions obtained by moving the diffraction grating so as to deviate the intensity distribution by a half period, as well as the phase modulation grating of the phase difference π/2.
[0161] When the phase modulation grating of the phase difference π/2 is used, the movement amount of the diffraction grating is ½ of the grating period. When the phase modulation grating of the phase difference π is used, the movement amount of the diffraction grating is ¼ of the grating period. When the intensity modulation grating is used, the movement amount of the diffraction grating is ½ of the grating period.
[0162] In this example, the phase distribution can be obtained by integrating the obtained differential phase of the diffraction grating in the periodicity direction.
[0163] To more accurately calculate the phase distribution, for example, it is possible to calculate the differential phases in the two or more directions by changing the periodicity direction by rotating the diffraction grating within the plane, and obtain the phase distribution by which the calculated differential phases are simultaneously satisfied.
Example 5
[0164] As an example 5, a constructive example of the wavefront measuring apparatus will be described with reference to FIG. 13 .
[0165] In this example, only portions which are different from the examples 1 to 4 will be described.
[0166] A light source 11 , which is constituted by, e.g., a laser, radiates coherent light. A specimen 13 is, e.g., an optical element, and more concretely a lens or a lens group which is a target of wavefront measurement.
[0167] An illumination optical system 12 , which is disposed between the light source 11 and the specimen 13 , converts a light wave generated by the light source 11 into a wavefront of which the aberration has been known. The illumination optical system 12 is constituted by, e.g., a pinhole of which the aperture is sufficiently small, and generates the wavefront which is approximated by a spherical wave.
[0168] A diffraction grating 14 periodically modulates an intensity or a phase of the light radiated by the light source, in one direction or perpendicular two directions. The light which transmitted through the diffraction grating 14 generates a periodic intensity distribution by the Talbot effect, at a position which satisfies the above-described expression (1).
[0169] A light detector 15 is a two-dimensional imaging element which images the intensity distribution. A CCD or the like is used as the light detector 15 . A moving unit 16 , which moves the diffraction grating 14 in a plane, can move the intensity distribution in the periodicity direction by a half period. A calculator 17 calculates a differential phase distribution of incident light to the diffraction grating 14 , from the imaging intensity distribution obtained according to the procedure indicated in FIG. 3 .
Namely, it is possible, from the differential phase distributions in the perpendicular two directions, to obtain the phase distribution which simultaneously satisfies these distributions, that is, the transmitted wavefront of the specimen 13 .
[0171] As just described, the embodiments and the examples of the present invention are explained. However, the present invention is not limited to these embodiments and examples. Namely, various modifications and equivalent arrangements can be attained within the spirit and scope of the invention.
[0172] The technical components described in the specification or the drawings exert technical utility by themselves or by various combinations thereof, but are not limited to the combination described in the appended claims. Further, the technique exemplified in the specification or the drawings accomplishes plural objects simultaneously. Furthermore, the technique has technical utility by accomplishing one of these objects.
INDUSTRIAL APPLICABILITY
[0173] The present invention can be used to an X-ray imaging apparatus which measures an X-ray phase image of a specimen, and a wavefront measuring apparatus which measures a transmitted wavefront of the specimen.
[0174] While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
[0175] This application claims the benefit of Japanese Patent Application No. 2010-016606, filed Jan. 28, 2010, which is hereby incorporated by reference herein in its entirety.
REFERENCE SIGNS LIST
[0176] 1 X-ray source
2 X-ray 3 specimen 4 diffraction grating 5 X-ray detector 6 diffraction grating moving unit 7 calculator
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There is provided an X-ray imaging apparatus which images a specimen. The X-ray imaging apparatus comprises: an X-ray source; a diffraction grating configured to diffract an X-ray from the X-ray source; an X-ray detector configured to detect the X-ray diffracted by the diffraction grating; and a calculator configured to calculate phase information of the specimen on the basis of an intensity distribution of the X-ray detected by the X-ray detector, wherein the calculator obtains a spatial frequency spectrum from the plural intensity distributions, and calculates the phase information from the obtained spatial frequency spectrum.
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TECHNICAL FIELD
[0001] The present disclosure relates generally to an improved technique for welding together multiple workpieces and, more particularly, to systems and methods for improved ultrasonic welding, using an algorithm for locating welding energy directors.
BACKGROUND
[0002] In automotive manufacturing, polymetric composites are being used increasingly due to their favorable characteristics, such as being lightweight, highly-conformable or shapeable, strong, and durable. Some composites are further colorable and can be finished to have most any desired texture.
[0003] The increased use in automobiles includes, for instance, in instrument and door panels, lamps, air ducts, steering wheels, upholstery, truck beds or other vehicle storage compartments, upholstery, external parts, and even engine components. Regarding engine components, and other under-the-hood (or, UTH) applications, for instance, polymers are configured, and being developed continuously, that can withstand a hot and/or chemically aggressive environment. Regarding external parts, such as fenders, polymers are being developed that are online paintability and have high heat and chemical resistance over longer periods of time. And many other potential usages in automotive applications are being considered continuously.
[0004] With the increased use of polymers and other low-mass materials, compression molding and post-mold joining techniques—e.g., ultrasonic welding—are also being used more commonly.
[0005] Because some materials being used increasingly, including polymer composites, have relatively low melting points, a challenge arises in efforts to melt the parts at an interface joining the parts quickly and with minimal melting of other portions of the workpieces.
[0006] Energy directors are sometimes used to expedite and control welding. Multiple challenges arise. One is that because the energy directors are usually not visible at the time for welding, it is difficult for the welder, attempting to focus welding at the director, to determine exactly where that is. The directors currently cannot be located with accuracy, or are located—i.e., manually, by eye and hand—with much additional work and time.
[0007] The increased time and energy requirements are cost prohibitive, especially when multiplied by repeated iterations processing in a manufacturing environment—e.g., automobile assembly plant.
SUMMARY
[0008] The present technology relates to systems and methods for improved ultrasonic welding using an algorithm for locating, automatically, energy-directing devices during the welding.
[0009] The algorithm outlines a sub-process by which locations of energy-directing devices, or energy directors, are identified. The locations are determined based on a displacement traveled by the welding horn, being controlled to move in a pre-determined manner toward the workpieces between which the device sits, to a point at which the horn is opposed by a threshold return force from the proximate workpiece.
[0010] Other aspects of the present invention will be in part apparent and in part pointed out hereinafter.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates a two-sided ultrasound system.
[0012] FIG. 2 illustrates an example multi-height energy director, according to an embodiment of the present technology.
[0013] FIG. 3 illustrates a leg, or protrusion, of the multi-height energy director of FIG. 2 .
[0014] FIG. 4 illustrates a method for locating an energy director, such as the multi-height energy director of FIG. 2 , positioned between workpieces to be welded together, and performing the welding to join the pieces.
[0015] FIG. 5 illustrates a side view of the multi-height energy director of FIG. 2 positioned between the workpieces.
[0016] FIG. 6 illustrates welding-tool positions occasioned in locating the workpiece according to example scenarios.
[0017] FIG. 7 shows a graph comparing welding-tool displacement in an application direction (e.g., vertical) an orthogonal tool position (e.g., lateral location over the workpiece).
[0018] FIG. 8 illustrates the multi-height energy director of FIG. 2 at an interim stage of welding, before a second level of the director contacts the second workpiece.
[0019] FIG. 9 illustrates the multi-height energy director of FIG. 2 at a subsequent interim stage of welding, at which the second level of the director first contacts the second workpiece.
[0020] FIG. 10 illustrates an example weld formed using the energy director of FIG. 2 .
[0021] FIG. 11 illustrates an example controller, for use in performing operations of the method of FIG. 4 .
DETAILED DESCRIPTION
[0022] As required, detailed embodiments of the present disclosure are disclosed herein. The disclosed embodiments are merely examples that may be embodied in various and alternative forms, and combinations thereof. As used herein, for example, exemplary, and similar terms, refer expansively to embodiments that serve as an illustration, specimen, model or pattern.
[0023] The figures are not necessarily to scale and some features may be exaggerated or minimized, such as to show details of particular components. In some instances, well-known components, systems, materials or methods have not been described in detail in order to avoid obscuring the present disclosure. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the technology foci (e.g., claims), listed below, and as a representative basis for teaching one skilled in the art to variously employ the present disclosure.
[0024] While the description includes a general context of computer-executable instructions, the present disclosure can also be implemented in combination with other program modules and/or as a combination of hardware and software. The term application, or variants thereof, is used expansively herein to include routines, program modules, programs, components, data structures, algorithms, and the like. Applications can be implemented on various system configurations, including single-processor or multiprocessor systems, microprocessor-based electronics, combinations thereof, and the like.
I. GENERAL OVERVIEW OF THE DISCLOSURE
[0025] The present disclosure describes an ultrasonic welding technique for joining workpieces, such as polymeric composites.
[0026] One aspect of the disclosure relates to systems and methods for improved ultrasonic welding. The system includes an algorithm (e.g., computer-readable code) configured for controlling apparatus elements for locating the multi-height energy-directing device for welding at the identified location. The location is determined based on a displacement traveled by a welding head, tip, or horn, such as an ultrasound servo horn, being controlled to move in a pre-determined manner toward the workpieces between which the device sits, to a point at which the horn is opposed by a threshold return force from the proximate workpiece.
[0027] More specifically, the welding tool is lowered onto a proximate workpiece, of the two workpieces being joined, and between which the energy director sits.
[0028] As the welding horn is controlled to lower onto the workpiece, a controller receives feedback indicating force, or resistance, countering the downward motion. According to the algorithm, e.g., computer-executable instructions, the controller determines, based on a distance traveled by the horn prior to the horn being opposed by a predetermined threshold force.
[0029] If the distance traveled indicates that the horn is not directly over a location of the workpiece having the energy directory directly below, the controller controls the welding horn to move to another location, preferably closer to the director center, based on the last measurements, and the descending and measuring are re-performed at the new position.
[0030] If the distance traveled indicates that the horn is directly over a location of the workpiece having the energy directory directly below, welding is performed. The welding is performed advantageously for many reasons related to the multi-height director configuration of the present technology.
[0031] The system components, algorithm, and operations are described further below with reference to FIGS. 1-9 .
II. PROCESS, SYSTEM TOOLING, AND WORKPIECES—FIGS. 1 - 11
[0032] The present technology is now described with reference to example systems, tooling, and workpieces. The figures are referenced to facilitate understanding of the technology, and not to limit scope thereof.
[0033] Reference to directions herein, such as upper, lower, up, down, and lateral, are provided to facilitate description of the present technology but does not limit scope of the technology. A description in which a servo horn is described as descending down upon a proximate workpiece is not limited, for example, to the horn moving vertically downward in the earth, or environment, frame. The horn in this case can be moving from left to right, for example, in the environment frame.
[0034] II.A. General Welding System— FIG. 1
[0035] Now turning to the figures, and more particularly, the first figure, FIG. 1 shows an example welding system, indicated generally by reference numeral 100 . The system 100 is used to weld together two workpieces 101 1 , 101 2 .
[0036] The system 100 includes a supporting, or under, structure 102 . The system also includes a welding arm 104 terminating in a welding energy application tip, or horn 106 . The horn can include, for instance, an ultrasonic servo horn, configured to apply energy, in the form of high-frequency vibrations, to the workpieces for welding them together.
[0037] The welding arm 104 extends from a second, or application-side, structure, or mass 108 .
[0038] In operation, an application-direction force 110 can be applied by and/or at the mass 108 . The force 110 pushes the arm 104 and horn 106 toward the workpieces 101 being welded together. A counterpart force 112 pushes the supporting structure 102 toward the workpieces. With the mass and application-direction force pushing toward the workpieces 101 from a first, application, direction, and the counter force 112 pushing toward the pieces 101 from an opposite direction, the workpieces 101 are kept at a desired compression during welding.
[0039] II.B. Multi-Height Energy-Directing Device— FIGS. 2 and 3
[0040] FIG. 2 shows an energy-directing device, or energy director 200 .
[0041] The energy director 200 can include any material described herein, including in connection with the workpieces.
[0042] In one embodiment, the energy director 200 is generally annular—e.g., has a generally annular, or ring-like, plan-view (e.g., top) profile. With reference to the figure, an upper portion of the annular configuration is identified by reference numeral 202 .
[0043] Importantly, it has been found that an annular weld can be as strong as continuous welds (i.e., welds not having a central void)—in one present finding, this is especially true when a ratio of an internal diameter to an external diameter is less than about 0.6. More specifically, under an applied tensile load, a predominant amount of the holding force created by a solid or continuous weld is provided by an outer annual portion of the weld, with a central portion of the weld contributing little holding force in comparison. A weld lacking the central portion, thus, can be formed with less energy than a continuous weld (one lacking a central void), and perhaps less time, without sacrificing joint strength.
[0044] While the energy director 206 , whether annular or other shape, can have other widths 208 without departing from the scope of the present technology, in one embodiment each director has a width 208 (e.g., diameter, or maximum width) between about 3 mm and about 20 mm. In one embodiment, the width 208 can be smaller, such as down to about 1 mm, and still possibly up to about 20 mm.
[0045] The upper portion 202 defines a central hole, or void 204 . While the void 204 , whether circular, oval, rectangular, or other, can have other internal widths 210 without departing from the scope of the present technology, in one embodiment each director 200 has one or more internal widths 210 between about 1.5 mm and about 12 mm. In one embodiment, the internal width 208 can be smaller, such as down to about 0.6 mm, and still possibly up to about 12 mm, for instance.
[0046] While the illustrated director 200 has a generally annular plan, or top, profile shape, the director can have other plan profile shapes. Other example shapes include oval, square, or other rectangular shapes, with a central void.
[0047] The energy director 200 includes a plurality of energy-director (ED) elements 206 . The elements may be referred to by other names such as a height-control ED element, protrusion, or ridge, or an elevation-control element, protrusion, or ridge.
[0048] The ED elements 206 extend, or protrude (e.g., protrude downward), from the upper portion 202 of the director 200 , such as shown in FIG. 2 . In one embodiment, the ED 200 is formed during compression molding of one of the workpieces (e.g., proximate workpiece 101 1 ), and so is a contiguous part of that workpiece.
[0049] While the ED element 206 can have other shapes, in the illustrated embodiment, each director has a generally triangular side profile. Other example shapes include square, otherwise rectangular, or rounded—e.g., semi-circle or ovular.
[0050] In the illustrated embodiment, each ED element 206 includes an upper, or first, side, or base, connecting to the upper portion 202 of the element 206 . In the embodiment in which the ED 200 is formed during compression molding of one of the workpieces (e.g., proximate workpiece 101 1 ), and so is a contiguous part of that workpiece, the upper portion 202 of the element 206 includes the workpiece 101 1 . The sides extend from the base to a point opposite the upper portion 202 .
[0051] Importantly, the ED elements 206 do not all have the same characteristics. In one embodiment, at least one characteristic differing amongst at least some of the ED elements 206 is a height 212 of the elements. Benefits of this feature are described further below in connection with the welding sub-process of the method 400 of FIG. 4 .
[0052] Generally, the benefits relate to an advantageous channeling of welding energy—e.g., ultrasonic vibrations—through primary ED elements initially, while passing less or not at all through secondary ED elements, in an early stage of welding, and through the secondary elements, while passing less or not at all through the primary ED elements in a subsequent stage of the welding.
[0053] FIG. 3 shows a side view of any of the ED elements 206 of FIG. 2 . Along with the height 212 indicated in FIG. 2 , FIG. 3 shows that the ED elements 206 can be defined by other features, such as width 302 .
[0054] While the ED elements 206 can have other widths 302 without departing from the scope of the present technology, in one embodiment each ED element 206 has a width 302 between about 1.0 mm and about 4.0 mm. In one embodiment, the width 302 can be smaller, such as down to about 0.2 mm, and still possibly up to about 4.0 mm.
[0055] Continuing with the triangular embodiment of FIGS. 2 and 3 , FIG. 3 shows a vertical side length 304 as another size characteristic of the ED director.
[0056] In one embodiment, a ratio of the height 212 to the width 302 (H/W) is between about 0.3 and about 1.0.
[0057] In one embodiment, each primary element 206 1 of the elements 206 has a height of between about 0.5 mm and about 6.0 mm, and each secondary element 206 2 has a height between about 0.4 mm and about 4.0 mm.
[0058] The ED elements 206 can have any appropriate thickness, and, related, any desired three-dimensional shape, and each element can have any desired size—e.g., thickness or thicknesses. The elements 206 can have a generally pyramid shape. For ED elements having rounded sides, the three-dimensional shape can be prismatic (e.g., rectangular or triangular prism), cylindrical, conical, frustoconical, pyramid (e.g., triangle pyramid, or tetrahedron), partial sphere (e.g., semi-sphere, demi-sphere, or hemisphere), etc. ED elements 206 can have straight and/or curbed sides.
[0059] As mentioned, the ED elements 206 do not all have the same characteristics. In a contemplated embodiment, along with or instead of varying heights, not every one of the ED elements 206 on a single energy director 200 has the same shape. Again, as with varying heights, benefits of varying the shape amongst the ED elements 206 are described further below in connection with the welding sub-process of the method 400 of FIG. 4 . And again, generally, the benefits relate to an advantageous channeling of welding energy—e.g., ultrasonic vibrations—through primary ED elements initially, while passing less or not at all through secondary ED elements, in an early stage of welding, and through the secondary elements, while passing less or not at all through the primary ED elements in a subsequent stage of the welding.
[0060] II.C. Algorithm and Method of Operation— FIGS. 4-11
[0061] Now turning to the fourth figure, FIG. 4 shows an exemplary algorithm, by way of a flow chart 400 , defining a method for (a) locating an energy director, such as the energy director 200 of FIG. 2 , and (b) welding workpieces together by applying welding energy to a proximate workpiece at the identified location so that it channels through, and melts, the novel energy director as desired. The result is effective and efficient welding, and a more accurate and robust weld formed with less overall cycle time, energy, and energy-director material as compared to traditional techniques.
[0062] In some embodiments, the algorithm controls only some aspects of the method, such as the sub-process associated in FIG. 4 with reference numeral 406 . In another, it controls operations 406 and 408 , and in another operations 404 , 406 , 408 , and 410 , for example. The operations are described further below, in turn.
[0063] While joining two workpieces is described primarily herein, the number is presented as an example, and more than two pieces may be joined according to the teachings of the present disclosure.
[0064] It should be understood that the steps of the method 400 are not necessarily presented in any particular order and that performance of some or all the steps in an alternative order is possible and is contemplated. The steps have been presented in the demonstrated order for ease of description and illustration. Steps can be added, omitted and/or performed simultaneously without departing from the scope of the appended claims. And it should also be understood that the illustrated method 400 can be ended at any time.
[0065] In certain embodiments, some or all steps of this process, and/or substantially equivalent steps are performed by, or at least initiated by a computing device, such as a processor executing computer-executable instructions stored or included at a computer-readable medium. And any one or more steps of the process can be performed, initiated, or otherwise facilitated by automated machinery, such as robotics.
[0066] The method 400 outlined by the flow chart of FIG. 4 is described now with additional reference to the tools and components of FIGS. 5-10 . Characteristics of the elements shown, e.g., shape, size, and number, are presented to facilitate the present description and not to limit scope of the present technology.
[0067] The method 400 begins 401 and flow proceeds to block 402 , whereat an energy director, such as the director 206 shown in FIG. 2 , is positioned between the workpieces. FIG. 5 shows an example positioning of the energy director between adjacent workpieces.
[0068] In a contemplated embodiment, the energy director is formed in a sub-process of molding at least one of the workpieces. For instance, a mold in which the first workpiece is compression molded can include recesses and/or protrusions configured (e.g., sized and shaped) to form the energy director at a desired location of the workpiece.
[0069] As provided, the workpieces being welded together can be similar or dissimilar. Regarding dissimilar workpiece materials, one workpiece can be a plastic or other polymer, for instance, and the other can be steel, aluminum, an alloy, or other metal, etc. Thus, the teachings of the present disclosure can be used to join a polymer (e.g., polymer composite) to another polymer, or to join a polymer to a metal, for instance.
[0070] In one embodiment, the material includes polyethylene. In one embodiment, the material includes polyethylene terephthalate (PET), high density polyethylene (HDPE) and/or ethylene vinyl alcohol (EVOH).
[0071] In one embodiment, at least one of the workpieces being joined includes a polymer. At least one of the workpieces can include synthetic, or inorganic, molecules. While use of so-called biopolymers (or, green polymers) is increasing, petroleum based polymers are still much more common.
[0072] Material of one or both workpieces may also include recycled material, such as a polybutylene terephthalate (PBT) polymer, which is about eighty-five percent post-consumer polyethylene terephthalate (PET).
[0073] In one embodiment one or both of the workpieces includes some sort of plastic. In one embodiment, the material includes a thermo-plastic.
[0074] In one embodiment one or both of the workpieces includes a composite. For example, in one embodiment one or both of the workpieces includes a fiber-reinforced polymer (FRP) composite, such as a carbon-fiber-reinforced polymer (CFRP), or a glass-fiber-reinforced polymer (GFRP). The composite may be a fiberglass composite, for instance. In one embodiment, the FRP composite is a hybrid plastic-metal composite.
[0075] The material in some implementations includes a polyamide-grade polymer, which can be referred to generally as a polyamide.
[0076] Material of one or both workpieces may also include includes polyvinyl chloride (PVC).
[0077] In one embodiment, the material includes acrylonitrile-butadiene-styrene (ABS).
[0078] In one embodiment, the material includes a polycarbonate (PC).
[0079] Material of one or both workpieces may also comprise a type of resin. Example resins include a fiberglass polypropylene (PP) resin, a PC/PBT resin, and a PC/ABS resin.
[0080] The workpieces may be pre-processed, such as heated and compression molded prior to the welding.
[0081] In most manufacturing processes, more than one weld will made to connect two adjacent workpieces. The positioning of step 402 can thus include positioning multiple energy devices between the workpieces.
[0082] With continued reference to FIG. 4 , with the energy director(s) positioned between the workpieces, flow proceeds to step 404 whereat the arrangement is positioned adjacent the weld system. This operation can include moving the workpiece/ED arrangement toward the welding system, and or moving aspects or an entirety of the welding system toward the arrangement.
[0083] The initial, coarse, positioning of step 404 can include positioning an ultrasonic horn of the system close to an estimated or believed location of the energy director to be used in the first weld.
[0084] Flow proceeds to the fine energy-director locating sub-process, or routine 406 . As shown in FIG. 4 , the locating routine 406 includes multiple sub-steps, distinguished by superscripts—i.e., 406 1-5 . From step 404 , the method turns particularly to the first routine step 406 1 whereat the welding head, or horn (e.g., ultrasonic servo horn, like the sonotrode tip of the example of FIG. 1 ) is lowered. The horn is lowered toward the proximate workpiece—i.e., the workpiece closest to the horn, such as in FIGS. 1 and 5 .
[0085] The descending is illustrated in FIG. 6 . The coarse positioning of step 404 does not usually position the horn directly over the energy director. Instead the horn usually ends up initially positioned only partially over the energy director, as indicated by path 604 in FIG. 6 , or not over the director at all, as indicated by path 602 in FIG. 6 . The target path is the third 606 , which is reached by one or more iterations of the routine 406 1-5 , as further described below.
[0086] The descending operation 406 1 is performed under the operation of a controller connected directly or indirectly to the welding horn. Features of an example controller is shown in FIG. 11 , and described further below. The controller controls, e.g., a rate at which the horn is lowered toward the proximate workpiece. The controller can, for instance, control or be a part of a robotic apparatus, or robot, controlling movement of the welding horn.
[0087] At the next step 406 2 of the routine 406 , the controller determines whether a push-back force being received at the weld horn from the workpiece, indicates that the horn has been lowered to a local terminal point. The controller determines this based on feedback (e.g., from a load cell) indicating a force, exerted by the workpiece 101 1 , on the welding horn. The control receives the force indications from a sensor (not shown in detail) that may be part of, or connected to, the welding system, or part of, or connected to, automated robotic apparatus controlling movement of the welding horn.
[0088] If it is determined at step 406 2 that the horn has not reached its local terminal point, then flow of the algorithm returns back to the first routine step 406 1 , as shown in FIG. 4 . This will occur, for instance, while the horn is being lowered and had not yet contacted the workpiece. It will also occur when the horn has contacted the workpiece but not been lowered enough to receive a sufficient amount of push-back force from the workpiece.
[0089] When it is determined at step 406 2 that the horn has reached its local terminal point, then flow of the algorithm proceeds to step 406 3 , whereat the controller determines a displacement that the horn traveled in order to reach the point, or otherwise determines a location of the terminal point—e.g., a vertical distance from any reference frame. The displacement can be determined by, e.g., an encoder connected directly or indirectly to the horn. In one embodiment, the system is configured to take horn displacement measurements continually, at short intervals, or otherwise quickly as the horn descends. The system is further configured to compare the regular displacement values determined with a target displacement value continuously or at short regular intervals or otherwise quickly as the horn descends.
[0090] At step 406 4 , the controller determines whether the displacement, or vertical position, of the horn corresponding to the local terminal point is indicative of the horn having been lowered to a target location of the workpiece arrangement—i.e., the location of the arrangement having the energy director between the workpieces and directly, fully, below the welding horn.
[0091] The controller is programmed, or calibrated, with data identifying values, or ranges, of horn displacements, or positions, corresponding to expected, or likely, positions of the horn with respect to the target location of the workpiece arrangement. The data indicates, for instance, that the horn will be at a predetermined vertical position, within an error window, or range, when the horn has contacted the target position, because the horn will be opposed by the threshold force earlier.
[0092] This is because the workpiece arrangement is thicker where the energy director is, or at least the top workpiece will not give as much to the horn when the energy director is there. When the horn pushes on a location of the workpiece that is not over the energy director, the horn is able to push down farther on the workpiece before the horn finally experiences the threshold push-back force. The data indicates, based on the horn displacement to the threshold force, where the horn is—e.g., over or not over the energy director, can be generated in lab testing, for instance. The data can also provide an indication, based on the horn displacement to the threshold force, of how far the horn is from the energy director.
[0093] This concept is described further with reference to FIGS. 6 and 7 .
[0094] As referenced, FIG. 6 shows three example paths 602 , 604 , 606 . At a first lateral position over the proximate workpiece 101 1 , the horn descends along the first example path 602 . Because the energy director 200 is nowhere near a line of the path 602 , when the horn contacts the workpiece 101 1 , the workpiece, not being restricted by any energy director, there, will give, or displace more than it would if the director were there. The horn is thus able to move farther downward before the predetermined threshold force, from the workpiece 101 1 , opposes the horn's downward movement.
[0095] FIG. 7 is a graphical representation corresponding to the three paths shown in FIG. 6 . More particularly, FIG. 7 shows a graph 700 having an y-axis 702 representing welding horn displacement and an x-axis 704 indicating horn lateral, or orthogonal, position. The first bar 706 corresponds to the first path 602 of FIG. 6 . Accordingly, the displacement is very high because the path 602 is not over, and not relatively near to, the energy director 200 in FIG. 6 .
[0096] The second bar 708 in FIG. 7 corresponds to the second path 604 of FIG. 6 . Accordingly, the displacement is lower, but still not as low as it should be because the path 606 is still not directly and completely over the energy director 200 . In some embodiments, the energy director is not rigid, and rather has some flexibility. The horn thus is opposed by less force when lowered on a portion of the workpiece 101 1 that is not completely over the energy director (e.g., the second path 604 ), because less of the director is acting to resist the downward movement of the horn. When the horn is lowered directly over the horn (e.g., the third path 606 ), more (i.e., all) of the energy director is beneath the workpiece where the horn is lowered, and so more of the director opposes the downward movement of the horn, and the workpiece thus displaces less before experiencing the threshold feed-back force.
[0097] The third bar 710 in FIG. 7 corresponds to the third path 606 of FIG. 6 . Accordingly, the displacement is relatively low because the path 606 is directly over the energy director 200 , which limits the horn from descending further.
[0098] With continued reference to FIG. 4 , assuming the welding horn is, in a first iteration of the routine 406 , at a first lateral position corresponding to the first path 602 , then at step 406 3 , the controller would determine that the horn has displaced a relatively-large amount to reach the termination point—e.g., the first relatively-large displacement 706 .
[0099] At the next step 406 4 , the controller determines whether the displacement (e.g., displacement 706 corresponding to the first path 602 ) indicates that that horn is directly over the energy director. Because the displacement is relatively high in this first iteration (e.g., displacement 706 ), the controller, based on the pre-programmed data (e.g., from previous lab testing) concludes that the horn is not directly over the director. Thus, from the decision 406 4 , flow of the algorithm continues to step 406 5 whereat the controller determines a next lateral location to move the horn to for a next descent and measuring.
[0100] Determining, in step 406 5 , where the horn should be moved for the next horn drop, in one embodiment includes consideration of the displacement determined in the last step 406 4 . For instance, if the last displacement (e.g., displacement 706 ) is very high, then the lateral distance to move the horn for the next drop would be greater. If the last displacement is low—e.g., very close to what it would be if the horn was directly over the energy director, then the later distance, to move the horn for the net drop, would be much less.
[0101] Following repositioning of the horn at step 406 5 , steps 406 1 to 406 5 are repeated.
[0102] Once the iteration results at step 406 4 with a horn displacement at or below a threshold, or target displacement, then the controller concludes that the horn has been lowered directly over the energy director. With reference to FIGS. 6 and 7 , for instance, when the horn is lowered along the third path 606 of FIG. 6 , the horn will only travel a minimal displacement 710 , being below a threshold displacement 712 also indicated in FIG. 7 . The displacement values at or below the threshold displacement 712 can be referred to as a displacement tolerance range.
[0103] In response to determining, at 406 4 that the horn moved only a target displacement (e.g., 710 ) to reach the threshold push-back force, and so that the horn was lowered onto the workpiece 101 1 directly over the workpiece, then flow of the algorithm proceeds from the energy-director-locating routine 406 to welding step 408 .
[0104] At step 408 , welding energy is applied from the to the proximate work piece 101 1 at the determined location, directly above the energy director. For ultrasonic welding, the energy includes high-frequency ultrasonic vibrations excited and passing from the welding horn.
[0105] As described above, the energy director is designed so that the welding energy passes initially more or completely through some of the energy-director (ED) elements ( 206 ) than others. For instance, in the multi-height embodiments, the energy would pass through the taller ED elements 206 1 initially, and not through the shorter elements 206 2 , because the taller elements contact the distal workpiece 101 2 creating a path between the workpieces 101 1 , 101 2 . The energy would not flow freely through the shorter ED elements at this point because the shorter elements do not touch the distal piece 101 2 , and so there is not path through the shorter elements to the distal piece 101 2 for the energy.
[0106] With the welding energy passing through the taller ED elements 101 1 , the taller elements are melted first, as well as the workpieces adjacent the taller elements. This stage is shown in FIG. 8 .
[0107] Regarding the welding operation, more particularly, for ultrasonic welding, heat is generated from intermolecular friction at and between the energy directors and the workpieces where the welding energy (e.g., HF vibrations) are passing. The heat causes the director and workpieces to melt, creating the joining weld.
[0108] The arrangement is under some compression, at least due to the weight of the proximate workpiece 101 1 , and by downward force of the horn. In some embodiments, the horn is configured (e.g., spring loaded) and/or controlled to apply a downward force on the proximate piece 101 1 during welding. Thus, as the ED elements melt, the top workpiece 101 1 lowers.
[0109] After the taller elements are melted further, a subsequent stage, shown in FIG. 9 , is reached whereby the taller ED elements 206 1 have melted sufficiently for the shorter ED elements 206 2 to contact the distal workpiece 101 2 .
[0110] At this point, because the taller ED elements 206 1 have been at least partially melted, and the shorter ED elements 206 2 have not yet been melted and not contact the lower workpiece 101 2 , the shorter ED elements 206 2 now present a lower-resistance path for the welding energy (e.g., HF vibrations) than the taller ED elements 206 1 .
[0111] Thus, from the stage shown in FIG. 9 of the welding sub-process 408 , the welding energy channels mostly, or at least more, through the shorter elements, melting them and the workpieces 101 1 , 101 2 adjacent the shorter elements.
[0112] Upon solidification, the melted portions form weld nuggets between the workpieces, and these welds will hold the workpieces 101 1 , 101 2 together. For embodiments in which a generally annular energy director is used (e.g., the director 206 of FIG. 2 ), the resulting weld can be generally annular, likewise. An example weld is shown in FIG. 10 (the weld is shown without the workpieces 1011 , 101 2 that the weld holds together).
[0113] As provided, it has been found that an annular weld can be as strong as continuous welds (i.e., welds not having a central void). More specifically, a predominant amount of the holding force created by a solid or continuous weld is provided by an outer annual portion of the weld, with a central portion of the weld contributing little holding force in comparison. A weld lacking the central portion, thus, can be formed with less energy than a continuous weld (one lacking a central void), and perhaps less time, without sacrificing joint strength.
[0114] After a pre-set amount of time, application of welding energy is ceased, and the horn retrieved from the proximate workpiece 101 1 . The system is pre-programmed with the amount of time to apply the welding energy. The timing can be determined in lab testing, for instance.
[0115] With final reference to FIG. 4 , at step 410 , the controller determines whether there are any other welds to make. If so, then flow returns to step 404 whereat the horn is repositioned for locating a next energy director in the locating routine 406 . Once the next energy director is located, flow proceeds again to the welding operation 408 , and so on.
[0116] While two ED element heights are disclosed, in a contemplated embodiment, the energy director includes more than two heights, and so a corresponding number of welding stages greater than two.
[0117] As referenced above, instead of or along with height difference between ED elements 206 , the elements can have shape difference controlling where and when the welding energy is channeled, thereby controlling what parts of the energy director melt in a first stage and which in a second stage. While two ED shapes are presented as a primarily example, here, more than two ED shapes is possible, and so a corresponding number of welding stages.
[0118] While two primary welding stages are described—e.g., a first stage during which the taller ED elements 206 1 channel the weld energy and melt, and a second stage during which the shorter ED elements 206 2 channel the weld energy and melt. As referenced, while the energy transfers through the shorter element more in the second stage, energy may still transfer, to a lesser degree, through the taller elements since they are still intact between the workpieces 101 1 , 101 2 .
[0119] The present welding technique 408 results in the ED elements, tall and then short, melting progressively, at a desired time interval.
[0120] The technique 408 also allows use of less energy to perform the welding than would be required if the energy director was solid with no ED elements, or if every ED element was the same height and shape. For instance, if the energy director had ten (10) equal ED elements, energy sufficient to channel the energy through all ten elements simultaneously would be needed throughout one long, single stage. If the energy director, though, included five taller ED elements and five shorter ED elements, then in the first stage, only energy sufficient to channel the energy through the five taller elements is needed, that energy level being less than the energy level of the previous example in which the energy had to be channeled through all ten equal ED elements. In the second stage, generally, only energy sufficient to channel the energy through the five smaller elements is mostly needed, that energy level also being less than the energy level of the previous example in which the energy had to be channeled through all ten equal ED elements. In theory, further, a sum of the first-stage and second-stage energy application is less than the total energy that would be required for the arrangement having the ten identical ED elements.
[0121] II.D. Example Controller— FIG. 11
[0122] FIG. 11 illustrates schematically features of an example controller, such as computing device. The controller is indicated in FIG. 11 by reference numeral 1100 . As provided, the controller 1100 can control or be part of a robotic apparatus 1102 .
[0123] As shown, the controller 1100 includes a memory, or computer-readable medium 1104 , such as volatile medium, non-volatile medium, removable medium, and non-removable medium. The term computer-readable media and variants thereof, as used in the specification and claims, refer to tangible, non-transitory, storage media.
[0124] In some embodiments, storage media includes volatile and/or non-volatile, removable, and/or non-removable media, such as, for example, random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), solid state memory or other memory technology, CD ROM, DVD, BLU-RAY, or other optical disk storage, magnetic tape, magnetic disk storage or other magnetic storage devices.
[0125] The controller 1100 also includes a computer processor 1106 connected or connectable to the computer-readable medium 1104 by way of a communication link 1108 , such as a computer bus.
[0126] The computer-readable medium 1104 includes computer-executable instructions 1110 . The computer-executable instructions 1110 are executable by the processor 1106 to cause the processor, and thus the controller 1100 , to perform any combination of the functions described in the present disclosure. These functions are described, in part, above in connection with FIG. 4 , and supporting illustrations of FIGS. 1-3 and 5 - 10 .
[0127] In a contemplated embodiment, the controller is in communication with one or more remote devices 1112 . For instance, a central computer or service in the manufacturing plant can communicate with the controller 1100 , such as to provide instructions to and/or receive feedback (e.g., operations reports) from the controller 1100 .
[0128] The computer processor 1106 is also connected or connectable to at least one interface 1112 for facilitating communications, between the controller 1100 and any other local components 1114 , such as, for instance, sensor devices like the force sensors referenced above.
[0129] The interface 1112 can also be configured to facilitated communications with any remote device 1116 .
[0130] For communicating with the local components 1114 , the interface 1112 can include one or both of wired connections and wireless components—e.g., transceiver, transmitter, and/or receiver.
[0131] For communicating with the remote components 1116 , the interface 1112 includes one or both of a short-range transceiver (or transmitter and/or receiver) and a long-range transceiver (or transmitter and/or receiver).
[0132] The remote components 1116 can include databases, servers, other processors, other storage mediums, and/or other computing devices, such as other systems in a manufacturing plant communicating instructions to and/or receiving data from (e.g., performance reports) the controller 1100 .
[0133] Although shown as being a part of the controller 1100 , completely, the interface 1112 , or any aspect(s) thereof, can be partially or completely a part of the controller 1100 . The interface 1112 , or any aspect(s) thereof, can be partially or completely external to and connected or connectable to the controller 1100 .
III. ADVANTAGES OF IMPLEMENTATION
[0134] A benefit of the present technology is energy savings, as less energy is needed to locate the energy directors.
[0135] Time is also saved, as less time is used locating energy directors.
[0136] Such efficient, effective, and robust processes of the welding process support increased use of polymeric components needing to be joined to similar materials (e.g., polymeric composite/polymeric composite connection) or dissimilar materials (e.g., a polymeric/metal connection, etc.). Related benefits of using such materials, including weight reduction, performance enhancements, and corrosion resistance follow.
IV. CONCLUSION
[0137] The law does not require and it is economically prohibitive to illustrate and teach every possible embodiment of the present technology foci (e.g., claims). Hence, the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the disclosure. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the technology foci (e.g., claims). All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following technology foci (e.g., claims).
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A process, for locating a welding energy director, for effective welding together of multiple workpieces at an area of the director. The director includes positioning a workpiece arrangement in preparation to make approaches, for locating the director, wherein the workpiece arrangement includes a proximate workpiece of the multiple workpieces, a distal workpiece, and the welding director positioned therebetween. The process also includes performing a sub-routine comprising moving a locating implement toward the proximate workpiece. The routine also includes determining whether a push-back force, being received at the locating implement from the workpiece, indicates that the locating implement has been lowered to a local terminal point. The routine includes relocating, in response to a negative result, the implement for repeating until a positive result, and determining, in response to the positive results in the location determination, that the director is located directly beneath an area corresponding to the positive result.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to the field of electron beam tubes and more particularly to an electron gun header having an adjustable perveance that enables the cathode flux to be adjusted and optimized for improved beam focusing.
2. Description of Related Art
Electron guns are well known and used in standard travelling wave tubes (TWTs), mini-TWTs, klystrons, linear accelerators, and other radio-frequency (RF) electron devices. Such devices typically cause an electron beam originating from an electron gun to propagate through an evacuated tunnel or drift tube that includes an RF interaction structure. The electron beam must be focused by magnetic or electrostatic fields, or both, within the device to minimize beam loss by collision with the walls of the device itself. For example, a TWT operates as a broad-band microwave amplifier that relies on the interaction of a propagating RF wave with the propagating electron beam. In such a tube, the focused electron beam propagates with a velocity slightly faster than that of the RF wave such that the electrons may lose kinetic energy to the wave, thus amplifying its power. Controlling the focusing and propagation of the electron beam is thus important to the performance of the TWT.
In a device such as a TWT, the electron beam is formed by an electron gun, which typically comprises an electron-emitting cathode and an anode. The cathode is typically heated to enable thermionic electron emission. When the anode is raised to a potential that is positive with respect to the cathode, the electrons begin to flow as a beam. The geometry of the anode, the cathode, and other focusing electrodes create electromagnetic fields that define the path of the electron beam. In a Pierce gun configuration, the electron beam passes through an opening in the anode to enter the main body of the electron device. In other configurations, a grid is positioned in front of the cathode and affixed to the electrically isolated focus electrode. When the grid is pulsed to a potential sufficiently negative with respect to the cathode, it cuts off the electron current flow and can be used to create a modulated or pulsed electron beam.
Many electron guns are designed to exhibit a high perveance, which is defined as the ratio of the space-charge-limited beam current to the gun cathode-to-anode voltage raised to the three halves power. A higher perveance thus indicates that the emitted electron beam is more heavily influenced by space-charge effects. In such a system, the voltage that must be applied to the focus electrode in order to completely cut off the beam current becomes very large. It would thus be beneficial to implement the gun header using a stacked ceramic structure that can support the various elements of the electron gun and also provide a high voltage standoff to support the high voltages necessary to sustain operation at a high perveance. It would also be beneficial to mechanically adjust the perveance of the electron gun and optimize the magnetic flux at the cathode to achieve improved beam focusing.
SUMMARY OF THE INVENTION
The invention is directed to an electron gun header having an adjustable perveance. In one embodiment of a gun header in accordance with the present invention, a novel vacuum enclosure comprises a stacked ceramic structure to support the structural elements of the electron gun and further to provide a high-voltage standoff to enable operation at voltages substantially higher than those of standard mini-TWT pin-type gun headers. In addition, the gun header includes a bellows assembly and other non-magnetic and magnetic elements that enable the cathode flux to be adjusted and optimized for improved beam focusing and electron gun performance.
In one embodiment of a gun header assembly in accordance with the present invention, the gap between the cathode and anode of the electron gun is configured to be mechanically adjustable by the bellows assembly in order to vary the perveance. In addition, magnetic field adjustment in the electron gun region can be accomplished using magnetic elements that are not affixed to the main body of the electron tube. A feature of certain embodiments of the present invention is that during the perveance adjustment process, no magnetic parts are bent or deflected. It is well known in the art that bending magnetic parts can cause work hardening of the material that reduces its ability to support the levels of flux intensity required for good and reliable beam focusing. The perveance adjustment process associated with certain embodiments of the present invention preserves axial alignment between gun elements and maintains azimuthal uniformity of the magnetic field in order to provide excellent beam focusing.
In a first embodiment in accordance with the present invention, an electron gun assembly comprises (1) a gun header assembly that includes a cathode adapted to emit an electron beam, wherein the cathode is coupled to a cathode lead connection permitting a cathode voltage bias to be applied to the cathode; a focus electrode fixed in position adjacent to the cathode but electrically isolated from the cathode, wherein the focus electrode is further coupled to a focus electrode lead connection permitting a focus electrode voltage bias to be applied to the focus electrode; and a plurality of ceramic isolating rings fixed in position such that at least one of the plurality of ceramic isolating rings provides electrical isolation between the cathode lead connection and the focus electrode lead connection; and (2) an input body assembly including an anode configured to be adjustably held in place with respect to and in proximity to the cathode and further configured such that an anode voltage potential can be applied to the anode; and a magnetic gun polepiece fixed with respect to the anode but adjustably held in place with respect to the cathode; wherein the input body assembly and the gun header assembly are mechanically coupled using a flexible bellows that enables the input body to be translated axially with respect to the gun header assembly such that a distance between the anode and the cathode and a distance between the magnetic gun polepiece and the cathode can be adjusted.
In a preferred embodiment in accordance with the present invention, the flexible bellows is made of a material that is nonmagnetic. In another embodiment in accordance with the present invention, the anode is configured to have a geometry that is substantially ring-shaped, such that the anode includes a central void through which the electron beam can propagate. Such a configuration is known in the art as a Pierce gun configuration.
In some embodiments in accordance with the present invention, the cathode is coupled to a cathode heater assembly such that the cathode can be heated to enable thermionic emission. However, a cold-cathode configuration may also be employed and would fall within the scope and spirit of the present invention.
In some embodiments in accordance with the present invention, a grid is positioned in front of the cathode and affixed to the electrically isolated focus electrode. In the case of a negative grid gun, the grid may range from a few volts negative with respect to cathode to a potential sufficiently negative with respect to cathode to suppress all emitted current. In the case of an intercepting gridded gun, a similar grid may be pulsed from level of a few hundred volts positive, enabling current flow, to a level a few hundred volts negative, cutting off all current flow. Other arrangements of grids such as shadow grids and tetrode grids may also be employed and would fall within the scope and spirit of the present invention.
In some embodiments of an electron gun in accordance with the present invention, the input body further includes a plurality of magnetic polepieces separated by nonmagnetic spacers to form a drift region for the electron beam. The electron gun may also be configured such that the plurality of ceramic isolating rings in the gun header assembly are made from an alumina ceramic material.
Further, in some embodiments of an electron gun in accordance with the present invention, the electron gun is surrounded by a nonmagnetic gun shield having a substantially cylindrical shape, such that it substantially encloses the gun header assembly. The electron gun may further include a magnetic flux adjustment shield having a substantially cylindrical shape and located outside of the nonmagnetic gun shield. The magnetic flux adjustment shield is configured such that it can be translated in an axial direction, causing an adjustment of the magnetic field within the gun header region. The adjustment of the magnetic field serves to optimize the cathode flux and electron beam focus. Further, the adjustment of the flexible bellows to alter the distance between the cathode and anode serves to adjust the perveance of the gun assembly.
Those skilled in the art will realize other embodiments and applications of the techniques and structures disclosed, and such will also fall within the scope and spirit of the present invention. The invention is described in detail below with reference to the attached sheets of drawings that are first described briefly. In the drawings, reference designators that appear in more than one drawing refer to corresponding physical structures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross section of an electron gun assembly in accordance with an embodiment of the present invention;
FIG. 2 is cross section of an input section of an electron gun in accordance with an embodiment of the present invention;
FIG. 3 is a three-dimensional drawing of an electron gun and perveance setting fixture in accordance with an embodiment of the present invention;
FIG. 4 is a plot of a DEMEOS electrical simulation of an embodiment of an electron gun in accordance with an embodiment of the present invention;
FIG. 5 is a plot of the beam filling factor and the tunnel emittance as a function of z-distance along the axis of the electron gun simulation depicted in FIG. 4 ;
FIG. 6 is a DEMEOS simulation plot of an embodiment of an electron gun in accordance with an embodiment of the present invention showing normal beam focusing;
FIG. 7 is a DEMEOS simulation plot of an embodiment of an electron gun in accordance with an embodiment of the present invention showing the effect of negative focus electrode voltage on the electron beam; and
FIG. 8 is a DEMEOS simulation plot of an embodiment of an electron gun in accordance with an embodiment of the present invention illustrating negative grid cutoff.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is directed to an electron gun header having an adjustable perveance. FIG. 1 is an axial cross section depicting features of an embodiment of an electron gun in accordance with the present invention. Centerline 130 represents the axis of symmetry. The cathode 102 includes a potted heater assembly 112 . One leg of the heater in assembly 112 is connected to the cathode head 102 and the other leg is electrically connected through lead 114 to ribbon 116 to rear flange 128 to cathode end cap 118 . The cathode end cap 118 includes a lead similar to 120 as shown in FIG. 3 as lead 310 . End cap 118 is sealed to flange 128 by weld joint 142 to produce a hermetic seal to support a vacuum in the gun region. The cathode 102 is mechanically supported near focus electrode 104 . The focus electrode 104 is electrically isolated from the cathode 102 and is coupled to the focus electrode lead 120 . The cathode 102 is electrically connected through metallic structures to a cathode flange lead similar to 120 (rotated in azimuth as shown in FIG. 3 as lead 320 ). Ceramic rings 110 provide mechanical support and also maintain isolation between the cathode 102 and the focus electrode 104 . In a preferred embodiment, the ceramic rings 110 comprise alumina ceramics, although other materials may also be used. Weld flange 108 is used to connect the gun assembly of FIG. 1 to the input body assembly depicted in FIG. 2 , discussed below. Ceramic ring 106 is interposed between the gun assembly of FIG. 1 and the rest of the input body depicted in FIG. 2 .
FIG. 2 is a cross section of an embodiment of an input section of an electron device in accordance with the present invention. Parts made from magnetic material such as soft iron are shown with dense crosshatching in FIGS. 1 and 2 . Referring to FIGS. 1 and 2 , nonmagnetic weld flange 108 is sealed to nonmagnetic ring 204 by weld joint 202 to produce a hermetic seal to support a vacuum in the gun and input section regions. A magnetic gun adjustment disk 206 is supported by nonmagnetic ring 204 and can be used to adjust the focus of the electron beam emitted by the cathode 102 . Magnetic gun polepiece 212 is situated in proximity to the focus electrode 104 , cathode 102 , and anode 214 . Translating the polepiece 212 axially toward or away from cathode 102 changes the focusing behavior of the electron beam. To enable axial movement of the polepiece and anode with respect to the cathode, a flexible bellows 208 is used to attach the magnetic gun adjustment disk 206 and a structural body adjustment disk 210 that is preferably made from a nonmagnetic material. It is preferred that the bellows 208 is made from a nonmagnetic material because it is known in the art that bending of magnetic parts can cause work hardening of the material, which reduces their ability to support sufficient magnetic flux densities to achieve good focusing. Adjusting the distance of the cathode 102 to the anode 214 by flexing the bellows 208 changes the beam current or gun perveance, where perveance is current divided by anode voltage to the 3/2 power. Additional magnetic polepieces 216 , spacers 218 , and ring magnets 230 form part a periodic permanent magnet (PPM) structure used to focus the electron beam downstream within the drift chamber. Although the embodiment depicted in FIGS. 1 and 2 includes a heated cathode, cold-cathode configurations are also possible, and the perveance-adjusting features of the present invention would apply in the same way to such a configuration.
The electron gun and input body structure depicted in FIGS. 1 and 2 , according to an embodiment of the present invention, thus enable the adjustment of the gun perveance and provide for optimized cathode flux and improved beam focusing. The stacked ceramic structure of the gun allows it to be operated at substantially higher voltages than standard electron gun headers. Adjustment of the spacing between the cathode 102 and anode 214 and magnetic gun polepiece 212 can be accomplished by a setting jig which captures the outer portion of the gun adjustment disk 206 and the outer portion of the structural body adjustment disk 210 . All parts of the setting jig including the screws are made from nonmagnetic materials. FIG. 3 shows such a setting jig comprised of a body clamp 370 and 371 and gun clamp 360 and 361 . The setting jig includes three push screws 370 and three pull screws 380 that enable the position of cathode 102 to be precisely set with respect to anode 214 . Additional magnetic polepieces, e.g., 216 , are interposed with non-magnetic spacer rings, e.g., 218 , along the drift tube. These, along with ring magnets 230 of alternating polarity (not shown in FIG. 3 ), comprise the PPM focusing structure.
Further, in accordance with an embodiment of the present invention, FIGS. 1 and 3 show a nonmagnetic gun shield 306 surrounded by a magnetic flux adjustment shield 304 . Moving the magnetic flux adjustment shield 304 axially along the gun shield 306 allows for further adjustment of the flux at the cathode for further optimization of the electron beam focusing properties.
FIG. 5 depicts the results of an electromagnetic simulation using the DEMEOS electron optics computer code. The geometry of an electron gun in accordance with an embodiment of the present invention is simulated to include a cathode 406 in proximity to a focus electrode 402 and an anode 404 . In this simulation, the cathode 406 is set at a potential of 0 V. Anode 404 is set to V 0 volts, and focus electrode 402 is set at a voltage of −0.00106 times V 0 , just slightly negative with respect to the cathode. A thermal or finite emittance electron beam model is used in the DEMEOS simulations and results of FIGS. 4 through 8 . Cathode-to-anode voltage, V 0 , ranges from 4 to 8 kV in these plots. However, voltages outside this range can also be applied. In actual guns, the reference for voltage is typically shifted so that the anode is at ground potential or 0 volts and the cathode is at minus V 0 .
In FIG. 4 , Voltage equipotential lines 410 illustrate the simulated electric potential within the gun region. Electrons are drawn from the cathode and are focused into a beam 408 by the electric field between the cathode and the anode and the applied magnetic field 412 . In FIG. 4 , the level of flux at the cathode has been adjusted by the apparatus and method described above to be 0.63 of the main PPM rms focusing field in accordance with the theory of the inventor. Note that in a PPM focusing system the flux at the cathode can be plus or minus since the value of the B field downstream is sinusoidal. In the case of FIG. 4 , flux density B at the cathode 406 is negative respect to the first magnetic peak. Further, the value of the first magnetic field peak can be adjusted to achieve an optimal match between the magnetic field at the cathode 406 and the magnetic field downstream. As a result of these adjustments, the focused beam is smooth and of extremely high quality. Note that these results are representative of a particular simulation of a gun header and input section in accordance with the present invention and are meant to be illustrative of gun performance and not limiting in any way.
FIG. 5 provides an additional illustration of the performance of the electron gun of FIG. 4 . FIG. 5 shows beam filling factor as a function of z distance along the gun axis. The beam filling factor is defined as the 95% beam radius divided by the inner radius of the tunnel through which the beam propagates 440 . In the case of microwave tubes, this tunnel radius is the inner radius of the RF interaction structure. In other words, this metric provides an indication of how well the focusing fields are keeping the electron beam away from the walls of the RF interaction structure. The tunnel emittance 504 is a further measure of beam quality. It is defined as the product of the beam filling factor and the standard deviation of the normalized transverse velocity distribution of the electron beam (parameter sigma). The value of tunnel emittance is quite low in comparison to other guns and beam focusing designs. Further, the model indicates that the emittance is not growing with distance downstream. This is a manifestation of flux at the cathode introduced by the apparatus and methods of this patent. These performance parameters have been achieved by one embodiment of an electron gun in accordance with the present invention. Again, FIG. 5 is meant to be illustrative of the performance achieved by a particular embodiment of an electron gun in accordance with the present invention and is not intended to be limiting.
FIG. 6 depicts an additional DEMEOS electromagnetic simulation of an electron gun header and input section in accordance with an embodiment of the present invention. The geometry of the electron gun and input section is simulated to include alumina ceramic insulators 610 , an electron-emitting cathode 602 , a focus electrode 604 , and an anode 606 . In this simulation, the cathode 602 is held at 0 V, the focus electrode 604 is set just slightly below the cathode potential at −0.00106 times V 0 , and the anode 606 is set to V 0 volts, drawing electrons from the cathode 602 . The resulting electric potential 608 within the gun focuses the electrons into a highly laminar beam 612 . Further inspection of this plot discloses low electrostatic field levels in this configuration resulting in reliable high voltage standoff. Note that the region between the alumna insulators 610 and the nonmagnetic gun shield 620 includes a rubberized potting material which may be Sylgard or other commercially available potting compound. The embodiment depicted in FIG. 7 also includes this potting material. In FIGS. 6 and 7 , the heater voltage is −6.3 volts below the potential of the cathode.
FIG. 7 depicts an additional DEMEOS simulation of the gun of FIG. 6 in which the cathode 702 held at a potential of 0 V and the anode 706 at a potential of V 0 volts. However, in this case, the focus electrode 704 has been switched to a potential of −0308 times V 0 , which changes the voltage potential 708 within the gun and partially cuts off the flow of electrons from the cathode. It can be seen that electron flow occurs below the 0 volt equipotential 718 and is completely suppressed above it. The intensity of the electron beam 712 is reduced in comparison to FIG. 6 and it can be seen that at least a portion of the beam impinges on the anode 706 . FIGS. 6 and 7 do not include any magnetic focusing field, which is why a portion of the emitted beam is striking the anode. Further, in the gun of FIG. 7 , if −0360 times V 0 is applied to focus electrode 704 , 100% of the cathode current is suppressed. As in FIG. 6 , this case illustrates that the electrostatic field levels are also low, resulting in reliable high-voltage standoff. Because the potential of the focus electrode is maximum, referenced to the nonmagnetic gun shield 720 , and the voltage across the gap between the focus electrode 704 and cathode 702 is higher than in the case of FIG. 6 , it is significant that the design possesses adequate design margin under these conditions.
FIG. 8 shows a DEMEOS simulation of a gun with a grid 820 affixed to focus electrode 804 and positioned in front of cathode 802 . When the grid is set to a negative potential with respect to the cathode and equal to the cut off voltage, all electron current from the cathode ceases to flow. The cutoff voltage in this case is −0.088 times V 0 , where V 0 is the applied anode voltage. It can be seen that the 0 volt equipotential 818 is everywhere in front of cathode 802 . Thus, the negative electrostatic fields in front of the cathode suppress all cathode current. In this particular embodiment of an electron gun in accordance with the present invention, the grid thus provides a structure and method of reducing the magnitude of negative voltage required to cut off all beam current.
In summary, a robust and high-performance electron gun and input section are disclosed that provide the ability to tune the gun perveance and cathode magnetic field in order to adjust the electron beam focus and device performance. This is accomplished by movement of the anode and magnetic polepiece with respect to the cathode by providing a flexible bellows section that seals the vacuum chamber while allowing for axial translation. Further adjustment of the cathode flux can be accomplished by adjustment of the value of the first magnetic field peak and the adjustment of an external magnetic flux shield. The disclosed configuration has the advantage that no magnetic parts need be bent or flexed in making adjustments to the perveance. This preserves the ability of the magnetic parts to handle large magnetic fluxes necessary for good focusing performance. While the principles and techniques of the present invention are disclosed herein with respect to particular embodiments of an electron gun header and input section, the invention is not limited to the particular configurations discussed. Those skilled in the art will appreciate other embodiments and applications of the novel techniques disclosed herein, and such would also fall within the scope and spirit of the present invention. The invention is further defined by the following claims.
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In an electron gun for use in a TWT, klystron, linear accelerator or other electron device, an electron gun header assembly and an input body assembly are coupled using a flexible bellows that allows the distance between the cathode and anode to be varied. As such, the perveance of the electron gun can be tuned, and the cathode magnetic field optimized for efficient operation. In addition, an external magnetic shield is adapted to be translated along the axial dimension of the electron gun to further optimize the cathode magnetic field and focusing characteristics to achieve improved electron gun performance.
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BACKGROUND
Decorative strip bundles are used in many applications and may be most popularly recognized as pom pons used, for example, for cheering at a sporting event. The bundles of strips may come in various sizes and configurations and may be made of materials such as plastic strips, metallic strips, and metallic strips with holographic or other images printed on them, and others.
In most cases, it is advantageous for the bundle of strips to have some rigidity to provide a three-dimensional appearance and effect while still providing movement as the pom is shaken.
SUMMARY
In one embodiment in accordance with the invention, a machine for creating a bundle of creased strips includes a strip supply source capable of supplying a twisted strip of material, a crimp surface over which the twisted strip of material is passed, and a strip accumulation device for accumulating the strip after it has passed over the crimp surface.
In another embodiment in accordance with the invention, a machine for creating a bundle of creased strips includes a strip supply source capable of supplying a twisted strip of material, a crimp surface over which the twisted strip of material is passed, and a strip accumulation device for accumulating the strip after it has passed over the crimp surface. In this embodiment the strip supply source has a revolving reel of strip material. In variations of this embodiment, more than one, and possibly four, revolving reels of strip material may be used.
In yet another embodiment, a machine for creating a bundle of creased strips includes a strip supply source capable of supplying a twisted strip of material, a crimp surface over which the twisted strip of material is passed, and a strip accumulation device for accumulating the strip after it has passed over the crimp surface. In this embodiment the crimp surface is a roller. In variations of this embodiment the crimps surface could be textured with a pattern.
In another embodiment in accordance with the invention, a method of creating a decorative bundle of strips includes twisting a strip of material and drawing the twisted strip of material across a crimp surface. The method also involves wrapping the strip of material around a take-up reel to from a roll of material on a reel and gathering the roll of material within a retainer that is oriented perpendicularly to the strips of material making up the roll. The roll of material is then cut at a point generally opposite the retainer to create a bundle of strips bound together at their approximate centers by the retainer.
In still another embodiment in accordance with the invention, a handle portion has a first handle portion body from which a tab extends and a slot located on the handle portion body. The body has an opening configured to accept and retain a cable tie gear rack. The tab and slot of this embodiment are located so that a second handle portion body may be attached to the first handle portion body by engaging the tabs of each handle portion with the slots of the other handle portion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a machine in accordance with embodiments of the invention.
FIG. 2 is a plan view of a cable tie in accordance with embodiments of the invention.
FIG. 3 is a perspective view of a handle portion in accordance with embodiments of the invention.
FIG. 4 is an end view of the handle portion of FIG. 3 .
FIG. 5 is a cross section of the handle portion of FIG. 4 taken at line 5 - 5 .
DETAILED DESCRIPTION
Embodiments of the invention relate to a machine for producing bundles of decorative strips of material attached to a handle, as in a pom pon. The “fluffing” of pom pons and similar devices by manually creasing individual strips or rubbing the bundle on a textured surface can be used to enhance the three-dimensional effect of the bundles of strips. These techniques can be time-consuming and can produce inconsistent results and appearances for the final product. Machines in accordance with embodiments of the invention may twist strips of material and pass the twisted strips over crimp surfaces to crease the strips in a generally longitudinal but skew fashion. Strips can be crimped in a more consistent fashion, although still somewhat randomly and crimp angle and severity can be adjusted to achieve a desired appearance.
Turning now to the Figures, FIG. 1 is a perspective view of a machine in accordance with embodiments of the invention. The machine 10 has a revolving reel 20 that revolves around a collection region 40 . Strip material is drawn from the reel 20 as the wheel revolves around the collection region 40 , and the material is twisted as it passes through the collection region 40 . The embodiment shown in FIG. 1 has four reels 20 , but conceivably any number of reels, including one, could be used. In embodiments where multiple reels 20 are employed, the strips coming off of the reel are twisted together generally at the collection point 40 .
The rate that the material is drawn from the reel 20 relative to the rate that the reel 20 revolves around the collection point 40 determines the number of twists per unit length of strip and ultimately the angle of the creases formed in the strip. For example, if a reel makes one revolution per foot of strip material drawn off, the strip will have one twist per foot and have a certain average crease angle once creased. If the reel makes two revolutions per foot of strip material, the angle of the ultimate crease relative to the strip will be greater.
In the embodiment shown in FIG. 1 , four reels 20 are mounted on a belt-driven turntable 25 . Any supply source capable of providing a twisted strip of material could be used, but the arrangement shown in FIG. 1 has the advantage of allowing for multiple strips to be twisted together. This arrangement also provides for simple switching out of feedstock material depending on consumer preferences and the like.
The reel 20 of this embodiment may be mounted with a wear plate and springs or an analogous tension maintaining device so that operators can adjust the amount of tension it takes to pull the strips from the reel. By making this adjustment, the pressure with which the strip of material is drawn across the crimp surface 30 may be adjusted and the severity of the crimps or creases may be adjusted until a desired appearance is reached.
Once the material is twisted it passes over a crimp surface 30 . When the strip is described as passing over a crimp surface, the word “over” is intended to connote only contact with the surface and not relative height of the strip to the surface. In the embodiment in FIG. 1 , crimp surface 30 is a roller, and the material passes under the roller but “over” the crimp surface 30 . When the twisted material is drawn over the roller the roller forms creases in the material. Any crimp surface could be used, including but not limited to rotating surfaces with geographic (i.e., triangular, square) cross sections that place transverse creases in the strip while the material is drawn over them, stationary surfaces, textured rotating or stationary surfaces, or surfaces designed to puncture the strip, for example.
In the embodiment shown in FIG. 1 , the creased strip of material passes from the crimp surface 30 to a roller 50 that may also act as a crimp surface. From roller 50 the strip is adjusted by level winder 80 . The level winder 80 synchronizes back and forth linear movement with spool rotation to wind the strip onto take-up reel 70 . The level winder 80 is designed to provide smooth, even spooling of the strip onto the take up reel 70 with reduced material build-up or “valleys” across the surface of the take-up reel 70 .
The take-up reel 70 may be powered by a drive belt or other means of delivering a motive force. As strip is initially fed through the machine 10 to the take-up reel 70 . In some embodiments, the take up reel 70 draws the strip through the machine 10 , while the source of supply for the strip provides tension to provide for appropriate crimping of the strip.
Once the appropriate amount of strip is collected on the take up reel 70 , the reel is stopped. In one exemplary embodiment, the reel may be brought to a stop using reciprocal plungers 90 that extend to contact the reel 70 and, optionally, to secure the strip on the reel 70 .
It may be advantageous for some applications to have a take-up reel 70 of some width. If the take up reel is too narrow, strip that is taken up by the reel later in the process will be wrapped around strip that is already around the take-up reel, resulting in a longer strip each time around the take-up reel due to the larger circumference of the reel plus the strip. If the roll of strip is to be used to create a pom pon, the longer strips may detract from the appearance of the finished product.
In some embodiments, the reel 70 has a generally cylindrical portion oriented about axis A. The generally cylindrical portion of this embodiment is interrupted by two channels 100 , the channels being oriented generally parallel to axis A. In this embodiment the strip could be gathered by placing a retainer in the channel between the roll of strip and the reel 70 . The retainer could be any retainer capable of retaining the collection of strips, but in a preferred embodiment the retainer could be a cable tie.
FIG. 2 is a plan view of a cable tie in accordance with embodiments of the invention. In some embodiments, a cable tie 110 consists of a sturdy strap 120 with an integrated gear rack 130 on one end and a ratchet 160 within an opening 140 . The end of the tie with the gear rack may have a tip 150 . The tip 150 may, but need not be, pointed to allow for easier insertion into openings. Cable ties may be made of several materials including but not limited to ethylene tetrafluoroethylene (ETFE), ethylene chlorotrifluoroethlyene (ECTFE) and Nylon.
In the event that the retainer is a cable tie 110 , the cable tie may be placed in the channel 100 between the roll of strip and the reel 70 . The cable tie is then bent around the bundle of strips until the tip 150 can be inserted into the opening 140 . Once the gear rack 130 engages with the ratchet 160 it is essentially prevented from being pulled back and the resulting loop may only be pulled tighter.
Once the strips are bound within the retainer, a cutting tool may be placed in the other channel 100 to cut the strips. This results in a bundle of strips bound together by the retainer at their approximate centers. Take up reels 70 of various sizes may be used to produce bundles of strips of various lengths. For example, a take-up reel 70 that is eight inches in circumference will result in a bundle of eight inch strips bound at their approximate centers. By changing the reel 70 , one can change the length of the strips because the circumference of the take-up reel is different.
FIG. 3 is a perspective view of a handle portion in accordance with embodiments of the invention. The handle portion of this embodiment has a generally cylindrical body 180 from which extend a tab 200 or a plurality of tabs 200 . In this embodiment two tabs are shown, but any number of tabs could be used. The body has a slot 190 or a plurality of slots 190 (one shown) located on it. The tabs 200 and slots 190 are configured so that two identical handle portions 170 can be joined into one handle by aligning the tabs 200 of one handle portion 170 with the slots 190 of a second handle portion 190 and moving them together so that the tabs 200 of each handle portion engage with the slots 190 of the other handle portion.
FIG. 4 is an end view of the handle portion of FIG. 3 . The tabs 200 and slots 190 are oriented generally at the perimeter of the handle portion 170 . An opening 210 is configured to receive the end 150 of a cable tie such as is described in connection with FIG. 2 .
FIG. 5 is a cross section of the handle portion of FIG. 4 taken at line 5 - 5 . The tab 200 and slots 190 are shown, and a ratchet 220 for retaining the gear rack 130 of a cable tie such as is described in connection with FIG. 2 .
Handle portions such as those shown in FIGS. 3 , 4 , and 5 may be used to retain anything that is secured by a cable tie. As describe above, a cable tie may secure objects such as, but not limited to, a bundle of strips by wrapping the cable tie around the object and inserting an end of the cable tie having a gear rack into an opening located on the other end of the cable tie. The end having the gear rack can then be pulled through the opening until a desired tightness is achieved. Once a cable tie has secured an object or collection of objects, the excess strap can be inserted into the opening 210 of a handle portion 170 and pulled through the other side. This strap can be pulled through the handle portion 170 and tightened to a desired degree. This tightening may be done manually or by a cable tie tensioning device as is known in the art. Once the cable tie is secure to a handle portion, the excess strap may be cut off. Some cable tie tensioning devices include the capability to repeatedly cut remove all but a desired length of excess strap.
After securing the cable tie and its contents to a handle portion and optionally tensioning and cutting off excess cable tie strap, a second handle portion can be affixed to the handle portion retaining the cable tie through the use of a tab and slot configuration as described above. Adhesives, stickers, welding, and other means of securing the handle portions together may optionally be employed and will occur to those of skill in the art upon reading this disclosure.
As a non-limiting example, strips crimped and gathered on a take-up reel as described with respect to FIG. 1 could be formed into a pom pon by pulling the excess strap of a cable tie that is securing a bundle of crimped strips through the opening 210 of a handle portion 170 . The strap can be tensioned and/or cut if desired. A second handle portion can be secured to the handle portion into which the cable tie was inserted, and a bundle of crimped strips secured by a handle, or a pom pon, is produced.
Crimped strips formed by, for example, a machine such as that disclosed in FIG. 1 , will “fluff” and take on a pleasing three-dimensional effect. Crimping, bundling, and securing crimped strips to a handle as can be accomplished using the above disclosed structures can produce a aesthetically pleasing pom pon of high quality in a repeatable and efficient fashion.
A cable tie tensioning device or tool may be used to apply a cable tie with a specific degree of tension. The tool may cut off the extra tail flush with the head in order to avoid a sharp edge which might otherwise cause injury.
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A machine for creating a bundle of creased strips of material and handles for use with bundles of creased strips and other applications. Also contemplated are bundles of strips with or without handles for various applications.
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This application is a 35 U.S.C. §371 National Stage Application of PCT/EP2010/054704, filed on Apr. 9, 2010, which claims the benefit of priority to Application Serial No. DE 10 2009 026 816.2, filed on Jun. 8, 2009 in Germany, the disclosures of which are incorporated herein by reference in their entirety.
BACKGROUND
The disclosure relates to a connecting element for electrically connecting a first component to a second component of the generic type according to a related fluid assembly.
Laid-open application DE 44 12 664 A1 therefore discloses, for example, an electrohydraulic pressure adjustment apparatus for a slip-controlled vehicle brake system. The described pressure adjustment apparatus has at least one valve which is joined to the valve block and has a valve dome which projects from the valve block and onto which a coil, which is arranged in a cover, can be fitted. Electrical contact elements which are cohesively connected to one another emerge from the coil and from the cover. The electrical contact elements of the coil and of the cover are of flexible design. They implement both the electrical connection and the holding function for the coil. They also allow the coil to be aligned when it is fitted onto the valve dome. The electrical contact elements of the cover are designed in the form of stamped-grid strips which are cast into the cover which is composed of an insulating material. The stamped-grid strips extend at a right angle to the longitudinal axis of the coil running plane and have meandering angled sections, as a result of which the stamped-grid strips have a relatively high degree of elastic flexibility in a plane which runs at a right angle to the longitudinal axis of the coil. The stamped-grid strips have, at their free end, a fastening lug which runs parallel to the associated connecting wire of the coil and is connected to said connecting wire by a cohesive connection such as welding or soldering.
SUMMARY
The connecting element according to the disclosure for electrically connecting two components having the features of independent patent claim 1 has, in contrast, the advantage that the connecting element is of one-piece design, and the first electrical contact element and the second electrical contact element are connected to one another by means of at least one tolerance compensation element, with a first variable tolerance compensation element permitting length compensation in at least one direction in space in order to prespecify a desired spatial positioning of the first contact element and of the second contact element in relation to one another, and with the first variable tolerance compensation element being three-dimensionally shaped by bending. The three-dimensional design of the first variable tolerance compensation element results in operation in the manner of a torsion spring and therefore considerably improved mechanical decoupling and a reduction in forces in the contact region of the first contact element.
A fluid assembly having a connecting element according to the disclosure for electrically connecting a magnet assembly of a solenoid valve to a printed circuit board of a controller having the features set forth below has the advantage that a magnet coil of the magnet assembly is electrically connected to the printed circuit board by means of at least one connecting element according to the disclosure, with the first contact element of the connecting element respectively being connected to a connecting dome of the magnet assembly, and the second electrical contact element of the connecting element being connected to a contact region of the printed circuit board. After being electrically connected to the printed circuit board, the magnet assembly is fitted on a valve cartridge, which projects beyond a fluid block of the fluid assembly, with a first variable tolerance compensation element, which connects the first contact element to the second contact element, permitting length compensation in at least one direction in space in order to prespecify a desired spatial positioning of the first contact element and of the second contact element in relation to one another and to compensate for existing positional tolerances since the magnet coil surrounds the valve cartridge, which is mounted in the fluid block, with radial play. Furthermore, the tolerance compensation element can compensate for changes in length which are caused by changes in temperature. The connecting element according to the disclosure can be used to advantageously electrically connect the magnet coil directly to the printed circuit board without a stamped grid and without a welding or soldering process.
Embodiments of the present disclosure permit very good mechanical decoupling of the thermal and dynamic reciprocating movements of the intermediate base of the controller in relation to the contact point on the coil wire of the magnet coil. In addition, this provides a sufficient degree of freedom from forces and freedom of movement of the coil wire contact-making means for a cold contact-making connection. The three-dimensional shaping of the tolerance compensation element of the connecting element according to the disclosure can create additional installation space above the magnet coil, so that a considerably extended meander for the tolerance compensation element can be accommodated, it being possible, in addition, for said meander to be loaded not only as a bending bar but also as a torsion spring in the event of various relative movements. Both extending the meander of the tolerance compensation element and changing the loading result in considerably reduced mechanical stresses in the connecting element according to the disclosure itself and considerably reduced amounts of force being introduced at the contact point of the first contact element in relation to the coil wire of the magnet coil.
Advantageous improvements to the connecting element specified in independent patent claim 1 and to the fluid assembly specified in independent patent claim 9 are possible by virtue of the measures and developments cited in the dependent claims.
It is particularly advantageous for the bent portion of the first variable tolerance compensation element to be shaped to form an omega. Shaping the bent portion of the meander of the first tolerance compensation element to form an omega provides the best-possible compromise between the installation space, the elasticity for mechanical decoupling, the stability for absorbing vibrations and mechanical forces before installation and the ease of manufacture of the connecting element, for example by stamping and bending.
In one refinement of the connecting element according to the disclosure, the two contact elements implement different types of cold contact-making connections, with the types of cold contact-making connections comprising an insulation displacement connection and/or a plug connection. On account of the use of an insulation displacement connection, it is no longer necessary to strip the insulation coating of the coil wire at the wire ends of the winding. In addition, no thermal processes, which are susceptible to faults, are required in the case of an insulation displacement connection or plug connection, as a result of which process monitoring and the process devices can be realized at lower cost.
The connecting element according to the disclosure is designed, for example, in the form of a one-piece stamped part which can be produced in a simple and cost-effective manner. In this case, the bent portion, which is designed in the form of an omega for example, of the meander of the first tolerance compensation element, is, after stamping, bent over substantially perpendicular to the starting position in a further production step.
In one refinement of the connecting element according to the disclosure, the first contact element comprises, for example, a cutting element for establishing the electrical insulation displacement connection to the coil wire. In addition, the first contact element comprises an integrally formed mechanical connection element in order to mechanically connect the first contact element to a corresponding contact receptacle of the magnet assembly. In addition, an additional hole, can be made in the first contact element, above the cutting element, for alignment purposes during mounting. The second contact element is designed, for example, in the form of a plug connection at one end, it being possible to insert said plug connection into a corresponding plug receptacle in the printed circuit board in order to establish an electrical and mechanical connection. The second contact element, which is designed in the form of a plug connection, can have a mechanical connection element at the other end, it being possible to press the second contact element into an aperture by way of said mechanical connection element.
In one refinement of the fluid assembly according to the disclosure, the first tolerance compensation element, which is arranged between the first electrical contact element and the second electrical contact element, performs length compensation in at least one direction in space in order to prespecify a desired spatial positioning of the first contact element and of the second contact element in relation to one another, with a lateral spacing between the two contact elements being selected such that the second contact element projects laterally beyond the magnet assembly by way of the mechanical connection element. A second tolerance compensation element, which is arranged between the second contact element and the mechanical connection element, performs length compensation between the printed circuit board and the intermediate base of the controller.
Advantageous embodiments of the disclosure are illustrated in the drawings and will be described in the text which follows. In the drawings, identical reference symbols designate components and elements which perform the same or similar functions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic sectional illustration of an exemplary embodiment of a fluid assembly according to the disclosure.
FIG. 2 shows a schematic illustration of an exemplary embodiment of a connecting element according to the disclosure.
FIG. 3 shows a side view of the exemplary embodiment of a connecting element according to the disclosure from FIG. 2 .
FIG. 4 shows a plan view of the exemplary embodiment of a connecting element according to the disclosure from FIG. 2 .
FIG. 5 shows a schematic illustration of a belt having a plurality of connecting elements according to the disclosure.
FIG. 6 shows a schematic perspective illustration of an exemplary embodiment of a magnet assembly for the fluid assembly according to the disclosure as per FIG. 1 .
FIG. 7 shows a side view of the exemplary embodiment of the magnet assembly from FIG. 6 for the fluid assembly according to the disclosure as per FIG. 1 .
FIG. 8 shows a plan view of the exemplary embodiment of the magnet assembly from FIG. 6 for the fluid assembly according to the disclosure as per FIG. 1 .
DETAILED DESCRIPTION
A conventional fluid assembly, which is used, for example, in an anti-lock brake system (ABS) or a traction control system (ASR system) or an electronic stability program system (ESP system), generally comprises a controller and a fluid region, which comprise at least one fluid component, which is designed in the form of a fluid block or in the form of a pump motor for example, and at least one fluid control element which is designed, for example, in the form of a valve cartridge which is part of a related solenoid valve. In order to actuate the at least one fluid component and the at least one fluid control element, the controller comprises a printed circuit board which, at the same time, are used as a circuit mount and to connect a consumer plug, which is located on the housing, and the solenoid valves. In addition, the controller comprises magnet assemblies which are likewise part of the respectively related solenoid valve and are required to adjust the fluid control elements which are designed in the form of valve cartridges. The magnet assemblies generate a magnetic force by means of electrical magnet coils in each case, it being possible to use said magnetic force to adjust the fluid control elements which set corresponding volumetric flows which are routed in fluid ducts of the fluid component which is designed in the form of a fluid block. The magnet coils usually comprise an iron core, a winding carrier and a wire winding and can be electrically connected to electronic circuits on the printed circuit board. The electrical magnet coils of the magnet assemblies are contacted via a stamped grid which is electrically connected to at least one electronic circuit of the printed circuit board, with the magnet assemblies, which are electrically connected to the printed circuit board via the stamped grid, being fitted on the fluid control elements which are designed in the form of valve cartridges and are firmly connected, preferably caulked, for example, to the fluid component which is designed in the form of a fluid block. The stamped grid used is highly complicated in terms of design and tools required, is highly inflexible and can be varied only with difficulty over the life of the process. In addition, a further electrical connection piece, for example in the form of individual connecting pins, is required between the stamped grid and the printed circuit board, in conjunction with the printed circuit board technology.
As can be seen in FIG. 1 , a fluid assembly 1 according to the disclosure comprises a fluid block 3 , a printed circuit board 4 which is arranged in a controller, and a plurality of solenoid valves 2 , of which two solenoid valves 2 are illustrated. The solenoid valves 2 each comprise a magnet assembly 2 . 1 , which has a magnet coil 2 . 3 and two connecting domes 2 . 4 , and a valve cartridge 2 . 2 which is mounted in the fluid block 3 . The magnet assemblies 2 . 1 of the solenoid valves 2 are each fitted on the valve cartridges 2 . 2 , which project beyond the fluid block 3 . The magnet coils 2 . 3 of the magnet assemblies 2 . 1 are each electrically connected to the printed circuit board 4 by means of two connecting elements 10 according to the disclosure. As can also be seen in FIG. 1 , the magnet assemblies 2 are each pressed on the fluid block 3 by an elastic holding element 6 , which is supported on the intermediate base 5 of the controller housing, in order to prevent or to reduce vibrational loading on the connecting elements 10 .
As can be seen in FIGS. 2 to 4 , a connecting element 10 according to the disclosure for electrically connecting the magnet coil 2 . 3 to the printed circuit board 4 comprises a first electrical contact element 11 for making electrical contact with the magnet coil 2 . 3 and a second electrical contact element 12 for making electrical contact with the printed circuit board 4 , with the two contact elements 11 , 12 being connected to one another by means of a first tolerance compensation element 13 and a second tolerance compensation element 14 .
As can also be seen in FIGS. 2 to 4 , the two contact elements 11 , 12 implement different types of cold contact-making connections, with the first contact element 11 comprising a cutting element 11 . 1 for establishing an electrical insulation displacement connection to a coil wire of the magnet coil 2 . 3 and an integrally formed mechanical connection element 15 in order to mechanically connect the first contact element 11 to the corresponding connecting dome 2 . 4 of the magnet assembly 2 . 1 . The second contact element 12 is designed in the form of a plug connection at one end, it being possible to insert or press said plug connection into a corresponding plug receptacle 4 . 1 , which is illustrated in FIG. 1 , in the printed circuit board 4 in order to establish an electrical and mechanical connection, and thus in order to implement the cold contact-making connection between the plug connection and the plug receptacle 4 . 1 . At the other end, the second contact element 12 , which is designed in the form of a plug connection, has a mechanical connection element 16 , it being possible to press the second contact element 12 into an aperture 5 . 1 in an intermediate base 5 of the controller by way of said mechanical connection element. The first variable tolerance compensation element 13 allows length compensation in at least one direction in space in order to prespecify a desired spatial positioning of the first contact element 12 and of the second contact element 13 in relation to one another, with the first variable tolerance compensation element 13 being three-dimensionally shaped by bending. The bent portion of the first variable tolerance compensation element 13 is shaped to form an omega in the illustrated exemplary embodiment. The second tolerance compensation element 14 is arranged between the second contact element 12 and the mechanical connection element 16 and permits length compensation between the printed circuit board 4 and the intermediate base 5 of the controller. In the illustrated exemplary embodiment, the connecting element 10 according to the disclosure is designed in the form of a one-piece stamped part which can be produced in a simple and cost-effective manner. In this case, the bent portion, which is designed in the form of an omega, of the meander of the first tolerance compensation element 13 , is, after stamping, bent over substantially perpendicular to the starting position in a further production step, as can be seen in FIGS. 2 to 4 .
As can also be seen in FIGS. 2 to 4 , the second contact element 12 can have a defined material thickness, which is different from the first contact element 11 , depending on the design of the plug receptacle 4 . 1 or the press-in zone in the printed circuit board 4 , and therefore a material thickness difference 18 is produced between the second contact element 12 and the first tolerance compensation element 13 . The material thickness difference 18 can be realized, for example, by a milled step.
Therefore, the connecting elements 10 according to the disclosure electrically connect the magnet coils 2 . 3 of the magnet assemblies 2 . 1 to the electronics on the printed circuit board 4 . The connecting element 10 is mechanically connected to an aperture 5 . 1 in the intermediate base 5 of the controller, for example, by means of a mechanical connection element 16 , which is designed in the form of a latching contour, by being pressed on. This ensures that, starting from the magnet coil 2 . 3 , no mechanical forces can be transmitted to the electrical cold contact-making connection of the second contact element 12 in the printed circuit board 4 . The insulation displacement connection of the first contact element 11 to the connecting dome 2 . 4 is shaped such that the electrical cold contact-making connection to the coil wire of the magnet coil 2 . 3 is made in the cutting element 11 . 1 , which is designed in the form of a slot, and the mechanical connection to the connecting dome 2 . 4 of the magnet assembly 2 . 1 is established at the mechanical connection element 15 which is designed in the form of an external tooth system.
As can be seen in FIGS. 6 to 8 , a magnet assembly 2 . 1 , which is illustrated by way of example, comprises two connecting domes 2 . 4 and a housing casing 2 . 5 which covers the magnet coils 2 . 3 which are wound onto a winding former. In order to mount the two connecting elements 10 for making contact with the magnet assembly 2 . 1 , the connecting elements 10 are, as can be seen in FIG. 5 , supplied on a belt 20 . The connecting elements 10 are then separated and the portion, which is designed in the form of an omega, of the meander of the first tolerance compensation element 13 is bent over substantially perpendicular to the starting position. For mounting purposes, the connecting element 10 according to the disclosure is picked up by a grabber at a first grabber position 17 . 1 above the first contact element 11 and pushed into the corresponding connecting dome 2 . 4 of the magnet assembly 2 . 1 , with the electrical contact between the first contact element 11 and the coil wire being established by the insulation displacement connection. An additional hole 11 . 2 is made in the first contact element 11 , above the cutting element 11 . 1 , for alignment purposes during mounting. The fact that the connecting elements 10 are routed laterally beyond the diameter of the magnet assembly 2 . 1 allows the connecting element 10 to be picked up directly at a second grabber position 17 . 2 below the second contact element 12 and allows the connecting element 10 , together with the magnet assembly 2 . 1 , to be pressed into the intermediate base 5 of the controller housing with force. In addition, the forces which act on the second contact element 12 as the printed circuit board 4 is being pressed can be absorbed via this grabber position 17 . 2 . The magnet coil 2 . 3 surrounds the valve cartridge 2 . 2 , which is mounted in the fluid block 3 , with very little radial play, and therefore the position of the magnet coil 2 . 3 , which is premounted in the controller, is influenced directly by the positional tolerances of the valve cartridge. Since the latching positions of the connecting elements 10 in the intermediate base 5 of the controller housing are independent of these tolerances, the connecting elements 10 have the option of one-off tolerance compensation during mounting by virtue of the first tolerance compensation elements 13 . Therefore, the second contact elements 12 can be picked up by means of the second grabber position 17 . 2 and be aligned for mounting in the corresponding aperture 5 . 1 in the intermediate base 5 of the controller housing by deformation of the first tolerance compensation elements 13 . The first tolerance compensation elements 13 each extend substantially at a right angle to the longitudinal axis of the first contact element 11 and to the longitudinal axis of the second contact element 12 , and therefore the longitudinal axes of the two contact elements 11 and 12 run substantially parallel to one another. In the illustrated exemplary embodiment, the first tolerance compensation element 13 has two meandering angled sections between which the bent-over portion which is designed in the form of an omega is arranged, as a result of which the respective connecting element 10 has a relatively high degree of elastic flexibility between the two contact elements 11 , 12 .
The connecting element according to the disclosure advantageously performs the requisite tolerance compensation between the magnet assembly and the wiring plane, allows a cost saving to be made by reducing the number of parts or quantities of material, processes, systems etc., and increases the flexibility and ability to modularize the assembly for various applications, for example in an anti-lock brake system (ABS) or a traction control system (ASR system) or an electronic stability program system (ESP system). In addition, the space requirements in the entire system can be reduced.
Furthermore, the connecting element according to the disclosure allows considerably improved mechanical decoupling and a reduction in forces in the contact region on the coil side. The three-dimensional shaping of the meander of the first tolerance compensation element by bending additionally results in operation in the manner of a torsion spring. This provides optimum mechanical decoupling of the thermal and dynamic reciprocating movements of the controller intermediate base in relation to the contact point on the coil wire. In addition, a considerably extended meander of the first tolerance compensation element can be accommodated on account of the additionally obtained installation space above the magnet coil, said meander, in addition, being loaded not only as a bending bar but also as a torsion spring in the event of various relative movements. Both extending the meander of the tolerance compensation element and changing the loading result in considerably reduced mechanical stresses in the connecting element according to the disclosure itself and considerably reduced amounts of force being introduced at the contact point of the insulation displacement contact (IDC) in relation to the coil wire.
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A connecting element for electrically connecting two components to a first electric contact element for electrically contacting a first component, to a second electric contact element for electrically contacting a second component, and to at least one tolerance compensating element is disclosed. The fluid assembly includes at least one such connecting element. The connecting element is configured as one piece and the first electric contact element and the second electric contact element are connected to each other by way of the at least one tolerance compensating element. The first variable tolerance compensating element enables a compensation in length in at least one spatial direction in order to predetermine a desired spatial position of the first contact element and the second contact element in relation to each other. The first variable tolerance compensating element may be three-dimensionally shaped by bending.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method and apparatus for receiving solar energy, and more particularly to a method and macro receiver for absorbing large amounts of radiant energy provided by heliostats, the method and apparatus particularly providing a large target area with low irradiation losses from the receiver.
2. Description of the Prior Art
Heliostats have been known since ancient times. Basically, heliostats constitute a plurality of reflective surfaces which track the sun and concentrate the reflected energy into a limited area. However, because of the finite image of the sun provided by the heliostats, and because of the errors both in tracking and in the optical surface of the heliostat, a relatively large receiver for the reflective solar energy is desirable. Since heliostats may be arrayed for many miles from the receiver, tremendous amounts of energy are focused upon the receiver thus generating high temperatures. As a result, and particularly since irradiation is a function of the fourth power of the absolute temperature of the receiver, a large receiver which accommodates the tracking and focusing errors of the heliostats and operates at high temperatures soon compromises the efficiency of the system as a result of irradiation losses from the receiver.
This is a long standing problem as illustrated by the Calver U.S. Pat. No. 294,117. More recently, Falbel U.S. Pat. No. 3,841,302; Cummings U.S. Pat. No. 3,869,199; and Levi-Setti U.S. Pat. No. 3,899,672 illustrate a continuing interest in the problem of concentrating solar energy.
SUMMARY OF THE INVENTION
The present invention, which provides a heretofore unavailable improvement over previous methods for solar energy receiving and apparatus for receiving solar energy, comprises an apparatus formed substantially of a series of diverging vanes forming either partially or completely, an absorbing cavity and terminating in a series of exterior defined openings providing a large target for receiving solar energy. The portions of the vanes immediatly adjacent the interior ends of the vanes may be solar energy absorbing, i.e., display black body characteristics, the intermediate portions and interior portions of the vanes not absorbing are provided with a selective coating surface, and the outer portions of the vanes are provided with a reflective surface. In a particularly preferred embodiment, a barrier substantially transparent in the solar spectrum is provided substantially at the interface between the reflective and selective surfaces of the vane to enclose the inner volumes defined by the vanes. A working fluid is flowed through the enclosed volume to assist in cooling the vanes and also to absorb irradiation, and particularly infrared radiation, emitted by the cavity walls and/or vanes.
Accordingly, an object of the present invention is to provide a new and improved method and apparatus for receiving macro amounts of concentrated solar energy.
Another object of the present invention is to provide a new and improved method and apparatus for providing a larger target for receiving concentrated solar energy.
Yet another object of the present invention is to provide a new and improved method and apparatus for minimizing irradiation losses from a solar receiver having a large target area.
Still another object of the present invention is to provide a new and improved method and apparatus for receiving solar energy in which specific areas of the vanes guiding solar energy to an absorption cavity are coated with reflective, selective or absorbing surfaces.
Yet another object of the present invention is to provide a new and improved method and apparatus for receiving solar energy in which a radiation absorbing working fluid is flowed between portions of the vanes to absorb radiation irradiated by the portions of the receiver at elevated temperatures.
These and other objects and features of the present invention will become apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
In the Drawing
FIG. 1 is a perspective view of a typical solar energy receiver in accordance with the instant invention disposed relative to a typical array of heliostats;
FIG. 2 is a simplified top view of the arrangement of FIG. 1;
FIG. 3 is a top sectioned view of a solar receiver in accordance with the instant invention;
FIG. 4 is a sectioned view of the vanes of the solar receiver of FIG. 3 particularly illustrating typical ray paths into the solar receiver; and
FIG. 5 is an enlarged sectioned view of a single vane of the solar receiver of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, wherein like components are designated by like reference numerals throughout the various figures, an apparatus for receiving solar energy is illustrated in FIGS. 1 and 2 and generally designated by reference numeral 10. As will be described in more detail hereinafter, receiver 10 is formed by walls defining partially enclosed optional cavity 12 with a number of vanes 14 opening into and converging towards cavity 12. Of course in some instances the volume defined by the walls of vanes 14 can serve the function of distinct cavity 12. Though the discussion will be directed to the preferred embodiment including cavity 12, it is to be understood that cavity 12 is optional. Outlet 15 communicates with cavity 12 and is adapted to convey a media transmitting absorbed energy to appropriate utilization means (not shown), or conveying a process stream from receiver 10. While the nature of such utilization is beyond the scope of this invention, conventional uses include direct use as a working fluid in generation of electricity, process heat, or super heated steam for heating large installations, driving turbines, in situ reformation such as steam reformation of organic compound, etc.
Receiver 10 is positioned at the apex of a natural mound such as mountain 17. Thus, heliostats 19, arrayed below receiver 10, are individually directed to reflect solar energy into the openings defined by vanes 14. Alternatively, heliostats 19 may be, as is conventionally understood, arrayed on the walls of a bowl-shaped topography with receiver 10 positioned below heliostats 19. In any event, it is necessary that receiver 10 be vertically spaced relative to heliostats 19 in order that one row of heliostats 19 not shade an adjacent row of heliostats 19, or block the reflected energy therefrom.
Heliostats 19 are well known and do not constitute a critical aspect of the invention. Basically, heliostats 19 are tracking devices, preferably in the form of movable, slightly concave mirrors which move with the sun to reflect the energy from the sun from heliostats 19 into the openings defined by vanes 14.
In a particularly preferred embodiment of the invention, receiver 10 includes transparent barrier 21 which serves functions which will be more fully described below.
FIG. 3 particularly well describes the detailed structure and function of receiver 10. As shown, vanes 14 have a reflective surface 23 at the portion outward of transparent barrier 21. Immediately inward of transparent barrier 21, vanes 14 carry a selective surface 24. The innermost portions of vanes 14 may optionally have an absorbing surface 25 on limited portions of the innermost portions of vanes 14, or this portion may be of the selective surface 24. Absorbing surfaces 25 may be positioned to intercept rays which would be reflected at a large angle of incidence across cavity 12. The general functions of reflective surface 23 and absorbing surface 25 are well known. Essentially, reflecting surface 23 reflects most energy falling thereon. Absorbing surface 25 absorbs the energy falling thereon. Again, as is well known, reflecting surface 23 has a low emissivity while absorbing surface 25 has a high emissivity. On the other hand, selective surface 24 displays a high absorptivity for energy impinging thereon with a small angle of incidence, i.e., plus or minus 15°, a high reflectivity for energy impinging thereon with a relatively large angle of incidence and a low overall emissivity. Such surfaces are conventionally micro wavetraps such as an array of tungsten dendrities. Thus, the projecting surfaces absorb radiation traveling substantially parallel to the dendrites, but reflect energy traveling substantially transverse to the depth of the dendrities. Typical selective surfaces are discussed in the article at Page 5 of The Colorado Engineer, March, 1975; the May 15, 1976 volume of Applied Physics Letters; and IBM Research Report 4974 entitled "A New Concept for Solar Energy Thermal Conversion" published Apr. 6, 1974. While tungsten dendrities arrays are preferable as selective coatings for surfaces 24, other such materials of course are also functional. As will be described below with regard to a particularly preferred embodiment of the invention, other materials having a greater propensity to oxidize than the tungsten dendrities are workable in conjunction with the preferred embodiment of the invention.
As illustrated in FIG. 4, it is an established geometrical precept that rays impinging upon converging surfaces such as vanes 14 tend to successively impinge at smaller angles of incidence until, unless the rays pass through the converging vanes, the rays ultimately reverse themselves and tend to reflect from the converging surfaces. Thus, rays initially striking reflective surfaces 23 at relatively small angles of incidence tend to be reflected at smaller angles of incidence until the rays reach selective surfaces 24. At selective surfaces 24 the rays striking at a small angle of incidence are absorbed to preclude reversing of the direction, while rays impinging at a large angle of incidence are reflected by selective surface 24. Deeper in the throat of vanes 14, rays striking absorbing surface 25 tend to be absorbed at such surface. However, a great percentage of the radiant energy reflected towards receiver 10 pass either directly or with reflection at a relatively large angle of incidence, through the throat of vanes 14 into cavity 12. Absorbing surfaces 25 are located to absorb rays which would be reflected across cavity 12 and out from receiver 10 between other vanes 14. Cavity 12 includes an absorbing surface 28 and a series of cooling channels 30. Accordingly, the radiant energy passing through the throats of vanes 14 into cavity 12 is absorbed at absorbing surface 28 or the inner surfaces of cooling channel 30. A cooling medium is flowed through channels 30 into volume 32 to permit the energy to be carried away through outlet 15. Preferably, the cooling medium also passes through inlets 34 into the volume defined by vanes 14 and transparent barrier 21. Thus, the cooling medium also cools surfaces of vanes 14, and particularly the surfaces including selective surfaces 24 and absorbing surfaces 25. If cavity 12 is omitted, this latter mechanism provides for cooling.
In a particularly preferred embodiment of the invention, the cooling medium is a medium absorbing infrared radiation but transmitting shorter wave lengths of the solar spectrum. Similarly, transparent barrier 21 is a material which transmits shorter wave lengths of the solar radiation, but blocks infrared radiation, i.e., the radiation emitted by the various surfaces after being heated by absorption of ultraviolet radiation. Carbon dioxide gas is particularly useful as a cooling medium in that it absorbs infrared radiation and thus blocks irradiation losses from cavity 12 and/or the walls of vane 14. Thus, carbon dioxide gas flowed through inlets 34, through cavity 12 and out through cooling channels 30 into volume 32 and outlet 15 would be heated to an elevated temperature, i.e., on the order of 500° C and may be thereafter employed as a working fluid in a power cycle, or as the hot side media in a heat exchange process. Also, since carbon dioxide is relatively inert, selective surfaces 24 which would oxidize in air at the operating temperature contemplated are protected. Other process streams can be flowed through receiver 10 in a similar manner.
As shown in FIG. 5, the portion of vane 14 having selective surfaces 24 and optional absorbing surfaces 25 include internal cooling passages 36 to carry away the substantial heat energy at vanes 14 resulting from absorption of solar energy at selective surfaces 24 and optional absorbing surfaces 25. Cooling passages 36 may contain the same cooling media as flows through cooling channels 30, or, alternatively, cooling passages 36 may include a cooling media such as sodium, water, air etc., which thereafter may be subject to a heat exchange process or used directly as a working fluid for a power cycle. While cooling passages 36 are illustrated as tubes adapted for pressurized working fluids, it is to be understood that vanes 14 could be spaced plates and a lower pressure cooling media flowed between the plates.
Thus, while receiver 10 is provided with a particularly large aperture for receiving energy from heliostats 19, many of the conventional losses resulting from such a large aperture are avoided. The outer surfaces 23 of vanes 14 are reflective and thus do not reach an elevated temperature or emit infrared energy. At the point where a substantial quantity of the rays initially striking vanes 14 at a relatively small angle of incidence tend to reverse direction and thus escape, selective surfaces 24 are provided to absorb such rays while reflecting rays intercepting vanes 14 at a larger angle of incidence. Further into the throat of vanes 14, optional absorbing surfaces 15 absorb substantially all of the energy impinging thereon. Although absorbing surfaces 25 have a high emissivity, such energy is emitted rather deep in the throat of vanes 14, and thus tends to be ultimately reabsorbed rather than lost through the aperture of vanes 14. Cooling channels 36 serve to carry away such energy and thus little energy is lost through irradiation.
In a particularly preferred embodiment of the invention, transparent barrier 21 is provided to permit a cooling media such as carbon dioxide to be flowed through the throat area of vanes 14, i.e., that bounded by selective surface 24 and/or absorbing surface 25. The carbon dioxide is transparent to ultraviolet light, thus permitting solar radiation to be transmitted therethrough and into cavity 12. However, carbon dioxide and other known fluids are substantially absorbing media for infrared radiation thus blocking the remission of energy. The infrared energy emitted by the throat area of vanes 14 and cavity 12 is absorbed by the carbon dioxide, the carbon dioxide is thus heated and thereafter utilized after being further heated by passing through channels 30, as a source of high temperature energy, or as a working fluid. Optionally, this permits the volume defined by vanes 14 to completely serve the function of cavity 12. Other process streams, i.e., steam reformation streams could similarly be flowed through receiver 10.
Summarily, though the critical use of selective surface 24 is the prime operative structure to permit a large aperture receiver with low losses to irradiation. The efficiency, i.e., energy received to energy lost ratio may be further enhanced by optionally utilizing as a heat conductive cooling media a fluid which is transparent to ultraviolet radiation and absorbs infrared radiation.
Although only limited embodiments of the present invention have been illustrated and described, it is anticipated that various changes and modifications will be apparent to those skilled in the art, and that such changes may be made without departing from the scope of the invention as defined by the following claims.
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A method and apparatus for receiving solar energy reflected from a heliostat configuration in which the apparatus is formed of converging vanes defining cavities therebetween, and preferably converging towards a cavity. The vanes may partially or completely define an enclosed volume. Surfaces of the vanes are provided with reflective surfaces near the outer portions of the receiver, selective surfaces at the intermediate portions and, optionally, absorbing surfaces at the interior portions. Cooling means are provided within the vanes of the receiver adjacent the selective and absorbing surfaces. In a preferred embodiment, a transparent barrier is provided transverse to the vanes substantially at the change from the reflective to the selective surfaces, and an infrared absorbing heat transfer fluid is flowed inwardly from the transparent barrier to the cavity to cool the receiver and absorb energy irradiated from the vanes and cavity.
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BACKGROUND
[0001] The control of noise in the home, office, factory, automobile, train, bus, airplane, etcetera involves reducing the travel or transmission of both airborne noise and structure borne noise, whether generated by sources within or outside your environment.
[0002] Airborne noise is produced initially by a source which radiates directly into the air. Many of the noises we encounter daily are of airborne origin; for example, the roar of an overhead jet plane, the blare of an auto horn, voices of children, or music from stereo sets. Airborne sound waves are transmitted simply as pressure fluctuations in the open air, or in buildings along continuous air passages such as corridors, doorways, staircases and duct systems. The disturbing influences of airborne noise generated within a building generally are limited to areas near the noise source. This is due to the fact that airborne noises are less intense and are easier to dissipate than structure borne noise.
[0003] Structure borne noise occurs when floor or other building elements are set into vibratory motion by direct contact with vibrating sources such as mechanical equipment or domestic appliances, footsteps, falling of hard objects, objects being moved, bounced or rolled across the floor, to name a few examples. In a building for example, the vibrational or mechanical energy from one floor or wall assembly is transmitted throughout the structure to other wall and floor assemblies with large surface areas, which in turn are forced into vibration. These vibrating surfaces, which behave somewhat like the sounding board of a piano, amplify and transmit the vibrational energy to the surrounding air, causing pressure fluctuations resulting in airborne noise to adjacent areas. The intensity of structure borne noise produced by a wall or floor structure when it has been forced into vibration is generally more intense and harder to dissipate than an airborne sound wave. Unlike sound propagated in air, the vibrations of structure born noise are transmitted rapidly with very little attenuation through the skeletal frame or other structural paths of the building and radiate the noise at high levels.
[0004] Since there are so many environments such as roofing, siding, appliances, automobiles, and airplanes to name a few, where this invention can be used, we will concentrate on flooring for the remainder of this patent since there are established standards, test methods and independent testing laboratories that can test and validate floor systems for the reduction of airborne and structure borne noise. Also floors constitute an important focus for sound insulation between living areas in multi-family or single-family dwellings. Floors allow the transmission of airborne and especially structural borne noise to adjoining rooms and building structure.
[0005] In North America, acoustical consultants, architects, builders, contractors and homeowners rely on sound testing to help gauge the performance of a floor and ceiling assembly for evaluation and comparison to determine how well the floor and ceiling assembly insulates against impact and airborne noises. The International Building Code (IBC) requires minimum ratings of 50 or above for both the Impact Insulation Class (IIC) and Sound Transmission Class (STC) sound tests performed in a controlled environment to measure the amount and extent of sound vibration or noise that travels from one living area to another.
[0006] The Impact Insulation Class utilizes American Society for Testing and Measurement (ASTM) standards ASTM E 492 and ASTM E 989 for testing the ability to block impact sound by measuring the resistance to transmission of impact noise or structure borne noise by simulating footfalls, objects dropped, rolled or bounced on the floor, to name a few. The Sound Transmission Class comprises ASTM E 90 and ASTM E 413 and evaluates the ability of a specific construction assembly to reduce airborne sounds, such as voices, stereo systems, and televisions to name a few. Both tests involve a standardized noise making apparatus in an upper chamber and a sound measuring system in a lower chamber. Decibel measurements are taken at various specified frequencies in the lower chamber. Those readings are then combined using a mathematical formula to create a whole number representation of the test, the higher the number, the higher the resistance to noise.
[0007] Many condominium associations have adopted the International Building Code minimum ratings of 50 for both the Impact Insulation Class and Sound Transmission Class sound tests for floor and ceiling assemblies. It should be noted that non-laboratory, “Field” tests for Impact Insulation Class (FIIC) and for Sound Transmission Class (FSTC) are also recognized by the International Building Code. These sound tests utilize the same testing methods which are used for Impact Insulation Class and Sound Transmission Class tests but are conducted in situ in an actual building after the floor installation is completed. The International Building Code suggests ratings of 45 or higher for Field Impact Insulation Class and Field Sound Transmission Class testing.
[0008] Another test that more directly evaluates impact sound of underlayment materials is ASTM E-2179, also known as the “Delta” test. This test basically consists of two Impact Insulation Class tests conducted over the same concrete sub-floor. One test is over the bare concrete subfloor (no flooring materials) and the other is over the concrete sub-floor with floor covering material and underlayment included. The measured Impact Insulation Class values are compared to the reference floor levels defined in the standard and adjusted to provide the Impact Insulation Class the covering would produce on the reference concrete floor. The Delta Impact Insulation Class or Improvement of Impact Sound Insulation is obtained by subtracting 28 (the value for the reference bare floor from the standard) from the adjusted Impact Insulation Class of the whole assembly. As long as the same floor covering material is used, one can conduct a series of Delta tests to evaluate various underlayment materials.
[0009] It is important to note that Impact Insulation Class and Sound Transmission Class tests are not single component tests, but an evaluation of the whole floor/ceiling assembly, from the surface of the floor covering material in the upper unit, to the ceiling in the lower unit. An integral part of a report for any of these sound tests is a detailed description of the floor/ceiling assembly used in the test. The Impact Insulation Class rating of a floor should be equal to or better than its Sound Transmission Class rating to achieve equal performance in controlling both airborne and structure bore sound.
[0010] Concrete slab flooring is used extensively throughout the world in buildings and homes. A concrete slab finished with a hard surface such as ceramic tiles is the prevalent floor structure for many commercial and institutional buildings. The ceramic tiles over a concrete slab provide an aesthetically pleasing, durable and smooth surface. Because of their easy maintenance and very long durability, ceramic tiles over a concrete slab, have the lowest lifetime cost of any flooring. On average, the concrete slab by itself has a Sound Transmission Class value around 50 and meets the International Building Code requirements. However, the Impact Insulation Class rating for typical concrete slabs is relatively low, 25 to 28 on average depending on the thickness of the concrete slab and is well below the International Building Code requirement of 50 minimum. The reason for the low Impact Insulation Class rating numbers is due to the transmission of high frequency sounds through the slab and into the room below. Hard-finish flooring materials (e.g., ceramic tiles) adhered directly to concrete slabs does not improve the Impact Insulation Class rating achieved by the concrete itself. Thus, concrete slabs finished with ceramic tiles or similar materials provide low Impact Insulation rating values and the addition of a noise reduction layer is essential to reduce impact noise for this type of extensively used floor structure.
[0011] The addition of an acoustic ceiling, if included as part of the floor and ceiling assembly, will cause an increase in both the Impact Insulation and Sound Transmission rating numbers, so the test becomes less critical when acoustic ceilings are part of the floor and ceiling assembly. Adding an acoustical ceiling to the home or office can be very expensive and adds additional labor and material costs. It would be desirable to have a floor system by itself, as defined in this patent, meet the International Building Code requirements without the added costs and labor associated with installing an acoustical ceiling.
[0012] Several methods have been used in the past to try to meet the International Building Code requirement for the Impact Insulation Class rating of a 50 minimum for the concrete slab with a hard-finish tile surface as mentioned above. One method used primarily in new construction or during renovating a structure consists of using a “floating” floor option. This method isolates the concrete slab floor from the substructure using various isolation techniques in an effort to reduce the impact noise through the floor structure as seen in FIG. 1 below.
[0013] This option is very expensive and requires extra space in renovating a building or in new construction and is not practical in many existing buildings today.
[0014] A second option used in industry today is to use a resilient layer or underlayment between the concrete slab and the hard ceramic tile finish surface in new construction or when renovating a floor in an existing building. This option is more advantageous because it is less expensive, easier to install and can be used in an existing building without reducing the overall living space of a room needed to isolate a floor structure.
[0015] There are several types of underlayments in the market used to reduce sound between a concrete slab and a hard tile surface that appears to meet the Impact Insulation Class rating of 50 minimum but each of these materials has a disadvantage. These materials are shredded or foamed rubber, natural and synthetic cork mats, natural fiber mats and modified and non-modified bituminous membranes. Shredded or foamed rubber can be very expensive, hard to install, is very heavy 1.0 to 1.4 lbs/square foot at a 6 mm thickness and it requires 6 mm of thickness to meet the Impact Insulation Class 50 minimum rating required by the International Building Codes. Cork (both natural and synthetic) and natural fiber mats can reduce the noise and approach the International Building Code requirements of 50 minimum Impact Insulation Class rating if thick enough, but these materials are not recommended for wet or humid areas since mold and mildew can develop over time and can cause health problems. Modified and non-modified bituminous membranes appear to be a good choice for use as a sound proof underlayment since they can act as a vapor barrier and are chemical resistant, easy to install, durables and are not prone to mold growth. Unfortunately, current bitumen and modified bitumen membranes in the market for floor underlayments have failed to reach the Impact Insulation Class rating of 50 minimum required by the International Building Code.
[0016] There appears to be a genuine need for a membrane that meets the International Building Code requirements for Impact Insulation Class and Sound Transmission Class ratings of 50 minimum that is easy to install that is light weight that is lower in thickness that can be used in wet or humid environments to reduce potential mold growth at a reasonable installed cost.
SUMMARY OF THE INVENTION
[0017] A novel self adhered membrane for use in homes, industries and environments where excess noise can be a detriment which: (1) reduces impact and airborne sound transmission; (2) is easy to install; (3) is thin (less than 2 mm thick); (4) is lightweight (less than 0.3 lbs/square feet); (5) has an improved tensile adhesive strength; (6) reduces labor required; (7) is environmentally safe; and (8) is ecologically friendly. The membrane can be used as part of the floor, roofing and/or wall system in buildings, automobiles, spacecraft, appliances, etcetera, wherever noise reduction is desired.
[0018] A sound barrier membrane disclosed herein meets these requirements and overcomes all of the detriments of the existing options mentioned. The disclosed membrane further provides or acts as a crack isolation, vapor barrier and sound barrier membrane combined into one single underlayment. This single underlayment meets the International Building Code Impact Insulation and Sound Transmission Class ratings as tested by a fully accredited testing facility for acoustical and structural testing, achieving a 50 Impact Insulation Class rating and 52 Sound Transmission Class rating tested between a 6 inch concrete slab and a hard ceramic tile flooring without an acoustic ceiling. This is the most cost effective floor and ceiling construction used in many buildings today and the hardest to pass the IBC requirements of 50 minimum for the IIC and STC due to the minimum thickness of the concrete slab and the use of hard ceramic tiles as a flooring material.
[0019] Acoustic tests on the disclosed sound membrane performed by an accredited third party testing laboratory verified that the present invention meets the sound requirements established by the International Building Code. Acoustic tests were carried out over 6 inch concrete slab and stoneware tile as flooring surface with and without acoustic ceiling. The following ratings were obtained: Impact Insulation Class 50 and Sound Transmission Class 52 without acoustic ceiling and Impact Insulation Class 70 and Sound Transmission Class 66 with acoustic ceiling.
[0020] The disclosed sound membrane also meets all the requirements of ANSI A118.12 and A118.13 for crack isolation and sound reduction membrane for flooring applications. Furthermore, a critical property for flooring application is tensile adhesion strength. The disclosed membrane was is tested according to ISO 13007 for ceramic tiles, grouts and adhesives. The importance of this test is to warranty good structural integrity and bonding of the underlayment to the concrete slab over time, the higher the tensile adhesive strength values the better. The disclosed sound membrane shows an increase of up to 225% for the adhesive strength values over competitive membranes that are offered in the industry today and exceeds the established current standard for this test standard.
[0021] Table 1 and 2 summarizes the Impact Insulation Class and Sound Transmission Class test results and the tensile adhesive strength values, respectively. A, B, C, and D are existing products offered in the market today for use as sound reduction membranes and were tested by a certified independent laboratory.
[0000]
TABLE 1
Independent Certified Laboratory Test results for Impact Insulation (IIC)
and Sound Transmission Class (STC) rating with no acoustic ceiling.
Disclosed
sound
A
B
C
D
membrane
IIC (ASTM 492/E 989)
48
46
49
46
50
6″ concrete slab/no acoustic ceiling
STC (ASTM E90, E413)
50
50
51
52
52
6″ concrete slab/no acoustic ceiling
[0000]
TABLE 2
Tensile adhesion test results
Disclosed
Sound
A
B
C
D
Membrane
Tensile adhesion strength,
44
42
20
28
65
psi (ISO 13007-1)
[0022] No existing sound proof membrane meets the sound requirements at the weight and thickness of the underlayment disclosed herein. The disclosed underlayment membrane which is positioned between the concrete slab and hard tile surface consists of a decoupling layer, a barrier layer and dampening layer in such a way as to prevent noise vibrations from being transmitted to the surrounding environment. The decoupling layer reduces the transmission of sound waves while the barrier layer prevents the dampening layer from penetrating the decoupling layer and imparts some rigidity to the system and acts in part like a secondary decoupling layer that contributes to dissipating sound vibrational energy. The dampening layer acts as a dampening material with sound absorbing, sound reducing characteristics that can also have viscoelastic and elastic properties or non-viscoelastic properties depending on the material used and can also act as an adhesive to attach the membrane to the concrete. The dampening material is capable of storing strain energy when deformed, while dissipating a portion of this energy through hysteresis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a sectional view of the typical existing floating floor.
[0024] FIG. 2 is a cross-sectional view of typical embodiment.
DETAILED DESCRIPTION
[0025] FIG. 2 is a schematic cross-sectional view of the construction of one embodiment. A generic example of the construction consists of a decoupling layer 1 , typically adhered with an adhesive layer 2 to a barrier layer 3 with a dampening layer 4 adhered to the opposite side of the barrier layer. The separation of decoupling layer 1 from the dampening layer 4 enhances the sound reduction properties. A release material 5 can be used to prevent the dampening layer from sticking to itself if the material is wound into a roll or stacked on top of itself.
[0026] A decoupling layer is a material used in the separation of previously linked systems so that they may operate independently. The decoupling layer separates the barrier layer from the surface to be applied on the sound barrier membrane, such as tile, which will applied on the sound barrier membrane. The decoupling layer also helps reduce sound transmission. The decoupling layer 1 can consist of various types or combinations of materials. Examples of the materials which can act as a decoupling layer are but not limited to fabric, foam, rubber and or cork but other materials can also be used. These materials can be used alone or in combination at different basis weights and thicknesses. Some examples of fabrics include but are not limited to polyester, glass, polypropylene, polyethylene, nylon or other manmade fibers, cotton or other natural fibers untreated or treated to prevent mold growth or any combination thereof. Examples of foam which can be used include but are not limited to urethane, polypropylene, polyethylene, rubber and or silicone to name a few, or any combination thereof. It should be noted in the case of flooring that the first decoupling layer should typically have a minimum porosity of about 50-300 cubic ft/square foot/minute using an 11 mm nozzle as measured using ASTM D 737 Standard Test Method for Air Permeability of Textile Fabrics using a Frazier Differential Pressure Air Permeability Tester. This allows penetration of the mortar, cement, glue, thin-set or any other material used in the industry to ensure adhesion to tiles, wood or other flooring materials to decoupling layer 1 for good mechanical bonding typically have a minimum of 20 PSI tensile adhesive strength as tested by the Pull Out Test Method. Thus the tiles, wood or other floor surfacing materials stay bonded, secure and affixed to the decoupling layer 1 during the service use of the material. Decoupling layer 1 should also resist mold and moisture and should maintain its integrity in the alkaline environment common in flooring applications.
[0027] A barrier layer is a material that blocks or impedes something. The barrier layer 3 is used primarily to separate decoupling layer 1 from dampening layer 4 enhancing the ability of the decoupling layer 1 to reduce sound transmission. The barrier layer 3 can consist of rigid and semi-rigid materials at different basis weights and thicknesses. The barrier layer must be somewhat stiff to maximize the effect between the dampening layer and the barrier layer. It prevents the dampening layer 4 from penetrating decoupling layer 1 if dampening layer 4 is a liquid or in a liquid state when it is applied to barrier layer 3 so that decoupling layer 1 can maximize the decoupling effect and channel the vibrational energy away from dampening layer 4 . Barrier layer 3 also helps to dissipate vibrational energy so that the barrier layer 3 in combination with dampening layer 4 allows vibrational energy to be converted to heat reducing vibrational noise from being transferred to the room below it. The rigid and semi-rigid materials can be used alone or in various combinations and can consist of but are not limited to aluminum, copper, steel, nickel, zirconium, vanadium, lead and tungsten to name a few of the materials that can be used to form a barrier layer for specific applications. Conductive ceramics can be also used, such as tantalum nitride, indium oxide, copper silicide, tungsten nitride, and titanium nitride to name a few. Other possible materials include but are not limited to polyester, polypropylene, polyethylene, vinyl or other plastic foam or plastic sheets alone or in combination unfilled or filled with mineral materials.
[0028] The dampening layer 4 utilizes a material which dampens or reduces the transmission of sound waves. Dampening is the action of a substance or of an element in a mechanical or electrical device that gradually reduces the degree of oscillation, vibration, or signal intensity, or prevents it from increasing. For example, sound-proofing technology dampens the oscillations of sound waves. Built-in dampening is a crucial design element in technology that involves the creation of oscillations and vibrations. Dampening layer 4 has viscoelastic and or elastic properties that help dissipate vibrational energy and turn it into heat reducing sound transmission.
[0029] Viscoelasticity is the property of materials that exhibit both viscous and elastic characteristics when undergoing deformation. Viscous materials, like honey, resist shear flow and strain linearly with time when a stress is applied. An elastic material is the physical property of a material that returns to its original shape. Elastic materials strain instantaneously when stretched and just as quickly return to their original state once the stress is removed. Viscoelastic materials have elements of both of these properties and, as such, exhibit time dependent strain. Whereas elasticity is usually the result of bond stretching along crystallographic planes in an ordered solid, viscosity is the result of the diffusion of atoms or molecules inside an amorphous material.
[0030] Viscoelastic materials used for dampening layer 4 can be but are not limited to bitumen, modified bitumen that consists of but is not limited to bitumen (asphalt) blended with styrene butadiene rubber, styrene butadiene styrene rubber, styrene isoprene styrene rubber, styrene ethylene butylene styrene rubber, natural rubber, recycled tire rubber with or without mineral filler, oils or stabilizers with or without tackifying resins, atactic polypropylene, ethylene propylene copolymer, or other rubber types like: acrylic rubber, butadiene rubber, butyl rubber, chlorobutyl, chlorinated polyethylene, chlorosulphonated polyethylene, epichlorohydrin ethylene oxide rubber, ethylene-propylene rubber, fluoroelastomer, hydrogenated nitrile rubber, isoprene rubber, natural rubber, nitrile rubber, perfluoroelastomers, polychloroprene, polynorbornene rubber, polysulfide rubber, polyurethane rubber, silicon and fluorosilicon rubber, styrene butadiene rubber, tetra-flouroethylene polypropylene or any combination thereof, cork, polypropylene foam, urethane foam, silicone foam, or rubber to name other viscoelastic, elastic or dampening materials. All of these can be utilized in any combination, weight and thickness.
[0031] Some of the dampening materials are adhesive in nature and thus may not need a separate adhesive layer. If needed an adhesive layer 6 can be factory applied or applied on site in the field to bond the barrier layer 3 to the dampening layer 4 . ( FIG. 3 ) The bond between the decoupling layer 1 and the barrier layer 3 can also be achieved by using an adhesive layer 2 consisting of glues such as Albumin, Casein, Meat, Canada balsam Coccoina, Gum Arabic, Latex, Starch, Methyl cellulose, Mucilage, Resorcinol resin, Urea-formaldehyde resin, Polystyrene cement/Butanone, Dichloromethane, Acrylonitrile, Cyanoacrylate, Acrylic, Resorcinol, Epoxy resins, Ethylene-vinyl acetate, Phenol formaldehyde resin, Polyamide, Polyester resins, Polyethylene, Polysulfides, Polyurethane, Polyvinyl acetate, Polyvinyl alcohol, Polyvinyl chloride, Polyvinyl chloride emulsion, Polyvinylpyrrolidone, rubber cement and Silicones. Additional means to create the adhesive layer 2 which are known in the industry include but are not limited to pressure sensitive adhesives, contact adhesives, heat sensitive, heat activated, welding, curtain coating, kiss coating, spraying or other methods known to those adept in the industry.
[0032] The barrier layer 3 may be bonded to the dampening layer 4 during manufacturing or applied in the field as a separate layer. The dampening layer 4 could have adhesive characteristics so that it adheres to the barrier layer 3 without an additional adhesive layer 2 . Also the dampening layer 4 can be applied in a molten or liquid form to the barrier layer 3 during manufacturing of the material or in the field. This bond can be achieved by using various glues or techniques know in the industry and include but are not limited to glues like Albumin, Casein, Meat, Canada balsam Coccoina, Gum Arabic, Latex, Starch, Methyl cellulose, Mucilage, Resorcinol resin, Urea-formaldehyde resin, Polystyrene cement/Butanone, Dichloromethane, Acrylonitrile, Cyanoacrylate, Acrylic, Resorcinol, Epoxy resins, Ethylene-vinyl acetate, Phenol formaldehyde resin, Polyamide, Polyester resins, Polyethylene, Polysulfides, Polyurethane, Polyvinyl acetate, Polyvinyl alcohol, Polyvinyl chloride, Polyvinyl chloride emulsion, Polyvinylpyrrolidone, Rubber cement and Silicones. Additional techniques include but are not limited to: pressure sensitive adhesives, contact adhesives, heat sensitive, heat activated, heat welding, curtain coating, kiss coating, spraying or other methods known to those adept in the industry.
[0033] In one specific embodiment, the construction of the invention is as shown in FIG. 2 . The decoupling layer 1 consist of a polyester or polypropylene fabric or mat with a basis weight of 50 to 450 grams per square meter and is bonded using a urethane or acrylic based adhesive layer 2 to a barrier layer 3 consisting of an aluminum foil with a thickness of 0.1 to 5.0 mils. The barrier layer 3 is then coated with a dampening layer 4 consisting of a styrene butadiene, styrene Isoprene styrene, modified bitumen pressure sensitive adhesive with a thickness of 0.1 to 5 mm and a propylene silicone release liner 5 .
[0034] In a second specific embodiment as shown in FIG. 2 , the decoupling layer 1 consists of a polyester or polypropylene fabric or mat with a basis weight of 100 to 300 grams per square meter and is bonded using a urethane or acrylic based adhesive layer 2 to a barrier layer 3 consisting of an aluminum foil with a thickness of 0.6 to 2.0 mils. The barrier layer 3 is then coated with a dampening layer 4 consisting of a styrene butadiene, styrene Isoprene styrene, styrene butyl rubber, hydrocarbon resin, paraffinic or naphthenic oil, calcium carbonate modified bitumen pressure sensitive adhesive with a thickness of 0.2 to 2 mm and a propylene silicone release liner 5 .
[0035] In a third specific embodiment as shown in FIG. 2 , the decoupling layer 1 consists of a polyester or polypropylene fabric or mat with a basis weight of 160 to 200 grams per square meter and is bonded using a urethane or acrylic based adhesive layer 2 to a barrier layer 3 consisting of an aluminum foil with a thickness of 0.8 to 1.2 mils. The layer 3 is then coated with a dampening layer 4 consisting of a styrene butadiene, styrene Isoprene styrene, styrene butyl rubber, hydrocarbon resin, paraffinic or naphthenic oil, calcium carbonate modified bitumen pressure sensitive adhesive with a thickness of 0.5 to 1.2 mm and a propylene silicone release liner 5 .
[0036] In a fourth specific embodiment, one or more additional layers may be added. The additional layer(s) may include multiple decoupling layers and or multiple barrier layers rigid or semi-rigid materials, fillers or extenders and or multiple dampening layers that could be viscoelastic, elastic or non-viscoelastic materials with or without mineral or manmade fibers, fillers or extenders and can be added to or sandwiched into the present invention thus forming multiple decoupling layers, multiple barrier layers and multiple dampening layers. It is obvious to those adept in the industry that since the construction of the disclosed embodiments using one decoupling layer 1 , one barrier layer 3 and one dampening layer 4 exceeds the International Building Code minimum requirement of a 50 Impact Insulation Class and 50 minimum Sound Transmission Class rating, that adding more layers, or using multiple layers of any or all components or by adding extenders or fillers would only enhance the sound reduction properties of the material.
[0037] In a fifth specific embodiment alternate materials can be used for layer 5 to prevent the roll from sticking to itself if the material is wound into a roll or stacked on top of itself. Alternate materials for layer 5 include but are not limited to sand, limestone, talc, fly ash, mineral particles, granules, glass spheres and or ceramic nano-particles alone or in combination. This is obvious to those adept in the industry. Also a film or paper or chemical or nonchemical treatment could be used as a separation layer or means to prevent the material from bonding or sticking to itself and can be used instead of the release liner 5 . It is also obvious to those adept in the industry that an adhesive can be used in situ to bond the membrane to the floor, wall or ceiling or other substrates.
[0038] In a sixth specific embodiment the barrier layer 3 is removed and replaced by using a heat, chemical, material and or other treatment such as a nip or calendar roll on the surface of the decoupling layer 1 . Other techniques to maintain the separation of the dampening layer 4 from the decoupling layer 1 are obvious to those adept in the industry. This is another method to achieve the effective decoupling properties of the present invention and is obvious to anyone adept in the field.
[0039] The sound barrier membrane is typically created by: (1) selecting a material for the decoupling layer; (2) selecting a material for the barrier layer; (3) selecting a material for the dampening layer; (4) bonding the decoupling layer to the barrier layer; and (5) bonding the barrier layer to the dampening layer. This is typically performed in a factory and sent to a site for sale or installation.
[0040] In another embodiment of the method for assembly of the sound barrier membrane, the dampening layer 4 is not factory applied to the barrier layer 3 during manufacturing. The decoupling layer 1 is bonded to a barrier layer 3 using an adhesive layer 2 during manufacturing process but the dampening layer 4 is applied in the field as a separate layer during installation. This dampening layer 4 can be a membrane or any material that acts as a dampening layer 4 such as cork, rubber, tire rubber, silicone caulk, asphalt, rubber compound, modified bitumen compound, urethane, silicone, polypropylene or other foams alone or in combinations. This dampening layer 4 is bonded to the substrate, floor, wall or other structure using any technique known in the industry such as using a glue, caulk, asphalt, compound or modified bitumen compound or adhesive. The barrier layer 3 is then bonded to the dampening layer 4 . The barrier layer 3 can be bonded to the dampening layer 4 using glue that can acts as a dampening layer 4 such as a urethane or silicone adhesive, caulk or paste.
[0041] In another specific embodiment all of the layers shown in FIG. 2 (the decoupling layer 1 , the adhesive layer 2 , the barrier layer 3 and the dampening layer 4 ) can be sold individually or in kits of various combinations and combined in the field. The decoupling layer 1 can be sold separately or with a glue or other combination of materials and can be bonded to a barrier layer 3 using the adhesive in the kit or any glue, welding or fastening technique known in the industry such as hook and loop material, hot glue, double sided tape, or other techniques known in the industry. The dampening layer 4 does not have to be factory applied but can be field applied to the barrier layer 3 using glue that acts as a viscoelastic, elastic or dampening layer 4 such as a urethane or silicone adhesive that is itself a viscoelastic, elastic or dampening material. A viscoelastic, elastic or dampening material including modified bitumen, rubber, recycled tire rubber, cork, or other material, can be bonded using any glue, adhesive. Other techniques for bonding include: mopping or head welding applying asphalt or modified bitumen, cold welding, UV curing, using double sided adhesive tapes, pressure sensitive adhesives, contact adhesives, caulk, paste or other adhesives like urethane, silicone, epoxy, or starch based glues. All of the above techniques and materials allow the creation of this embodiment in pieces or layers. This also allows the creation of the embodiments disclosed by the addition of one or parts of the above to existing sound reduction membranes, panels or system like sound channel panels, rods, strips, and or blocks to name a few.
[0042] The embodiments disclosed can also be used in roofing, walls, buildings, appliances, aircraft, automotive, naval, and/or other sound reducing applications.
[0043] The above is a detailed description of particular embodiments of the invention. It is recognized that departures from the disclosed embodiments may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. Those skilled in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed herein and still obtain a like or similar result without departing from the spirit and scope of the invention. All of the embodiments disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure.
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A sound barrier membrane comprises of a decoupling layer, a barrier layer and a dampening layer. The membrane also provides crack isolation, and acts as a vapor barrier. Numerous materials are disclosed which can be used to create these layers. Methods for assembly of the sound barrier membrane are also disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to methods and devices for cleaning and remediating a subsurface safety valve or other downhole tool having a sliding sleeve member.
2. Description of the Related Art
Flapper-type valves are often used as safety valves within wells to selectively close off production. The usual flapper valve uses a torsion spring to bias the valve member toward a closed position. During normal operation, however, the flapper member is retained in an open position by an axially moveable flow tube. When the flow tube is moved upwardly within the production tubing, the flapper member is permitted to close under influence of the spring. To reopen the valve, the flow tube is moved downwardly within the production tubing to urge the valve back towards its open position.
One problem that has traditionally been faced by valves of this type is that scale, dirt, and other debris will often build up within the production tubing during typical production operations. This build up can render the safety valve partially or completely inoperable. The most deleterious build up will be that which occurs on and around the flow tube that is used to open the valve, making the flow tube difficult to physically move upwardly and downwardly. Additionally, the flapper mechanism may be encrusted with scale and other debris making it less likely to fully close when necessary. This means that the valve will be unable to function well in the event of an emergency requiring production flow to be closed off.
U.S. Pat. No. 6,273,187, entitled “Method and Apparatus for Downhole Safety Valve Remediation,” describes a technique for removing scale and debris build up using explosive charges. The use of explosives, however, carries with it risks of damage to wellbore valve components as well as the potential for a breach of the production tubing string.
The harmful effects of scale and debris build up can be prevented and reduced by exercising the safety valve, through operation of its components, before the build up has reached a point where the safety valve is no longer fully operational. In the past, this has been accomplished using a gripping tool having mechanical slips that are set against the inside of the flow tube. Once the slips are set, the gripping tool can be pulled upwardly to move the flow tube upwardly or jarred downwardly to move the flow tube downwardly. Unfortunately, tools of this type tend to physically damage the flow tube and other wellbore components, due to the use of the slips.
The present invention addresses the problems of the prior art.
SUMMARY OF THE INVENTION
The invention provides an improved flow tube exercising tool and method of use. An exemplary flow tube exercising tool is described that is used in conjunction with the hydraulic controller of the safety valve to move the flow tube axially upwardly and downwardly in order to remove build ups of scale and debris from the safety valve and ensure proper operation. The exercising tool provides an engagement portion that underlies the lower end of the safety valve flow tube so that upward movement of the exercising tool will move the flow tube upwardly. Hydraulic fluid is provided to the hydraulic controller to move the flow tube downwardly. Only a single trip of the flow tube exercising tool is necessary to accomplish multiple upward and downward movements of the flow tube.
BRIEF DESCRIPTION OF THE DRAWINGS
For a thorough understanding of the present invention, reference is made to the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing.
FIG. 1 is a side, cross sectional view of an exemplary flow tube exercising tool constructed in accordance with the present invention wherein the exercising tool is being run into production tubing.
FIG. 2 is a side, cross-sectional view of the exercising tool shown in FIG. 1 now with the lower engagement portion of the exercising tool engaging the lower end of the safety valve flow tube.
FIG. 3 is a side, cross-sectional view of the exercising tool shown in FIGS. 1 and 2 now with the flow tube having been raised to an upper position by the exercising tool.
FIG. 4 is a side, cross-sectional view of the exercising tool shown in FIGS. 1-3 now with the tool being disengaged from the safety valve flow tube for removal from the production tubing.
FIG. 5 is an enlarged view of upper portions of the exercising tool shown in FIGS. 1-4 .
FIG. 6 is an enlarged view of upper portions of the exercising tool shown in FIGS. 1-4 now with the exercising tool engaged with the safety valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-4 illustrate a section of a subterranean wellbore 10 that has been lined with steel casing 12 that has been cemented in place by cement layer 14 . The wellbore 10 contains a string of production tubing 16 that defines a production flowbore 18 along its length. A safety valve, generally indicated at 20 is integrated into the production tubing string 16 . The safety valve 20 is a flapper valve, of a type that is well known in the art and described in, for example, U.S. Pat. No. 4,415,036 issued to Carmody. U.S. Pat. No. 4,415,036 is owned by the assignee of the present invention and is incorporated herein by reference. In the safety valve 20 , a flapper valve member (not shown) is biased toward a closed position by a spring (not shown), in the manner well known in the art. The flapper member is opened and retained in an open position by an axially moveable flow tube 22 which, in turn, is actuated by a hydraulic piston-type controller 24 . For clarity, only the flow tube 22 and hydraulic controller 24 portions of the safety valve 20 are depicted in FIGS. 1-4 .
At its upper end, the safety valve 20 includes a nipple adapter 26 that is secured by threaded connection 28 to a production tubing string member 30 . The structure of the nipple adapter 26 is best appreciated by further reference to FIGS. 5 and 6 , which depict portions of it in greater detail. The nipple adapter 26 defines an interior axial flowbore 32 along its length, and an annular dog recess 34 is located within the flowbore 32 . An upwardly directed stop shoulder 35 is also located within the flowbore 32 .
At its lower end, the nipple adapter 26 is affixed to the hydraulic controller 24 . The hydraulic controller 24 has an annular outer housing that is made up of an upper hydraulic control sub 36 and a lower hydraulic control sub 38 . The lower sub 38 is secured at its lower end to a flapper valve housing 40 that encloses the flapper valve member (not shown). An inner housing portion 42 is secured to the lower sub 38 and a hydraulic fluid piston chamber 44 is defined within the upper and lower control subs 36 , 38 . An axially moveable piston member 46 is disposed within the chamber 44 . At its lower end, the piston member 46 is secured to the flow tube 22 such that downward axial movement of the piston member 46 within the chamber 44 will result in axial downward movement of the flow tube 22 . One or more hydraulic lines 48 extend from surface (not shown) of the wellbore 10 to the upper hydraulic control sub 36 and interconnect to a fluid passage 50 within the upper sub 36 . The fluid passage 50 interconnects the hydraulic line 48 to the hydraulic fluid piston chamber 44 .
Also shown in FIGS. 1-4 is a flow tube exercising tool 52 that is run into the flowbore 18 of the production tubing string 16 at the lower end of a wireline “GS” type running tool 54 of a type known in the art. The flow tube exercising tool 52 includes a tubular mandrel body 55 that is made up of an outer mandrel 56 and a radially inner mandrel 58 . A shear pin 60 releasably interconnects the outer and inner mandrels 56 , 58 against axial movement with respect to each other. The outer mandrel 56 includes an aperture 62 within which a locking dog 64 is disposed. The inner mandrel 58 has a dog recess 66 (see FIG. 5 ) which partially houses the dog 64 as well. The dog recess 66 is formed to have an angled cam face 67 at its upper end that faces downwardly and outwardly.
The outer mandrel 56 is composed of an upper section 68 and a lower section 70 that are releasably affixed to one another by a shear pin 72 . The shear pin 72 is designed to rupture in response to a higher level of force than the shear pin 60 . The lower section 70 also carries a shifting pin 74 . The shifting pin 74 extends radially inwardly through a slot 76 in the inner mandrel 58 and extends further inwardly to project into the flowbore 77 that is defined within the inner mandrel 58 .
The lower end of outer mandrel 56 is provided with an inwardly-directed tapered surface 78 . The inner mandrel 58 has, at its lower end, a flow tube engagement portion 80 that is shaped and sized to underlie the lower end 82 of the flow tube 22 . In a currently preferred embodiment, the engagement portion 80 is a colleted section 84 with each of the collets 86 presenting a radially outwardly protruding flange 90 . The collets 86 are biased radially outwardly due to shape memory, and, in the initial run-in configuration depicted by FIG. 1 , are restrained radially inwardly by the lower section 70 of the outer mandrel 56 . The outer radial surface 92 of the outer mandrel 56 presents a downwardly facing stop shoulder 94 (see FIG. 5 ) that is shaped and sized to abut the stop shoulder 35 of the nipple adapter 26 .
In operation, the flow tube exercising tool 52 is run down into the flowbore 18 of the production string 16 and lowered until the stop shoulder 94 of the outer mandrel 56 abuts the stop shoulder 35 of the nipple adapter 26 . This is the position shown in FIG. 1 . Further downward movement of the running tool 54 will cause the shear pin 60 to rupture, thereby permitting the inner mandrel 58 to be moved axially downwardly with respect to the outer mandrel 56 , until the position depicted in FIG. 2 is reached.
As the inner mandrel 58 is moved downwardly with respect to the outer mandrel 56 , two things occur. First, the locking dog 64 is set into the dog recess 34 of the nipple adapter 26 in order to securely lock the outer mandrel 56 within the nipple adapter 26 . FIGS. 5 and 6 illustrate the setting operation. As the inner mandrel 58 moves downwardly (from the position shown in FIG. 5 to the position shown in FIG. 6 ), the angled cam face 67 cams the locking dog 64 radially outwardly and into the dog recess 34 in the nipple adapter 26 . The body of the inner mandrel 58 then blocks the locking dog 64 from moving radially inwardly, securing it in place within the dog recess 34 .
Also, as the inner mandrel 58 reaches its lowermost position, the collets 86 are no longer restrained from outward movement by the lower section 70 of the outer mandrel 56 and will move outwardly so that the flange 90 will underlie the lower end 82 of the flow tube 22 . Once in this position, the flow tube exercising tool 52 may be used, in conjunction with the hydraulic controller 24 to move the flow tube 22 axially upwardly and downwardly in order to remove scale and debris from the safety valve 20 and to ensure that the valve 20 is fully operational. By pulling upwardly on the running tool 54 , the inner mandrel 58 of the exercising tool 52 is moved upwardly with respect to the outer mandrel 56 . Due to the engagement of the flange 90 with the lower end 82 of the flow tube 22 , the flow tube 22 is moved axially upwardly within the valve 20 .
To return the flow tube 22 to its lowered position, hydraulic fluid is pumped down the hydraulic line 48 to the hydraulic controller 24 and into the hydraulic chamber 44 to cause the piston member 46 and flow tube 22 to move axially downwardly. The flow tube 22 may be manipulated upwardly and downwardly by repeating the above operational steps as many times as desired to ensure proper operation of the valve 20 and the removal of scale and other deposits from its components.
Normally, the exercising tool 52 may be detached from the flow tube 22 by merely pulling upwardly with sufficient force that the collets 86 are deflected radially inwardly and thus released from the lower end 82 of the flow tube 22 . At that point, the exercising tool 52 is withdrawn from the safety valve 20 and from the tubing string 16 . If, however, the exercising tool 52 cannot be detached in this manner, a release tool 100 , shown in FIG. 4 , can be run into the interior flowbore 77 of the exercising tool 52 and used to disengage the exercising tool 52 from the valve 20 . The release tool 100 is a tubular sleeve 102 having an axial end portion 104 for contacting the shifting pin 74 . The sleeve 102 is run into the flowbore 77 using a wireline running tool 106 , of a type known in the art. In operation, the end portion 104 of the sleeve 102 contacts the shifting pin 74 and urges it axially downwardly. The shear pin 72 then ruptures, allowing the upper and lower sections 68 , 70 of the outer mandrel 56 to separate. The lower portion 70 is moved downwardly so that the tapered surface 78 will urge the collets 86 radially inwardly and out of engagement with the lower end 82 of the flow tube 22 . The body of the lower portion 70 essentially acts as a wedge to physically separate the collets 86 from the flow tube 22 . Once disengaged by the release tool 100 , the exercising tool 52 may be removed from the valve 20 by pulling upwardly on the running tool 54 . In so doing, the locking dog 64 will be released from the dog recess 34 when the inner mandrel 58 is raised to the point where the recess 66 is adjacent the locking dog 64 . When this occurs, the dog 64 is cammed radially inwardly toward the recess 66 by sloped surface 110 on the upper side of the dog recess 34 .
The flow tube 22 may be moved axially upwardly and downwardly in an alternating manner as described above as necessary to remove scale and other debris and ensure proper operation of the safety valve 20 . Movement of the flow tube 22 may be exercised in this manner using only a single trip of the exercising tool 52 into the production tubing 16 . However, the exercising tool 52 may also be run into the production tubing 16 on several separate occasions during the life of the wellbore to ensure continued proper operation of the safety valve 20 throughout.
Those of skill in the art will recognize that numerous modifications and changes may be made to the exemplary designs and embodiments described herein and that the invention is limited only by the claims that follow and any equivalents thereof.
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A flow tube exercising tool and method for use are described for actuating the flow tube of a downhole safety valve in order to remove build ups of scale and debris from the safety valve and ensure proper operation. The exercising tool provides an engagement portion that underlies the lower end of the safety valve flow tube so that upward movement of the exercising tool will move the flow tube upwardly. Hydraulic fluid is then provided to the safety valve hydraulic controller to move the flow tube downwardly. Only a single trip of the flow tube exercising tool is necessary to accomplish multiple upward and downward movements of the flow tube.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/395,843, entitled “Adaptive Weighting Of Reference Pictures In Video CODEC” and filed Jul. 15, 2002, which is incorporated by reference herein in its entirety. In addition, this application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/395,874, entitled “Motion Estimation With Weighting Prediction” also filed Jul. 15, 2002, which is incorporated by reference herein in its entirety. Additionally, this application is closely related to U.S. patent application Ser. No. 10/410,456, filed on 9 Apr. 2003.
FIELD OF THE INVENTION
The present invention is directed towards video decoders, and in particular, towards utilization of adaptive weighting of reference pictures in video decoders.
BACKGROUND OF THE INVENTION
Video data is generally processed and transferred in the form of bit streams. Typical video compression coders and decoders (“CODECs”) gain much of their compression efficiency by forming a reference picture prediction of a picture to be encoded, and encoding the difference between the current picture and the prediction. The more closely that the prediction is correlated with the current picture, the fewer bits that are needed to compress that picture, thereby increasing the efficiency of the process. Thus, it is desirable for the best possible reference picture prediction to be formed.
In many video compression standards, including Moving Picture Experts Group (“MPEG”)-1, MPEG-2 and MPEG-4, a motion compensated version of a previous reference picture is used as a prediction for the current picture, and only the difference between the current picture and the prediction is coded. When a single picture prediction (“P” picture) is used, the reference picture is not scaled when the motion compensated prediction is formed. When bi-directional picture predictions (“B” pictures) are used, intermediate predictions are formed from two different pictures, and then the two intermediate predictions are averaged together, using equal weighting factors of (½, ½) for each, to form a single averaged prediction. In these MPEG standards, the two reference pictures are always one each from the forward direction and the backward direction for B pictures.
SUMMARY OF THE INVENTION
These and other drawbacks and disadvantages of the prior art are addressed by a system and method for adaptive weighting of reference pictures in video decoders.
A video decoder and corresponding methods for processing video signal data for an image block and a particular reference picture index to predict the image block are disclosed that utilize adaptive weighting of reference pictures to enhance video compression. A decoder includes a reference picture weighting factor unit for determining a weighting factor corresponding to the particular reference picture index.
A corresponding method for decoding video includes receiving a reference picture index with the data that corresponds to the image block, determining a weighting factor for each received reference picture index, retrieving a reference picture for each index, motion compensating the retrieved reference picture, and multiplying the motion compensated reference picture by the corresponding weighting factor to form a weighted motion compensated reference picture.
These and other aspects, features and advantages of the present invention will become apparent from the following description of exemplary embodiments, which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Adaptive weighting of reference pictures in video coders and decoders in accordance with the principles of the present invention are shown in the following exemplary figures, in which:
FIG. 1 shows a block diagram for a standard video decoder;
FIG. 2 shows a block diagram for a video decoder with adaptive bi-prediction;
FIG. 3 shows a block diagram for a video decoder with reference picture weighting in accordance with the principles of the present invention;
FIG. 4 shows a block diagram for a standard video encoder;
FIG. 5 shows a block diagram for a video encoder with reference picture weighting in accordance with the principles of the present invention;
FIG. 6 shows a flowchart for a decoding process in accordance with the principles of the present invention; and
FIG. 7 shows a flowchart for an encoding process in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention presents an apparatus and method for motion vector estimation and adaptive reference picture weighting factor assignment. In some video sequences, in particular those with fading, the current picture or image block to be coded is more strongly correlated to a reference picture scaled by a weighting factor than to the reference picture itself. Video CODECs without weighting factors applied to reference pictures encode fading sequences very inefficiently. When weighting factors are used in encoding, a video encoder needs to determine both weighting factors and motion vectors, but the best choice for each of these depends on the other, with motion estimation typically being the most computationally intensive part of a digital video compression encoder.
In the proposed Joint Video Team (“JVT”) video compression standard, each P picture can use multiple reference pictures to form a picture's prediction, but each individual motion block or 8×8 region of a macroblock uses only a single reference picture for prediction. In addition to coding and transmitting the motion vectors, a reference picture index is transmitted for each motion block or 8×8 region, indicating which reference picture is used. A limited set of possible reference pictures is stored at both the encoder and decoder, and the number of allowable reference pictures is transmitted.
In the JVT standard, for bi-predictive pictures (also called “B” pictures), two predictors are formed for each motion block or 8×8 region, each of which can be from a separate reference picture, and the two predictors are averaged together to form a single averaged predictor. For bi-predictively coded motion blocks, the reference pictures can both be from the forward direction, both be from the backward direction, or one each from the forward and backward directions. Two lists are maintained of the available reference pictures that may used for prediction. The two reference pictures are referred to as the list 0 and list 1 predictors. An index for each reference picture is coded and transmitted, ref_idx_l0 and ref_idx_l1, for the list 0 and list 1 reference pictures, respectively. Joint Video Team (“JVT”) bi-predictive or “B” pictures allows adaptive weighting between the two predictions, i.e.,
Pred=[(P0)(Pred0)]+[(P1)(Pred1)]+D,
where P0 and P1 are weighting factors, Pred0 and Pred1 are the reference picture predictions for list 0 and list 1 respectively, and D is an offset.
Two methods have been proposed for indication of weighting factors. In the first, the weighting factors are determined by the directions that are used for the reference pictures. In this method, if the ref_idx_l0 index is less than or equal to ref_idx_l1, weighting factors of (½, ½) are used, otherwise (2, −1) factors are used.
In the second method offered, any number of weighting factors is transmitted for each slice. Then a weighting factor index is transmitted for each motion block or 8×8 region of a macroblock that uses bi-directional prediction. The decoder uses the received weighting factor index to choose the appropriate weighting factor, from the transmitted set, to use when decoding the motion block or 8×8 region. For example, if three weighting factors were sent at the slice layer, they would correspond to weight factor indices 0, 1 and 2, respectively.
The following description merely illustrates the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the invention and are included within its spirit and scope. Furthermore, all examples and conditional language recited herein are principally intended expressly to be only for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.
Thus, for example, it will be appreciated by those skilled in the art that the block diagrams herein represent conceptual views of illustrative circuitry embodying the principles of the invention. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudocode, and the like represent various processes which may be substantially represented in computer readable media and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” or “controller” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (“DSP”) hardware, read-only memory (“ROM”) for storing software, random access memory (“RAM”), and non-volatile storage. Other hardware, conventional and/or custom, may also be included. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the implementer as more specifically understood from the context.
In the claims hereof any element expressed as a means for performing a specified function is intended to encompass any way of performing that function including, for example, a) a combination of circuit elements that performs that function or b) software in any form, including, therefore, firmware, microcode or the like, combined with appropriate circuitry for executing that software to perform the function. The invention as defined by such claims resides in the fact that the functionalities provided by the various recited means are combined and brought together in the manner which the claims call for. Applicant thus regards any means that can provide those functionalities as equivalent to those shown herein.
As shown in FIG. 1 , a standard video decoder is indicated generally by the reference numeral 100 . The video decoder 100 includes a variable length decoder (“VLD”) 110 connected in signal communication with an inverse quantizer 120 . The inverse quantizer 120 is connected in signal communication with an inverse transformer 130 . The inverse transformer 130 is connected in signal communication with a first input terminal of an adder or summing junction 140 , where the output of the summing junction 140 provides the output of the video decoder 100 . The output of the summing junction 140 is connected in signal communication with a reference picture store 150 . The reference picture store 150 is connected in signal communication with a motion compensator 160 , which is connected in signal communication with a second input terminal of the summing junction 140 .
Turning to FIG. 2 , a video decoder with adaptive bi-prediction is indicated generally by the reference numeral 200 . The video decoder 200 includes a VLD 210 connected in signal communication with an inverse quantizer 220 . The inverse quantizer 220 is connected in signal communication with an inverse transformer 230 . The inverse transformer 230 is connected in signal communication with a first input terminal of a summing junction 240 , where the output of the summing junction 240 provides the output of the video decoder 200 . The output of the summing junction 240 is connected in signal communication with a reference picture store 250 . The reference picture store 250 is connected in signal communication with a motion compensator 260 , which is connected in signal communication with a first input of a multiplier 270 .
The VLD 210 is further connected in signal communication with a reference picture weighting factor lookup 280 for providing an adaptive bi-prediction (“ABP”) coefficient index to the lookup 280 . A first output of the lookup 280 is for providing a weighting factor, and is connected in signal communication to a second input of the multiplier 270 . The output of the multiplier 270 is connected in signal communication to a first input of a summing junction 290 . A second output of the lookup 280 is for providing an offset, and is connected in signal communication to a second input of the summing junction 290 . The output of the summing junction 290 is connected in signal communication with a second input terminal of the summing junction 240 .
Turning now to FIG. 3 , a video decoder with reference picture weighting is indicated generally by the reference numeral 300 . The video decoder 300 includes a VLD 310 connected in signal communication with an inverse quantizer 320 . The inverse quantizer 320 is connected in signal communication with an inverse transformer 330 . The inverse transformer 330 is connected in signal communication with a first input terminal of a summing junction 340 , where the output of the summing junction 340 provides the output of the video decoder 300 . The output of the summing junction 340 is connected in signal communication with a reference picture store 350 . The reference picture store 350 is connected in signal communication with a motion compensator 360 , which is connected in signal communication with a first input of a multiplier 370 .
The VLD 310 is further connected in signal communication with a reference picture weighting factor lookup 380 for providing a reference picture index to the lookup 380 . A first output of the lookup 380 is for providing a weighting factor, and is connected in signal communication to a second input of the multiplier 370 . The output of the multiplier 370 is connected in signal communication to a first input of a summing junction 390 . A second output of the lookup 380 is for providing an offset, and is connected in signal communication to a second input of the summing junction 390 . The output of the summing junction 390 is connected in signal communication with a second input terminal of the summing junction 340 .
As shown in FIG. 4 , a standard video encoder is indicated generally by the reference numeral 400 . An input to the encoder 400 is connected in signal communication with a non-inverting input of a summing junction 410 . The output of the summing junction 410 is connected in signal communication with a block transformer 420 . The transformer 420 is connected in signal communication with a quantizer 430 . The output of the quantizer 430 is connected in signal communication with a variable length coder (“VLC”) 440 , where the output of the VLC 440 is an externally available output of the encoder 400 .
The output of the quantizer 430 is further connected in signal communication with an inverse quantizer 450 . The inverse quantizer 450 is connected in signal communication with an inverse block transformer 460 , which, in turn, is connected in signal communication with a reference picture store 470 . A first output of the reference picture store 470 is connected in signal communication with a first input of a motion estimator 480 . The input to the encoder 400 is further connected in signal communication with a second input of the motion estimator 480 . The output of the motion estimator 480 is connected in signal communication with a first input of a motion compensator 490 . A second output of the reference picture store 470 is connected in signal communication with a second input of the motion compensator 490 . The output of the motion compensator 490 is connected in signal communication with an inverting input of the summing junction 410 .
Turning to FIG. 5 , a video encoder with reference picture weighting is indicated generally by the reference numeral 500 . An input to the encoder 500 is connected in signal communication with a non-inverting input of a summing junction 510 . The output of the summing junction 510 is connected in signal communication with a block transformer 520 . The transformer 520 is connected in signal communication with a quantizer 530 . The output of the quantizer 530 is connected in signal communication with a VLC 540 , where the output of the VLC 440 is an externally available output of the encoder 500 .
The output of the quantizer 530 is further connected in signal communication with an inverse quantizer 550 . The inverse quantizer 550 is connected in signal communication with an inverse block transformer 560 , which, in turn, is connected in signal communication with a reference picture store 570 . A first output of the reference picture store 570 is connected in signal communication with a first input of a reference picture weighting factor assignor 572 . The input to the encoder 500 is further connected in signal communication with a second input of the reference picture weighting factor assignor 572 . The output of the reference picture weighting factor assignor 572 , which is indicative of a weighting factor, is connected in signal communication with a first input of a motion estimator 580 . A second output of the reference picture store 570 is connected in signal communication with a second input of the motion estimator 580 .
The input to the encoder 500 is further connected in signal communication with a third input of the motion estimator 580 . The output of the motion estimator 580 , which is indicative of motion vectors, is connected in signal communication with a first input of a motion compensator 590 . A third output of the reference picture store 570 is connected in signal communication with a second input of the motion compensator 590 . The output of the motion compensator 590 , which is indicative of a motion compensated reference picture, is connected in signal communication with a first input of a multiplier 592 . The output of the reference picture weighting factor assignor 572 , which is indicative of a weighting factor, is connected in signal communication with a second input of the multiplier 592 . The output of the multiplier 592 is connected in signal communication with an inverting input of the summing junction 510 .
Turning now to FIG. 6 , an exemplary process for decoding video signal data for an image block is indicated generally by the reference numeral 600 . The process includes a start block 610 that passes control to an input block 612 . The input block 612 receives the image block compressed data, and passes control to an input block 614 . The input block 614 receives at least one reference picture index with the data for the image block, each reference picture index corresponding to a particular reference picture. The input block 614 passes control to a function block 616 , which determines a weighting factor corresponding to each of the received reference picture indices, and passes control to an optional function block 617 . The optional function block 617 determines an offset corresponding to each of the received reference picture indices, and passes control to a function block 618 . The function block 618 retrieves a reference picture corresponding to each of the received reference picture indices, and passes control to a function block 620 . The function block 620 , in turn, motion compensates the retrieved reference picture, and passes control to a function block 622 . The function block 622 multiplies the motion compensated reference picture by the corresponding weighting factor, and passes control to an optional function block 623 . The optional function block 623 adds the motion compensated reference picture to the corresponding offset, and passes control to a function block 624 . The function block 624 , in turn, forms a weighted motion compensated reference picture, and passes control to an end block 626 .
Turning now to FIG. 7 , an exemplary process for encoding video signal data for an image block is indicated generally by the reference numeral 700 . The process includes a start block 710 that passes control to an input block 712 . The input block 712 receives substantially uncompressed image block data, and passes control to a function block 714 . The function block 714 assigns a weighting factor for the image block corresponding to a particular reference picture having a corresponding index. The function block 714 passes control to an optional function block 715 . The optional function block 715 assigns an offset for the image block corresponding to a particular reference picture having a corresponding index. The optional function block 715 passes control to a function block 716 , which computes motion vectors corresponding to the difference between the image block and the particular reference picture, and passes control to a function block 718 . The function block 718 motion compensates the particular reference picture in correspondence with the motion vectors, and passes control to a function block 720 . The function block 720 , in turn, multiplies the motion compensated reference picture by the assigned weighting factor to form a weighted motion compensated reference picture, and passes control to an optional function block 721 . The optional function block 721 , in turn, adds the motion compensated reference picture to the assigned offset to form a weighted motion compensated reference picture, and passes control to a function block 722 . The function block 722 subtracts the weighted motion compensated reference picture from the substantially uncompressed image block, and passes control to a function block 724 . The function block 724 , in turn, encodes a signal with the difference between the substantially uncompressed image block and the weighted motion compensated reference picture along with the corresponding index of the particular reference picture, and passes control to an end block 726 .
In the present exemplary embodiment, for each coded picture or slice, a weighting factor is associated with each allowable reference picture that blocks of the current picture can be encoded with respect to. When each individual block in the current picture is encoded or decoded, the weighting factor(s) and offset(s) that correspond to its reference picture indices are applied to the reference prediction to form a weight predictor. All blocks in the slice that are coded with respect to the same reference picture apply the same weighting factor to the reference picture prediction.
Whether or not to use adaptive weighting when coding a picture can be indicated in the picture parameter set or sequence parameter set, or in the slice or picture header. For each slice or picture that uses adaptive weighting, a weighting factor may be transmitted for each of the allowable reference pictures that may be used for encoding this slice or picture. The number of allowable reference pictures is transmitted in the slice header. For example, if three reference pictures can be used to encode the current slice, up to three weighting factors are transmitted, and they are associated with the reference picture with the same index.
If no weighting factors are transmitted, default weights are used. In one embodiment of the current invention, default weights of (½, ½) are used when no weighting factors are transmitted. The weighting factors may be transmitted using either fixed or variable length codes.
Unlike typical systems, each weighting factor that is transmitted with each slice, block or picture corresponds to a particular reference picture index. Previously, any set of weighting factors transmitted with each slice or picture were not associated with any particular reference pictures. Instead, an adaptive bi-prediction weighting index was transmitted for each motion block or 8×8 region to select which of the weighting factors from the transmitted set was to be applied for that particular motion block or 8×8 region.
In the present embodiment, the weighting factor index for each motion block or 8×8 region is not explicitly transmitted. Instead, the weighting factor that is associated with the transmitted reference picture index is used. This dramatically reduces the amount of overhead in the transmitted bitstream to allow adaptive weighting of reference pictures.
This system and technique may be applied to either Predictive “P” pictures, which are encoded with a single predictor, or to Bi-predictive “B” pictures, which are encoded with two predictors. The decoding processes, which are present in both encoder and decoders, are described below for the P and B picture cases. Alternatively, this technique may also be applied to coding systems using the concepts similar to I, B, and P pictures.
The same weighting factors can be used for single directional prediction in B pictures and for bi-directional prediction in B pictures. When a single predictor is used for a macroblock, in P pictures or for single directional prediction in B pictures, a single reference picture index is transmitted for the block. After the decoding process step of motion compensation produces a predictor, the weighting factor is applied to predictor. The weighted predictor is then added to the coded residual, and clipping is performed on the sum, to form the decoded picture. For use for blocks in P pictures or for blocks in B pictures that use only list 0 prediction, the weighted predictor is formed as:
Pred= W 0* Pred0+ D 0 (1)
where W0 is the weighting factor associated with the list 0 reference picture, D0 is the offset associated with the list 0 reference picture, and Pred0 is the motion-compensated prediction block from the list 0 reference picture.
For use for blocks in B pictures which use only list 0 prediction, the weighted predictor is formed as:
Pred=W1* Pred1+ D 1 (2)
where W1 is the weighting factor associated with the list 1 reference picture, D0 is the offset associated with the list 1 reference picture, and Pred1 is the motion-compensated prediction block from the list 1 reference picture.
The weighted predictors may be clipped to guarantee that the resulting values will be within the allowable range of pixel values, typically 0 to 255. The precision of the multiplication in the weighting formulas may be limited to any pre-determined number of bits of resolution.
In the bi-predictive case, reference picture indexes are transmitted for each of the two predictors. Motion compensation is performed to form the two predictors. Each predictor uses the weighting factor associated with its reference picture index to form two weighted predictors. The two weighted predictors are then averaged together to form an averaged predictor, which is then added to the coded residual.
For use for blocks in B pictures that use list 0 and list 1 predictions, the weighted predictor is formed as:
Pred=( P 0* Pred0+ D 0+ P 1* Pred1+ D 1)/2 (3)
Clipping may be applied to the weighted predictor or any of the intermediate values in the calculation of the weighted predictor to guarantee that the resulting values will be within the allowable range of pixel values, typically 0 to 255.
Thus, a weighting factor is applied to the reference picture prediction of a video compression encoder and decoder that uses multiple reference pictures. The weighting factor adapts for individual motion blocks within a picture, based on the reference picture index that is used for that motion block. Because the reference picture index is already transmitted in the compressed video bitstream, the additional overhead to adapt the weighting factor on a motion block basis is dramatically reduced. All motion blocks that are coded with respect to the same reference picture apply the same weighting factor to the reference picture prediction.
These and other features and advantages of the present invention may be readily ascertained by one of ordinary skill in the pertinent art based on the teachings herein. It is to be understood that the teachings of the present invention may be implemented in various forms of hardware, software, firmware, special purpose processors, or combinations thereof.
Most preferably, the teachings of the present invention are implemented as a combination of hardware and software. Moreover, the software is preferably implemented as an application program tangibly embodied on a program storage unit. The application program may be uploaded to, and executed by, a machine comprising any suitable architecture. Preferably, the machine is implemented on a computer platform having hardware such as one or more central processing units (“CPU”), a random access memory (“RAM”), and input/output (“I/O”) interfaces. The computer platform may also include an operating system and microinstruction code. The various processes and functions described herein may be either part of the microinstruction code or part of the application program, or any combination thereof, which may be executed by a CPU. In addition, various other peripheral units may be connected to the computer platform such as an additional data storage unit and a printing unit.
It is to be further understood that, because some of the constituent system components and methods depicted in the accompanying drawings are preferably implemented in software, the actual connections between the system components or the process function blocks may differ depending upon the manner in which the present invention is programmed. Given the teachings herein, one of ordinary skill in the pertinent art will be able to contemplate these and similar implementations or configurations of the present invention.
Although the illustrative embodiments have been described herein with reference to the accompanying drawings, it is to be understood that the present invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one of ordinary skill in the pertinent art without departing from the scope or spirit of the present invention. All such changes and modifications are intended to be included within the scope of the present invention as set forth in the appended claims.
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A video decoder, encoder, and corresponding methods for processing video signal data for an image block and a particular reference picture index to predict the image block are disclosed that utilize adaptive weighting of reference pictures to enhance video compression, where a decoder includes a reference picture weighting factor unit for determining a weighting factor corresponding to the particular reference picture index; an encoder includes a reference picture weighting factor assignor for assigning a weighting factor corresponding to the particular reference picture index; and a method for decoding includes receiving a reference picture index with the data that corresponds to the image block, determining a weighting factor for each received reference picture index, retrieving a reference picture for each index, motion compensating the retrieved reference picture, and multiplying the motion compensated reference picture by the corresponding weighting factor to form a weighted motion compensated reference picture.
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This is a division of application Ser. No. 872,413, filed Jan. 26, 1978.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel cyclopropanecarboxylate insecticide, to an insecticidal method and composition and to new intermediates in the preparation of this insecticide. More particularly, the invention relates to the preparation and insecticidal use of certain arylthiovinylcyclopropanecarboxylates.
2. Prior Art
Pyrethrins, naturally occurring extracts of chrysanthemum flowers, have long been of interest as insecticides. Since elucidation of the structures of these compounds, synthesis efforts have been directed toward preparation of related compounds having enhanced insecticidal activity and improved stability toward air and light. A noteworthy advance in this area was the discovery by Elliott, et al. of certain highly active compounds remarkably resistent to photo-oxidative degradation, for example, 3-phenoxybenzyl 3-(β,β-dichlorovinyl)-2,2-dimethylcyclopropanecarboxylate. This class of compounds is set forth in U.S. Pat. No. 4,024,163, issued May 17, 1977.
Since the discovery by Elliott, et al., there has been extensive research activity conducted in this area of insecticide chemistry. One such effort is disclosed in Belgian Pat. No. 851,465, published Aug. 16, 1977, which discloses certain phenylvinylcyclopropanecarboxylates as insecticides. In addition, U.S. Pat. Nos. 3,723,649 and 3,786,052 disclose certain other derivatives of vinyl cyclopropanecarboxylates and carboxylic acids.
In spite of the intensity of effort in this field, the phenylthiovinylcyclopropanecarboxylates have not been described prior to the present invention.
It has been found that these compounds are highly active insecticides, that they exhibit remarkable activity against insects of the order coleoptera and that they have excellent photo-stability.
SUMMARY OF THE INVENTION
The present invention comprises compounds of the formula ##STR2## wherein the groups R, Y and Z and the integer n are as described below. The insecticidally active members are those in which R represents the group--OR 1 wherein R 1 is as defined below. The invention also includes intermediates for these compounds in which R is halogen, hydroxy or lower alkoxy. An insecticidal composition and method is also provided.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of this invention are those of formula I in which Y is independently halogen, cyano, lower alkyl, lower haloalkyl, lower alkoxy, or lower alkylthio and n is an integer having a value of 0, 1, 2 or 3; Z is hydrogen, halogen, cyano, or lower alkyl; and R is halogen, hydroxy, lower alkoxy, or --OR 1 wherein R 1 is allethrolonyl, tetrahydrophthalimidomethyl, or is represented by the formula ##STR3## in which R 2 is hydrogen, lower alkyl, cyano, ethynyl or trihalomethyl; R 3 is divalent oxygen, divalent sulfur or vinylene; R 4 and R 5 are independently hydrogen, lower alkyl, phenyl, phenoxy, benzyl, phenylthio or are joined to form a divalent methylenedioxy group attached to two adjacent ring carbon atoms of a phenyl ring.
Throughout the specification the term "lower", as applied to an alkyl group means having 1-6 carbon atoms, preferably 1-4 carbon atoms, and the term "halo" or "halogen" means a bromine, chlorine, fluorine, and iodine, advantageously bromine, chlorine, and fluorine, preferably bromine and chlorine. These meanings are used throughout the specification except where a contrary meaning is clearly indicated.
In accordance with the present invention the insecticidal phenylthiovinylcyclopropanecarboxylates are those of formula I in which R is --OR 1 , defined above, whereas the intermediates for these insecticidal phenylthiocyclopropanecarboxylates are compounds of formula I in which R is halogen, hydroxy or lower alkoxy.
R 1 thus represents, for the insecticidal compounds, known alcohol residues which have heretofore been used in the cyclopropanecarboxylate insecticide art to produce insecticidally active compounds. The more readily available of these alcohol groups include those in which R 1 is 3-phenoxybenzyl, α-cyano-3-phenoxybenzyl, α-trihalomethyl-3-phenoxybenzyl and 5-benzyl-3-furylmethyl. The preferred compounds are thus esters which contain these alcohol residues.
Also in a preferred embodiment Z is hydrogen or halogen, particularly chloro or bromo, and Y is hydrogen or halogen, particularly chloro or fluoro.
The compounds of this invention may be prepared in accordance with the illustrative examples set forth below. While the invention is illustrated by preparation of compounds having the cis,trans-E,Z configuration, it is understood that the present invention contemplates and includes all possible isomeric configurations of the compounds.
In the examples which follow, unless a contrary intent is expressed, temperatures are in degrees centigrade, pressure is in mm Hg and liquid concentration is performed under reduced pressure produced by a water aspirator.
EXAMPLE 1
Synthesis of 3-phenoxybenzyl cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate
A. Preparation of ethyl cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate as an intermediate
A mixture of 40.0 grams (0.095 mole) of (phenylthio)-methyltriphenylphosphonium chloride in 200 ml of benzene, was stirred under a nitrogen atomosphere at 0° C. for 10 minutes. An equivalent (51 ml, 1.89 Molar, 0.095 mole) of n-butyllithium was added dropwise to the reaction mixture over a period of 30 minutes while maintaining the 0° C. reaction mixture temperature. Following addition the reaction mixture was stirred for 30 minutes at 0°-5° C., then siphoned into a chilled (0° C.), stirred solution of 16.2 grams (0.095 mole) of caronaldehyde in benzene. The reaction mixture was allowed to warm to ambient temperature for 2 hours, was then filtered and the filtrate washed successively with two 80 ml portions of water, 60 ml of a saturated aqueous solution of sodium bisulfite and 100 ml of a saturated aqueous solution of sodium chloride. The organic layer was dried with magnesium sulfate and filtered. The filtrate was evaporated under reduced pressure to a residue which then was dissolved in a small amount of diethyl ether. Upon standing, crystalline triphenylphosphine oxide precipitated from the solution. The mixture was filtered and the filtrate was evaporated under reduced pressure to a residue which was purified by vacuum distillation using a short-path Kugelrohr distillation system. The distillate was further purified by elution through a silicic acid cone (100 grams) with petroleum ether and a second vacuum distillation using the short-path Kugelrohr distillation system, to give 14.0 grams (53.2%) of ethyl cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate.
B. Preparation of cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylic acid as an intermediate
To a stirred solution of 13.0 grams (0.047 mole) of ethyl cis,trans-3[-2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate in 50 ml of ethanol was added in one portion of a solution of 3.3 grams of potassium hydroxide in 10 ml of water. The reaction mixture was stirred at 40°-60° C. for 6 hours, then at ambient temperature for 18 hours. The reaction mixture was evaporated under reduced pressure to a residue which was dissolved in water and the solution extracted with 25 ml of diethyl ether. The aqueous layer was acidified with concentrated hydrochloric acid and extracted twice with 75 ml, then 50 ml, of diethyl ether. The combined ether layers were dried with magnesium sulfate and filtered. The filtrate was evaporated under reduced pressure to give 11.2 grams (96%) of cis,trans-3-[-2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylic acid; m.p. 82°-96° C.
Analyses calc'd for C 14 H 16 O 2 S: C 67.71; H 6.50; Found: C 67.47; H 6.58.
C. Conversion to 3-phenoxybenzyl cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate
A stirred solution of 3.4 grams (0.014 mole) of cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylic acid and 1.8 grams (0.015 mole) of thionyl chloride in 25 ml of benzene was heated under reflux for 2 hours. The benzene and excess thionyl chloride were removed by evaporation under reduced pressure, and 30 ml of fresh benzene was added to the acid chloride. The solution was cooled to 0°-5° C. and 1.2 grams (0.015 mole) of pyridine was added. The reaction mixture was stirred at 0°-5° C. for 10 minutes and 2.7 grams (0.014 mole) of 3-phenoxybenzyl alcohol was added. A white precipitate formed almost immediately. The reaction mixture was warmed to ambient temperature and stirred for 1 hour and filtered. The filtrate was washed with 20 ml of 10% aqueous hydrochloric acid, 20 ml of 5% aqueous sodium hydroxide, then 20 ml of saturated aqueous sodium chloride. The benzene layer was dried with magnesium sulfate and filtered. The filtrate was evaporated under reduced pressure to a residue which was purified by elution through an alumina cone (30 grams) with petroleum ether, then 10% diethyl ether in petroleum ether, then 40% diethyl ether in petroleum ether and finally with diethyl ether. The appropriate fractions were combined and evaporated under reduced pressure to give 4.3 grams (74.7%) of 3-phenoxybenzyl cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate, as an oil. The nmr and the ir spectra were consistent with the assigned structure.
Analyses calc'd for C 27 H 26 O 3 S: C 75.32; H 6.09; Found: C 75.53; H 6.12.
EXAMPLE 2
Synthesis of α-cyano-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate
A stirred solution of 4.7 grams (0.019 mole) of cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylic acid and 2.5 grams (0.02 mole) of thionyl chloride in 35 ml of benzene was heated under reflux for 2 hours. The benzene and excess thionyl chloride were removed by evaporation under reduced pressure. The acid chloride residue was combined with 3.0 grams (0.015 mole) of 3-phenoxybenzaldehyde and added to a stirred, chilled (0° C.) solution of 1.0 gram (0.02 mole) of sodium cyanide in 12 ml of tetrahydrofuran and 12 ml of water. The reaction mixture was stirred at 0°-20° C. for 2 hours, then extracted with three portions, one 25 ml and two 40 ml, of diethyl ether. The combined ether extracts were washed with 40 ml aqueous sodium hydroxide solution and three times with 40 ml of water. The ether layer was dried with magnesium sulfate and filtered. The filtrate was evaporated under reduced pressure to a residue which was redissolved in fresh diethyl ether and stirred for 6 hours at ambient temperature with aqueous saturated sodium bisulfite. The ether layer was separated and dried with magnesium sulfate and filtered. The filtrate was evaporated under reduced pressure to a residue which was purified by elution through an alumina cone (35 grams) using petroleum ether, 5% diethyl ether in petroleum ether, 20% diethyl ether in petroleum ether, 40% diethyl ether in petroleum ether, then with diethyl ether. The appropriate fractions were combined and evaporated under reduced pressure to give 4.2 grams (62.2%) of α-cyano-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate, as an oil. The nmr and ir spectra were consistent with the assigned structure.
Analyses calc'd for C 28 H 25 NO 3 S: C 73.83; H 5.53; N 3.07; Found: C 73.59; H 5.59; N 3.03.
EXAMPLE 3
Synthesis of α-cyano-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate
A. Preparation of phenylthiomethyl chloride as an intermediate
With stirring, 37.5 grams (1.25 moles) of paraformaldehyde was added to 250 ml of benzene. To the benzene-paraformaldehyde mixture 500 ml of concentrated hydrochloric acid was added slowly at ambient temperature. The mixture was then heated at 31° C. for 30 minutes, and 110 grams of thiophenol was added. Upon complete addition the reaction mixture was heated at 50°-55° C. for 2 hours, then allowed to cool to ambient temperature where it stood for 18 hours. The reaction mixture was separated and the organic layer washed with 250 ml of water. The water wash was extracted with 250 ml of benzene and the two benzene layers were combined. The benzene combination was washed with 300 ml of aqueous saturated sodium chloride, dried with magnesium sulfate and filtered. The filtrate was evaporated under reduced pressure to a residue which was further evaporated under high vacuum and distilled to give 115.9 grams (73.2%) of phenylthiomethyl chloride; b.p. 80° C./3 mm. The nmr and the ir spectra were consistent with the assigned structure.
B. Preparation of diethyl phenylthiomethylphosphonate as an intermediate
A stirred solution of 40.0 grams (0.25 mole) of phenylthiomethyl chloride and 58.2 grams (0.35 mole) of triethylphosphite was heated at 150°-160° C. for 4 hours, cooled and excess triethylphosphite removed by evaporation under reduced pressure. The residue was purified by distillation to give 61.1 grams (93.1%) of diethyl phenylthiomethylphosphonate; b.p. 155° C./0.6 mm. The nmr and the ir spectra were consistent with the assigned structure.
Analyses calc'd for C 11 H 17 O 3 PS: C 50.75; H 6.58; Found: C 50.54; H 6.62.
C. Preparation of ethyl cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate as an intermediate
A solution of 16.4 grams (0.063 mole) of diethyl phenylthiomethylphosphonate in 150 ml of tetrahydrofuran, under a nitrogen atmosphere, was cooled to -78° C. where it stirred for 30 minutes. After this time 33.9 ml (0.063 mole-1.87 Molar) of n-butyllithium was added dropwise from a syringe, keeping the reaction mixture temperature below -60° C. Upon complete addition the reaction mixture was recooled to -78° C., where it was stirred for 15 minutes. A solution of 9.7 grams (0.063 mole) of carbon tetrachloride in 40 ml of tetrahydrofuran was then added dropwise. The reaction mixture was stirred for 15 minutes, then a solution of 9.8 grams (0.058 mole) of caronaldehyde in 40 ml of tetrahydrofuran was added dropwise. The reaction mixture stirred at -78° C. for 15 minutes then allowed to warm to ambient temperature where it was stirred for 16 hours. Solvent was removed from the reaction mixture by evaporation under reduced pressure, the residue slurried in 50 ml of water, and the slurry extracted with 100 ml and 25 ml of diethyl ether. The combined extracts were washed with 75 ml of aqueous saturated sodium chloride. The ether layer was dried with magnesium sulfate, the mixture filtered and the filtrate evaporated under reduced pressure to a residue. The residue was purified by passing it through a cone of silicic acid (100 grams) using petroleum ether, then 10% methylene chloride-petroleum ether, as eluents. Fractions homogeneous when subjected to thin layer chromatography (TLC) were combined and evaporated under reduced pressure to a residue. The residue was further purified by a second passage through a cone of silicic acid using petroleum ether, then 10% methylene chloride in petroleum ether as eluents. Fractions homogeneous when subjected to TLC were combined and evaporated under reduced pressure to a residue. The residue was taken up in diethyl ether and dried with magnesium sulfate. The mixture was filtered and the filtrate was evaporated under reduced pressure to a residual oil. The residual oil was 9.1 grams (51%) of ethyl cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate. The nmr and the ir spectra were consistent with the assigned structure.
Analyses calc'd for C 16 H 19 ClO 2 S: C 61.82; H 6.16; Cl 11.41; Found: C 61.92; H 6.17; Cl 11.32.
D. Preparation of cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylic acid as an intermediate.
This compound was prepared in the manner of Example 1.B., using 9.1 grams (0.029 mole) of ethyl cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate, 2.5 grams (0.044 mole) of potassium hydroxide in 30 ml of ethanol and 6 ml of water. The yield of liquid cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylic acid was 7.6 grams (91%). The nmr and the ir spectra were consistent with the assigned structure.
E. Conversion to α-cyano-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate
A solution of 4.6 grams (0.016 mole) of cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylic acid and 2.1 grams (0.018 mole) of thionyl chloride in 35 ml of benzene was heated under reflux for 2 hours. Excess thionyl chloride and benzene were removed by evaporation under reduced pressure to give the residual acid chloride. The acid chloride and 2.6 grams (0.013 mole) of 3-phenoxybenzyaldehyde were simultaneously added dropwise to a stirred solution of 0.9 gram (0.018 mole) of sodium cyanide in 10 ml of tetrahydrofuran and 10 ml of water and converted to α-cyano-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate as described in Example 2. The nmr and the ir spectra were consistent with the assigned structure.
Analyses calc'd for: C 28 H 24 ClNO 3 S: C 68.63; H 4.94; Cl 7.24; N 2.86; Found: C 68.85; H 4.98; Cl 7.13; N 2.85.
EXAMPLE 4
Synthesis of 3-phenoxybenzyl cis,trans-3-[2-(E,Z)chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate
A stirred solution of 3.4 grams (0.012 mole) of cis,trans-3-[2-(E,Z)-chloro-2-phenylthiothenyl]-2,2-dimethylcyclopropanecarboxylic acid and 1.0 ml (0.014 mole) of thionyl chloride in 20 ml benzene was heated at reflux under a nitrogen atmosphere for 2 hours. The benzene solvent was removed by distillation; 5 ml of benzene was added and this was removed by distillation. The reaction mixture was cooled to 40° C. and 5 ml of benzene was added. To this stirred mixture was added a solution of 2.4 grams (0.012 mole) of 3-phenoxybenzyl alcohol and 1.0 ml (0.012 mole) of pyridine in 5 ml of benzene. After addition was complete the reaction mixture was stirred under a nitrogen atmosphere for 4 hours and was then diluted with 15 ml each of diethyl ether and water. The organic layer was separated and extracted with a 5% aqueous solution of hydrochloric acid. The extract and the water layer were combined and backwashed with diethyl ether. The ether wash and the organic layer were combined and washed with aqueous solutions saturated with sodium bicarbonate and sodium chloride. The organic layer was dried with magnesium sulfate and filtered. The filtrate was evaporated under reduced pressure to a residue. The residue was taken up in 15 ml of carbon tetrachloride, stirred with 3 grams of powdered charcoal, filtered, and the filtrate evaporated under reduced pressure to a residue. The residue was purified by column chromatography, the column being 30 grams of silica gel. Elution was accomplished using petroleum ether, then successively 1%, 2%, 5%, 7.5%, 10%, 15%, 20%, 30%, and 35% mixtures of methylene chloride in petroleum ether. The appropriate fractions were combined and evaporated under reduced pressure to give 4.0 grams (72%) of 3-phenoxybenzyl cis,trans-3-[2-(E,Z)-2-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate as a liquid. For analytical purposes, a small sample was distilled under reduced pressure; b.p. 150° C./0.04 mm. The nmr spectra were consistent with the assigned structure.
Analyses calc'd for C 29 H 25 ClO 3 S: C 69.73; H 5.42; C 17.63; Found: C 69.58; H 5.44; C 17.59.
EXAMPLE 5
Synthesis of 3-phenoxybenzyl cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate
A. Preparation of 4-fluorophenylthiomethyl chloride as an intermediate
This compound was prepared in the manner of Example 3.A., using 45.0 grams (0.35 mole) of a 4-fluorothiophenol, 13.5 grams (0.44 mole) of paraformaldehyde and 180 ml (1.8 moles) of concentrated hydrochloric acid in 90 ml of benzene. The residue was distilled under reduced pressure to give 61.9 grams (99.8%) of 4-fluorophenylthiomethyl chloride; b.p. 65° C./0.5 mm.
Analyses calc'd for C 7 H 6 ClFS: C 47.59; H 3.42; Cl 20.07; Found: C 47.69; H 3.48; Cl 20.09.
B. Preparation of diethyl 4-fluorophenylthiomethylphosphonate as an intermediate
This compound was prepared in the manner of Example 3.B., using 59.3 grams (0.34 mole) of 4-fluorophenylthiomethyl chloride and 71.3 grams (0.43 mole) of triethylphosphite. The residue was distilled under reduced pressure to give 89.4 grams (95.7%) of diethyl 4-fluorophenylthiomethylphosphonate; b.p. 147° C./0.6 mm.
C. Preparation of ethyl cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate as an intermediate
This compound was prepared in the manner of Example 3.C., using 41.0 grams (0.15 mole) of diethyl 4-fluorophenylthiomethylphosphonate, 69.4 ml (0.17 mole, 2.4 Molar) of n-butyllithium, and 25.0 grams (0.15 mole) of caronaldehyde in 650 ml of tetrahydrofuran, except that no carbon tetrachloride was used. The residue was purified by distillation under reduced pressure using a short path Kugelrohr distillation system, to give 32.7 grams (75.3%) of ethyl cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate as an oil. The nmr and the ir spectra were consistent with the assigned structure.
Analyses calc'd for C 16 H 19 FO 2 S: C 65.28; H 6.51; Found: C 65.41; H 6.55.
D. Preparation of cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylic acid as an intermediate
This compound was prepared in the manner of Example 1.B., using 36.2 grams (0.12 mole) of ethyl cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate, 10.3 grams (0.18 mole) of potassium hydroxide in 100 ml of ethanol and 25 ml of water. The weight of crude liquid cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylic acid was 29.3 grams (90.6%). The product was purified by passing it through a silicic acid cone using 40% diethyl ether in petroleum ether. The nmr and the ir spectra were consistent with the assigned structure.
Analyses calc'd for C 14 H 15 FO 2 S: C 63.13; H 5.68; Found: C 63.27; H 5.73.
E. Conversion to 3-phenoxybenzyl cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate
This compound was prepared in the manner of Example 3, using 5.7 grams (0.021 mole) of cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylic acid, 2.8 grams (0.023 mole) of thionyl chloride, 4.3 grams (0.021 mole) of 3-phenoxybenzyl alcohol, 1.9 grams (0.023 mole) of pyridine, and 100 ml of benzene. The residue was purified by passing it through an alumina cone (50 grams) using petroleum ether, 10%, 20% methylene chloride in petroleum ether, and methylene chloride as eluents. The appropriate fractions were combined and evaporated under reduced pressure to give 7.2 grams (75%) of 3-phenoxybenzyl cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate as a liquid. The nmr and the ir spectra were consistent with the assigned structure.
Analyses calc'd for C 27 H 25 FO 3 S: C 72.30; H 5.62; Found: C 72.22; H 5.68.
EXAMPLE 6
Synthesis of α-cyano-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate
This compound was prepared in the manner of Example 2, using 6.9 grams (0.026 mole) of cis,trans-3-[2(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylic acid, 3.4 grams (0.028 mole) of thionyl chloride, 1.4 grams (0.029 mole) of sodium cyanide, 4.2 grams (0.021 mole) of 3-phenoxybenzaldehyde, 60 ml of benzene, 20 ml of tetrahydrofuran, and 20 ml of water. The residue was purified by passing it through an alumina cone (45 grams) using as eluents 5%, 10%, and 20% methylene chloride in petroleum ether, and methylene chloride. The appropriate fractions were combined and evaporated under reduced pressure to give 6.6 grams (66.6%) of α-cyano-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate as a liquid. The nmr and the ir spectra were consistent with the assigned structure.
Analyses calc'd for C 28 H 24 FNO 3 S: C 71.01; H 5.11; N 2.96; Found: C 70.92; H 5.20; N 2.85.
EXAMPLE 7
Synthesis of α-trifluoromethyl-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate
This compound was prepared in the manner of Example 1.C., using 3.0 grams (0.011 mole) of cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylic acid, 1.4 grams (0.012 mole) of thionyl chloride, 2.8 grams (0.011 mole) of α-trifluoromethyl-3-phenoxybenzyl alcohol, 0.92 gram (0.012 mole) of pyridine, and 60 ml of benzene. The residue was purified by passing it through an alumina cone (24 grams) using as eluents petroleum ether, and 20% diethyl ether in petroleum ether. The appropriate fractions were combined and evaporated under reduced pressure to give 2.8 grams (48.4%) of α-trifluoromethyl-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-chloro-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate as a liquid. The nmr and the ir spectra were consistent with the assigned structure.
Analyses calc'd for C 28 H 24 ClF 3 O 3 S: C 63.09; H 4.54; Cl 6.65; Found: C 62.87; H 4.58; Cl 6.57.
The following were also prepared in accordance with the foregoing examples.
EXAMPLE 8
α-cyano-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-chloro-2-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate
Analyses calc'd for C 28 H 23 ClFNO 3 S: C 66.17; H 4.56; N 2.75; Found: C 66.14; H 4.59; N 2.74.
EXAMPLE 9
3-phenoxybenzyl cis,trans-3-[2-(E,Z)-chloro-2-(4-chlorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate
Analyses calc'd for C 27 H 24 Cl 2 O 3 S: C 64.92; H 4.70; Cl 14.19; Found: C 64.18; H 4.99; Cl 14.48.
EXAMPLE 10
3-phenoxybenzyl cis,trans-3-[2-(E,Z)-bromo-2-phenylthioethenyl]-2,2-dimethylcyclopropanecarboxylate
Analyses calc'd for C 27 H 20 BrO 3 S: C 63.52; H 5.13; Found: C 63.12; H 5.38.
EXAMPLE 11
3-phenoxybenzyl cis,trans-3-[2-(E,Z)-chloro-2-(4-fluorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate
Analyses calc'd for C 27 H 25 ClFO 3 S: C 66.71; H 5.18; Found: C 66.99; H 5.20.
EXAMPLE 12
α-cyano-3-phenoxybenzyl cis,trans-3-[2-(E,Z)-chloro-2-(4-chlorophenylthio)ethenyl]-2,2-dimethylcyclopropanecarboxylate
Analyses calc'd for C 28 H 23 Cl 2 O 3 NS: C 64.12; H 4.40; N 2.67; Found: C 64.32; H 4.50; N 2.67.
It will be apparent to one skilled in the pyrethroid art that the appropriately substituted lower alkyl ester (R is alkoxy in formula I) may also be transesterified directly to produce the insecticidal compounds, rather than proceeding through hydrolysis of the lower alkyl ester, formation of the acid chloride and conversion of the acid chloride.
In the method of this invention an effective insecticidal amount of the compound is applied to the locus where insect control is desired, usually to the foliage or seeds of agricultural plants. The compound may be applied as technical material or as a formulated product. Typical formulations include compositions of the active ingredient in combination with an agriculturally acceptable carrier or extender, preferably with a surface-active agent, and optionally with other active ingredients. Suitable formulations include granules, powders, or liquids, the choice varying with the type of pests and environmental factors present at the particular locus of infestation. Thus, the compounds may be formulated as granules of various sizes, as dusts, as wettable powders, as emulsifiable concentrates, as solutions, as dispersions, as controlled release compositions, and the like. A typical formulation may vary widely in concentration of the active ingredient depending upon the particular agent used, the additives and carriers used, other active ingredients, and the desired mode of application. With due consideration of these factors, the active ingredient of a typical formulation may, for example, be suitably present at a concentration of about 0.5% up to about 99.5% by weight of the formulation. An agriculturally acceptable carrier may comprise about 99.5% by weight to as low as about 0.5% by weight of the formulation. Compatible surface-active agents, if employed in the formulation, may be present at various concentrations, suitably in the range of 1% to 30% by weight of the formulation.
The formulation may be used as such or diluted to a desired use dilution with a diluent or carrier suitable for facilitating dispersion of the active ingredients. The concentration of the active ingredient in use dilution is normally in the range of about 0.001 to about 5% by weight. Many variations of spraying, dusting, and controlled or slow release compositions in the art may be used by substituting or adding a compound of this invention into compositions known or apparent to the art.
The compounds of this invention may be formulated and applied with other compatible active ingredients, including nematicides, insecticides, acaricides, fungicides, plant regulators, herbicides, fertilizers, etc.
In applying these compounds, whether alone or with other agricultural chemicals an effective insecticidal amount of the active ingredient must be applied. While the application rate will vary widely depending on the choice of compound, the formulation and mode of application, the plant species being protected, and the planting density, a suitable use rate may be in the range of about 0.05 to 5 kg./hectare, preferably 0.1 to about 2 kg./hectare.
The compounds of this invention were tested for initial insecticidal activity and seven day residual activity as described below.
EXAMPLE 13
Toxicity to Insects and Mites
Initial Contact Activity:
The test compound was dissolved in a small amount of acetone, and the acetone solution was dispersed in water containing one drop of isooctylphenyl polyethoxyethanol to make a solution having 1250 ppm (w/w) active ingredient. Aliquots of this solution were diluted with an appropriate amount of water to provide solutions containing various concentrations of active ingredient. Test organisms and techniques were as follows: the activity against Mexican bean beetle (Epilachna varivestis Muls.) and southern armyworm (Spodoptera eridania [Cram.]) was evaluated by dipping the leaves of pinto bean plants into the test solution and infesting the leaves with the appropriate immature-form insects when the foliage had dried. The activity against the pea aphid (Acyrthosiphon pisum [Harris]) was evaluated on broad bean plants whose leaves were dipped before infestation with adult aphids. The activity against twospotted spider mites (Tetranychus urticae Koch) was evaluated on pinto bean plants whose leaves were dipped after infestation with adult mites. The activity against the milkweed bug (Oncopeltus faciatus [Dallas]) was evaluated by spraying the test solutions into glass dishes or jars containing the adult insects. Following application of the compound and infestation the tests were maintained in a holding room at 80° F. and 50% relative humidity for an exposure period of 72 hours. At the end of this time the dead and living insects or mites were counted and the percent kill was calculated. Results of these tests are summarized in Table I. Most of the compounds tested were active against all the insects. A number of them showed remarkable activity against the milkweed bug and Mexican bean beetle even at extremely low concentrations.
Residual Contact Activity:
The residual contact activity of certain of the compounds was determined on the same organisms using the techniques described above, except that in each case the treated surface was allowed to dry and was exposed to normal light and air for seven days before introduction of the mites or insects. Results of these tests are summarized in Table II. The seven day residual activity was minimal for the mite but substantial against the remaining organisms. Again, the remarkable activity of some of these compounds against milkweed bug and Mexican bean beetle was noted.
TABLE I______________________________________INITIAL ACTIVITYCompound Conc. Percent Killof Example ppm. MWB* MBB* AW* PA* SM*______________________________________1 1250 30 100 0 0 0 312 5 -- -- 0 0 78 10 62 0 0 0 20 10 0 0 0 0 5 28 0 1.2 44 0 Untreated 5 0 0 0 52 1250 100 100 41 75 0 312 90 5 0 78 20 80 0 0 0 20 0 22 0 0 0 5 0 0 1.2 6 0 Untreated 5 0 0 0 53 1250 100 94 100 100 49 312 100 85 0 78 100 92 75 60 0 20 70 92 0 27 0 5 100 0 1.2 80 0 Untreated 5 0 0 0 54 1250 100 95 100 100 42 312 90 100 89 100 31 78 10 100 68 75 20 94 0 5 100 11 Untreated 0 0 0 0 2.95 1250 15 7 35 0 312 5 95 0 45 0 78 0 35 0 0 0 20 33 5 1.2 Untreated 4.8 0 0 0 2.36 1250 100 56 100 0 312 38 100 0 10 0 78 5 94 0 0 0 20 68 5 1.2 Untreated 4.8 0 0 0 2.37 1250 100 0 100 62 312 32 100 0 100 78 5 100 0 94 20 90 Untreated 5 0 0 0 68 1250 100 90 93 100 312 100 100 80 94 78 75 100 40 46 20 100 Untreated 0 0 0 0 69 1250 90 20 100 0 312 70 100 0 100 78 0 100 0 71 20 100 Untreated 0 0 0 0 610 1250 100 100 95 81 312 71 94 44 94 78 5 95 0 24 20 72 Untreated 10 0 0 0 8______________________________________ *See footnote, Table II.
TABLE II______________________________________7-DAY RESIDUAL ACTIVITYCompound Conc, Percent Killof Example ppm. MWB.sup.1 MBB.sup.2 AW.sup.3 PA.sup.4 SM.sup.5______________________________________1 1250 0 -- 0 30 0 312 10 -- 0 10 78 5 -- 0 0 20 0 Untreated 20 -- 0 0 02 1250 5 -- 0 100 0 312 0 -- 0 23 78 5 -- 0 30 20 0 Untreated 20 -- 0 0 03 1250 100 97 100 100 0 312 85 53 65 78 70 100 56 50 39 100 20 62 10 75 2.5 66 Untreated 20 3 0 0 04 1250 100 100 95 85 0 312 20 100 55 0 78 100 5 20 89 0 Untreated 5 0 0 0 0______________________________________ .sup.1 Milkweed bug .sup. 2 Mexican bean beetle .sup.3 Southern armyworm .sup.4 Pea aphid .sup.5 Twospotted spider mite
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Arylthiovinylcyclopropanecarboxylates having the general formula ##STR1## are disclosed. The insecticidal efficacy and preparation of the compounds and novel intermediates therefor are also described and exemplified.
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This Application is a Divisional Application of U.S. patent application Ser. No. 12/472,259, filed May 26, 2009, and is hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
The invention relates to a charged particle source for producing a beam of charged particles, comprising: a charged particle emitting surface emitting charged particles, a lens for forming an image of the charged particle emitting surface, said lens showing an optical axis, a beam limiting diaphragm for limiting the beam, embodied in such a way that at least two beams are formed, a central beam going through the middle of the lens and an eccentric beam going eccentrically through the lens, a deflector embodied to deflect one of the beams towards the axis, an energy selecting diaphragm showing an energy selecting aperture for passing a part of the eccentric beam and a central aperture for passing the central beam, said energy selecting diaphragm positioned between the particle emitting surface and the deflector, and a second deflector to align the eccentric beam on the energy selecting aperture. The invention further relates to a particle-optical apparatus equipped with such a charged particle source.
BACKGROUND OF THE INVENTION
Such a charged particle source is known from U.S. Pat. No. 7,034,315, which is assigned to the assignee of the present invention and which is hereby incorporated by reference. The charged particle beam described therein can be used as e.g. an electron source in an electron microscope, such as a Scanning Electron Microscope (SEM), a Transmission Electron Microscope (TEM) or as an ion source in a Focused Ion Beam (FIB) apparatus.
In an apparatus using a charged particle source the beam is manipulated by particle-optical elements, such as lenses and deflectors. The beam is manipulated to e.g. form a focus on a sample and scan it over the sample.
The size of such a focus on a sample is at least in part determined by the so-named chromatic aberrations. Chromatic aberrations in particle-optical instruments are those aberrations that are caused by the particles in the beam having slightly different energies. For an electron source used in an electron microscope the energy spread of the electrons is typically in the order of between 0.3 to 1 eV, for an ion source used in a FIB the energy spread is typically between 1 and 10 eV. Especially when using low beam energies the relative energy spread ΔE/E is large, resulting in chromatic aberrations.
It is remarked that the chromatic aberrations can be reduced by reducing the beam diameter, but this results in lower beam current and may increase the contribution of the so-named diffraction to the spot size.
It is further remarked that also charged particle apparatus are known in which the sample is not illuminated with a focused beam, but with a parallel beam. In this case as well the chromatic aberrations are important.
The charged particle source described in U.S. Pat. No. 7,034,315 provides a solution to the problem of chromatic aberrations by offering a source with reduced energy spread. This is accomplished by filtering a part of the charged particles showing a relative small energy spread and stopping the rest of the particles. The eccentric beam will, due to the energy dispersive working of the lens, be imaged as an energy dispersed line on the energy selecting diaphragm. The width of the energy selecting aperture in the diaphragm on which it is imaged determines the energy spread of the energy selected beam passing through said aperture.
The known filter uses an off-axis part of a lens as energy dispersive element and forms an image of the particle emitting surface on an energy selective diaphragm. The energy dispersive working of the lens forms a dispersion line on a small aperture in the form of a slit in the diaphragm, passing a part of the energy disperse image and blocking the rest.
A problem of this energy filter is that at least two beams leave the gun module: the central beam and the energy filtered beam. Typically one of these is centred around the axis while the other diverges from the axis. This diverging beam may cause unwanted reflections, contaminations etc.
Another problem is that the charged particles of the energy filtered beam interact with the particles in the central beam. During this interaction the energy spread of the energy filtered beam may increase due to Boersch effect and trajectory displacement.
SUMMARY OF THE INVENTION
The invention describes a particle source in which energy selection occurs. The energy selection occurs by sending a beam of electrically charged particles eccentrically through a lens. As a result of this, energy dispersion will occur in an image formed by the lens. By projecting this image onto a slit in an energy selecting diaphragm, it is possible to allow only particles in a limited portion of the energy spectrum to pass. Consequently, the passed beam will have a reduced energy spread. Deflection unit deflects the beam to the optical axis. One can also elect to deflect a beam going through the middle of the lens toward the optical axis and having, for example, greater current.
The energy dispersed spot is imaged on the slit by a deflector. When positioning the energy dispersed spot on the slit, central beam is deflected from the axis to such an extent that it is stopped by the energy selecting diaphragm. Hereby reflections and contamination resulting from this beam in the region after the diaphragm are avoided. Also electron-electron interaction resulting from the electrons from the central beam interacting with the energy filtered beam in the area of deflector is avoided.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter. It should be appreciated by those skilled in the art that the conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be elucidated on the basis of figures, whereby corresponding elements are depicted using identical reference numerals. To this end:
FIG. 1 schematically shows a charged particle source according to the invention in which the central beam is blocked,
FIG. 2 schematically shows the energy distribution of the unfiltered and filtered beam exciting the particle source,
FIG. 3 schematically shows an alternative embodiment of the particle source according to the invention,
FIG. 4 schematically shows another alternative embodiment of the particle source according to the invention, and
FIG. 5 schematically shows yet another alternative embodiment of the particle source according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention aims to provide a charged particle source where only one beam leaves the source module.
To this end the particle source according to the invention is characterised in that when the eccentric beam is focused and aligned on the energy selecting aperture using the second deflector, the second deflector simultaneously deflects the central beam to such an extend that the central beam is blocked by the energy selecting diaphragm.
When the eccentric beam is aligned on the energy selecting aperture and passes through the energy selecting diaphragm, the central beam is stopped by the energy selecting diaphragm by slightly deflecting the central beam. Preferably the deflection of the central beam is done by the second deflector by the same deflection action that is needed to align the eccentric beam on the energy selecting aperture.
As a result the central beam does not exit the charged particle source. The particles of the central beam can thus not cause unwanted reflections, contamination or such like. Also charged particle interaction between particles of the energy selected beam and the central beam, such as Boersch effect and trajectory displacement, is eliminated, as the two beams do not mingle.
It is noted that preferably the charged particle source is formed in such a manner and used such that only one beam at a time leaves the charged particle beam.
It is further noted that the beam limiting diaphragm may be placed between the lens and the emitting surface, thereby forming an eccentric beam. However, the beam limiting diaphragm may be placed anywhere between the emitting surface and the second deflector: even when the beam is placed between the lens and the second deflector, an eccentric beam is excised from the beam illuminating the lens by the aperture defining said eccentric beam, resulting in a similar effect as when defining the eccentric beam before entering the lens.
It is also noted that the deflection of the eccentric beam and the central beam can be identical, i.e. that when the eccentric beam is deflected the central beam is deflected over the same angle, but that it is also possible to cause the deflection of the central beam to differ from the deflection of the eccentric beam by forming the second deflector such that the deflection field for the two beams differ in magnitude, extend, or direction.
It is mentioned that the dispersion line may be formed by the addition of a series of round images, each round image corresponding to one energy in the energy dispersed beam. However, also line images (with the line direction perpendicular to the direction of the energy dispersion) can be used, said line images to be formed in a round focus by optics following the gun module.
In an embodiment of the charged particle source according to the invention the further deflector and the lens are integrated in one multipole element.
By using a multipole element with at least two poles, the multipole element can act as a round lens with a deflector superimposed on it. By this integration the total number of parts, and thus the complexity of the gun module, is reduced.
It is noted that such a pole can be either a magnetic pole face or an electrostatic electrode.
It is further noted that such a multipole element has preferably four poles so that the orientation of the dipole can be adjusted.
In a further embodiment of the charged particle source according to the invention the multipole element is equipped to be used as a stigmator for the beam.
By using a multipole with at least four poles, a stigmator field can be superimposed on the lens field and deflector field.
As known to the skilled person such a pole can be a magnetic pole face or an electrostatic electrode. Also the combination of an electrode and a magnetic pole face in one construction element is known to the person skilled in the art.
It is noted that such a multipole element has preferably at least 8 poles so as to adjust the orientation of the stigmator, although a rotatable stigmator can be realised with e.g. a hexapole, that is: with less than eight poles.
In still a further embodiment of the charged particle source according to the invention the multipole element is an electrostatic multipole element.
By forming the poles as (electrostatic) electrodes, a multipole element with small dimensions can be made, resulting in a compact gun module.
In yet another embodiment of the charged particle source according to the invention the energy selecting diaphragm shows a multitude of energy selective apertures for passing a part of the eccentric beam.
The eccentric beam will, due to the energy dispersive working of the lens, be imaged as an energy dispersed line on the energy selecting diaphragm. The width of the energy selecting aperture on which it is imaged determines the energy spread of the energy selected beam passing through said aperture. Multiple energy selective apertures with different widths thus enable the choice of different energy spreads of the energy selected beam. Also, different apertures are attractive so that an alternative aperture can be used when one aperture is e.g. contaminated or damaged.
Preferable the slit width in the direction of the dispersion is approximately equal to the geometric image size of the charged particle emitting surface as imaged on the energy selecting diaphragm.
In yet another embodiment of the charged particle source according to the invention a multitude of eccentric beams is formed, each of which eccentric beam may be used as the eccentric beam to pass through an energy selective aperture.
An alternative way to form energy selected beams with different energy spreads is by selecting different eccentric beams that pass the lens in a more or a less eccentric fashion. The more eccentric beam will show more energy dispersion, and will thus for a given aperture result in a beam with less energy spread.
It is noted that the second deflector or the focussing action of the lens can be used to direct the desired eccentric beam to the energy selecting aperture.
In yet another embodiment of the charged particle source according to the invention no eccentric beam passes through the energy selective diaphragm when the central beam passes through the energy selective diaphragm.
Although the effect of reflections and contamination is typically most severe when the central beam should pass through the energy selecting diaphragm and then leave the charged particle source eccentrically (as it is deflected from the axis by the first deflector), as the central beam typically shows a much larger intensity than the eccentric beams, a similar effect occurs when the eccentric beam or beams leave the gun module eccentrically. It is thus advantageous to block all beams that leave the charged particle source eccentrically.
In yet another embodiment of the charged particle source according to the invention the second deflector causes a deflection of the eccentric beam that differs from the deflection of the central beam.
By forming the second deflector such that the deflection field differs for the two beams, a different deflection amplitude or direction may be realized. A special case is where the second deflector comprises a first electrode positioned between the eccentric beam and the central beam and two grounded electrodes, one at the side of the central beam opposite to the side where the first electrode is placed and one at the side of the eccentric beam opposite to the side where the first electrode is placed. This results in a deflection field for each of the beams of opposite direction, and possibly different amplitude, and the beams are thus deflected in different directions.
In yet another embodiment of the invention a particle optical apparatus for forming an image of a sample is equipped with a particle optical source according to the invention.
The charged particle source may be used in e.g. a Scanning Electron Microscope (SEM), a Transmission Electron Microscope (TEM), a Scanning Transmission Electron Microscope (STEM), a Focused Ion Beam instrument (FIB) or any other particle optical apparatus where there is a need for a charged particle source with low energy spread.
In a further embodiment of the particle-optical apparatus according to the invention the apparatus is equipped to form a focused beam on the sample.
A low energy spread is especially important when chromatic aberrations of particle-optical lenses and/or deflectors occur. This is especially the case when a beam is focused on a sample.
In another embodiment of the particle-optical apparatus according to the invention the apparatus is equipped to change the energy of the charged particles produced by the particle optical source and deflected by the deflector towards the axis before the charged particles impinge on the sample.
The charged particle source is typically constructed and optimized for a certain energy range of the charged particles produced. The produced beam of particles can be accelerated or decelerated to another value.
In a further embodiment of the particle-optical apparatus according to the invention the energy change is a lowering of the energy.
A low energy spread is especially important when using a beam of low energy, as a lowering of the energy results in a large relative energy spread ΔE/E and thus large chromatic aberration. Therefore, when using a charged particle source and then lowering the energy of the particles to a desired energy, an energy filter according to the invention is attractive.
FIG. 1 schematically shows a charged particle source according to the invention in which the central beam is blocked.
A charged particle emitting surface 102 produces a beam of charged particles 103 round an axis 101 . A beam limiting diaphragm 104 blocks part of the emitted particles and passes at least two beams, an axial beam 105 centred around the axis and an off-axis beam 106 . The axial beam 105 passes centrally through particle-optical lens 107 , while the off-axis beam passes through said lens eccentrically. The lens focuses the particle emitting surface 102 on the energy selecting diaphragm 108 . The energy selecting diaphragm shows two apertures, a central aperture 110 to pass the central beam (when said beam is not deflected) and an eccentric aperture 109 for passing a part of beam 106 . A deflector 111 , here schematically depicted by two deflector plates 111 a and 111 b , aligns the eccentric beam on the energy selecting eccentric aperture 109 in such a way that the most intense part of the beam passes through the eccentric aperture 109 . As the lens typically focuses low energetic particles stronger than high energetic particles, an energy dispersed line pointed to the axis is formed on the energy selecting diaphragm. The width of the eccentric aperture in the radial direction determines the energy spread of the energy selected beam 113 . Deflector 112 , here schematically depicted by two deflector plates 112 a and 112 b , aligns the eccentric beam round the axis.
When deflector 111 is not active, that is: when the central beam 105 is centred around the axis 101 , the central beam passes through the central aperture 110 of the energy selecting diaphragm 108 . Typically the central beam is the beam with the largest current when compared to the eccentric beam 106 . In this situation, where beam 105 is not deflected, eccentric beam 106 is typically blocked by the energy selecting diaphragm. When deflecting the eccentric beam so as to align it on the eccentric aperture 109 , the central beam is deflected as well. The deflection of the central beam is sufficient to position the (focused) central beam on the material of the energy selecting diaphragm and not on the central aperture. Thereby passage of the central beam is blocked and only a part of the eccentric beam passes the energy selecting diaphragm to form the energy selected beam 113 . This energy selected beam 113 is then deflected round the axis 101 to be manipulated (focused, deflected, scanned, etc.) by the rest of the apparatus in which the charged particle source is used.
It is noted that even when passing the central beam through the energy selecting diaphragm, it may be necessary to apply a deflection to the central beam to centre it on the central aperture 110 . This can be used to counter misalignments of the electrodes, or to counter a mechanical displacement and/or drift of the emitting surface, such as a Schottky emitter.
FIG. 2 schematically shows the energy distribution of the unfiltered and filtered beam exciting the particle source.
The energy distribution of the unfiltered beam is given by curve 201 . It shows the intensity as a function of the energy deviation from a nominal energy Enom. Enom can be changed by accelerating or decelerating the beam. Often this energy distribution curve 201 is assumed to be a Gaussian distribution, characterized by the Full Width at Half Maximum (FWHM) energy spread 203 . For electron sources the FWHM energy spread is typically between 0.5 to 1 eV, for liquid metal ion sources typically between 3 to 10 eV.
By filtering a small part of the electrons a distribution 202 can be obtained, which has a FWHM energy spread 204 . As known to the person skilled in the art such a filtered beam, although having less total current than an unfiltered beam, can in those cases where the chromatic aberration of a lens dominates be focused in a much smaller focus and results in a higher current density in the focus.
FIG. 3 schematically shows an alternative embodiment of the particle source according to the invention.
FIG. 3 can be thought to be derived from FIG. 1 . The beam limiting aperture 104 is now placed between the lens 107 and the second deflector 111 . Further the second deflector is now formed as an electrode 111 b placed between the eccentric beam 106 and the central beam 105 , and two grounded electrodes 111 a on the opposite side of each of the beams. As a result the eccentric beam is deflected in a direction opposite to the direction over which the central beam is deflected.
It is remarked that a different spacing of the two electrodes 111 a with respect to electrode 111 b results in different deflection field strengths, and thus different magnitude of the angle over which the beams are deflected. This arrangement of the deflector 111 can thus give rise to different mutual directions and magnitudes of the deflection angles of the two beams, thereby offering additional design flexibility.
FIG. 4 schematically shows an alternative embodiment of the particle source according to the invention. The embodiment shown in FIG. 3 is similar to that shown in FIG. 1 , but the beam limiting diaphragm 104 passes three beams, axial beam 105 , off-axis beam 106 a , and a second off-axis beam 106 b . By adjusting the voltage on deflectors 111 a and 111 b , either one of beam 106 a or beam 106 b can be selected to pass through aperture 109 , or beam 105 can be selected to pass through aperture 110 . Preferably only a single beam leaves the source.
FIG. 5 schematically shows an alternative embodiment of the particle source according to the invention. The embodiment shown in FIG. 5 is similar to that shown in FIG. 1 , but includes multiple energy selecting apertures, 109 a and 109 b , through which eccentric beam 106 can be deflected, thereby enabling a choice of different energy spreads for the selected energy beam. Other embodiments could combine the multiple apertures in beam limiting diaphragm 104 of FIG. 4 with the multiple energy selecting apertures of FIG. 5 . The multiple apertures in beam limiting diaphragm 104 shown in FIG. 4 and the multiple energy selecting apertures 109 shown in FIG. 5 could also be implemented separately or together in embodiments similar to FIG. 3 , that is, embodiments having multiple deflectors before the energy selecting aperture or having the lens positioned before the beam limiting diaphragm.
It is noted that it is also possible to use this source with the lens 107 not or almost not excited, so that the central beam is not or almost not focused by said lens. It is then possible to extract a central beam with another current from the gun module. Also exciting the lens sufficiently strong to form a cross-over between the lens and the energy selecting aperture is foreseen as a use to extract a desired current from the module, using the central beam. This enables the central beam, that is not energy selected to be chosen, with an appropriate current by tuning lens 107 , and to use the eccentric beam with a setting of the lens 107 in which the emitting surface is imaged on the energy selecting diaphragm. Multiple charged particle emitting surfaces 102 could be used in any embodiments, as shown in U.S. Pat. No. 7,034,315, FIG. 3.
It is remarked that the use of a gun module in this mode, using an extra lens in the gun module, is described in U.S. Pat. No. 6,693,282.
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A particle source in which energy selection occurs by sending a beam of electrically charged particles eccentrically through a lens so that energy dispersion will occur in an image formed by the lens. By projecting this image onto a slit in an energy selecting diaphragm, it is possible to allow only particles in a limited portion of the energy spectrum to pass. Consequently, the passed beam will have a reduced energy spread. The energy dispersed spot is imaged on the slit by a deflector. When positioning the energy dispersed spot on the slit, central beam is deflected from the axis to such an extent that it is stopped by the energy selecting diaphragm. Hereby reflections and contamination resulting from this beam in the region after the diaphragm are avoided. Also electron-electron interaction resulting from the electrons from the central beam interacting with the energy filtered beam in the area of deflector is avoided.
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FIELD OF THE INVENTION
This invention relates to compostable or biodegradable vinyl halide polymer compositions, for example, polyvinyl chloride (PVC) and composite sheets of such polymers
BACKGROUND OF THE INVENTION
For many years it has been desired to make plastic materials from vinyl halide polymers such as polyvinyl chloride (PVC) which are either biodegradable by microorganisms or environmentally degradable such as in a landfill. In spite of considerable efforts, landfills are becoming inundated with plastic materials, and articles made therefrom, that will not degrade perhaps for centuries. This is especially true for vinyl halide polymer materials such as PVC that are considered non-biodegradable, that is, they persist in landfills under anaerobic conditions indefinitely without noticeable decomposition. This factor limits the acceptance of PVC in many products where its useful balance of properties and low cost would be attractive. An example is that of printable film and sheet. If a sample of flexible (plasticized) PVC is tested per ASTM D 5526, Standard Test Method for Determining Anaerobic Biodegradation of Plastic Materials Under Accelerated Landfill Conditions, there is no appreciable weight loss or change in appearance after 100 days at 97° F. in contact with simulated household waste. In contrast, cellulosic polymers and other biodegradable plastics, such as polylactic acid and polycaprolactone, are completely consumed.
There has been a particular need for a compostable vinyl halide polymer composition for use in many end products such as polyvinyl chloride films, banners, billboards, signs, laminates, ink jet media, diapers, hygienic pads and the like. These products must satisfy properties for practical purposes such as tear strength, tensile and impact strengths to function in many useful articles. However, the same properties that make them useful lead to their lack of biodegradability. PVC and other vinyl halide polymers have achieved widespread usage in many practical articles. However, the goal of a compostable vinyl halide polymer composition or composite has not been satisfied.
SUMMARY OF THE INVENTION
This invention is directed to a compostable vinyl halide polymer composition. In particular, polyvinyl chloride (PVC) compositions have been rendered compostable by formulation with a prodegradant composition of an organotitanate or zirconate compound and an organotin compound.
In a broader form of the invention, polyvinyl chloride compositions have been formulated with plasticizer and stabilizer along with the prodegradant composition. Polymeric sheets containing this composition and composites with woven or nonwoven sheets have been made compostable.
It has now been found that PVC can be formulated to yield biodegradability comparable or superior to cellulosic polymers. In a more specific form of the invention, such compositions consist of (a) PVC; (b) a plasticizer selected from the group of completely aliphatic carboxylic acid esters; (c) a heat stabilizer selected from the group of sulfur-free dialkyl and monoalkyltin carboxylates; and (d) a reactive organotitanate or organozirconate. Such compositions can be used to produce PVC film and sheet by standard methods, such as extrusion, calendering or coating from plastisols or organosols. They may contain other additives routinely used in PVC compounding, such as fillers, pigments, antioxidants, UV light absorbers, bonding agents, etc. Such films may be laminated to biodegradable fabrics made from polymers such as polyvinyl alcohol, polyacryamide, polyacrylate, polymethacrylate and polyester, or to paper to produce laminates that are totally biodegradable under landfill conditions. These laminates are particularly useful for printable sheeting constructions that, after usage, may be disposed of in standard landfills.
The compositions and composites of this invention are compostable. “Compostable” means that the composition or sheet undergoes chemical, physical, thermal and/or biological degradation such that it may be incorporated into and is physically indistinguishable from finished compost (humus) and which ultimately mineralizes (biodegrades) to CO 2 , water and biomass in the environment like other known compostable matter such as paper and yard waste. The compostable films and composites are either biodegradable or environmentally degradable. “Biodegradable” means that the composition or composite is susceptible to being assimilated by microorganisms when buried in the ground or otherwise contacted with the organisms under conditions conducive to their growth. “Environmentally degradable” means that the film or layer is capable of being degraded by heat or surrounding environmental elements without microorganisms to a form that ultimately may be biodegradable when it mineralizes, for example, biodegrades to carbon dioxide, water and biomass. For purposes of this invention, “compostable” is intended to include “biodegradable” or “environmentally degradable”.
Composting conditions that enable the chemical, physical, thermal and/or biological degradation of the composition or composite may vary. The compositions or composites of this invention are especially adapted to be compostable in municipal solid waste composting facilities or landfills. For example, following ASTM D 5526-94 (reapproved 2002), Standard Test Method for Determining Anaerobic Biodegradation of Plastic Materials Under Accelerated Landfill Conditions, samples of PVC were degraded, incorporated into and physically indistinguishable in the test landfill.
Compostable vinyl halide polymer compositions and composites of this invention, their method of manufacture and compostability will be understood with reference to the following detailed description.
DETAILED DESCRIPTION OF THE INVENTION
A. Vinyl Halide Polymer
The vinyl halide resin employed is most commonly a homopolymer of vinyl chloride, i.e., polyvinyl chloride. It is to be understood, however, that this invention is not limited to a particular vinyl halide resin such as polyvinyl chloride or its copolymers. Other halogen-containing polymers or resins which are employed and which illustrate the principles of this invention include chlorinated polyethylene, chlorosulfonated polyethylene, chlorinated polyvinyl chloride, and other vinyl halide polymer or resin types. Vinyl halide polymer or resin, as understood herein, and as appreciated in the art, is a common term and is adopted to define those resins or polymers usually derived by polymerization or copolymerization of vinyl monomers including vinyl chloride with or without other comonomers such as ethylene, propylene, vinyl acetate, vinyl ethers, vinylidene chloride, methacrylate, acrylates, styrene, etc. A simple case is the conversion of vinyl chloride H 2 C—CHCl to polyvinyl chloride (CH 2 CHCl—)n wherein the halogen is bonded to the carbon atoms of the carbon chain of the polymer. Other examples of such vinyl halide resins would include vinylidene chloride polymers, vinyl chloride-vinyl ester copolymers, vinyl chloride-vinyl ether copolymers, vinyl chloride-vinylidene copolymers, vinyl chloride-propylene copolymers, chlorinate polyethylene, and the like. Of course, the vinyl halide commonly used in the industry is the chloride, although others such as bromide and fluoride may be used. Examples of the latter polymers include polyvinyl bromide, polyvinyl fluoride, and copolymers thereof.
B. Prodegradant System
The prodegradant system or composition of this invention comprises an organozirconate or organotitanate amide adduct and an organotin compound.
(1) Organotitanate or Organozirconate Amide Adducts
The chemical description and chemical structure of organotitanates or zirconates has been well developed. For instance, Kenrich LICA 38J is a reactive titanate under the chemical name titanium IV neoalkanolato, tri(dioctyl) pyrophosphato-O (adduct) N-substituted methacrylamide. Furthermore, with zirconium substituted for titanium, Kenrich produces NZ 38 under the chemical description zirconium IV neoalkanolato, tri(dioctyl) pyrophosphato-O (adduct) N-substituted methacrylamide. These compounds are generally referred to as amide salts of neoalkoxy modified monoalkoxy titanate or zirconate. While the invention has been exemplified with these amide adducts of these specific organotitanates or organozirconates, it is to be understood that other similar compounds can achieve the objectives of this invention.
These organotitanates or zirconates are further described in considerable detail in the following US Patents which are incorporated herein in their entireties by reference, namely, U.S. Pat. Nos. 4,069,192; 4,080,353; 4,087,402; 4,094,853; 4,096,110; 4,098,758; 4,122,062; 4,152,311; 4,192,792; 4,101,810; 4,261,913; 4,277,415; 4,338,220; 4,417,009.
(2) Organotin Compounds
Mono- and diorganotin compounds are well known stabilizers for PVC. The generalized organotin stabilizer formula is R 2 SnX 2 or R 2 SnX 3 . The R-group used in the above general formula of tin stabilizers can be lower alkyl such as butyl. More recently, because of availability and relatively low cost, fatty acid carboxylates have been employed. Cost-effective methods have been developed to produce tin intermediates which were then reacted with carboxylic acids or with ligands containing mercaptan groups to yield stabilizers for vinyl halide resins. Accordingly, among the class of organotin compounds suitable for use in accordance with this invention are organotin carboxylates or organotin sulfur-containing compounds are U.S. Pat. Nos. 2,641,588; 2,648,650, 2,726,227; 2,726,254; 2,801,258; 2,870,119; 2,891,922; 2,914,506 and 2,954,363; the organotin mercaptoacid esters as described in U.S. Pat. No. 2,641,596; organotin esters of mercapto alcohols of U.S. Pat. Nos. 2,870,119; 2,870,182; 2,872,468 and 2,883,363; and organo thiostannoic acids such as butyl thiostannoic acid as disclosed in U.S. Pat. Nos. 3,021,302; 3,413,264; 3,424,712 and 3,424,717. All of these patents are incorporated herein in their entireties by reference. Organotin carboxylates, such as dibutyltin dilaurate or dibutyltin maleate, are preferred. Other organotins can be used.
(3) Prodegradant Synergistic Composition
It has been discovered that the prodegradant composition of organotitanate or organozirconate compound and organotin displays an unpredicted synergism in the compostability of vinyl halide polymers. The remarkable compostability property exists over ranges of ratios of the essential components. The exact mechanism for the unexpected results and the compostability of vinyl halide polymers with the prodegradant system is not completely understood. Certainly there are theories which could be proposed, but regardless of theories, the beneficial results evident in the numerous examples of this invention which follow, in further view of this detailed description, speak for themselves. Applicant relies upon these empirical demonstrations of the principles of this invention to advance its merit.
In the prodegradant system of this invention, it has been found that the total composition of prodegradant is useful over a range of about 1 to about 10 parts (phr) by weight based upon 100 parts by weight of the vinyl halide polymer. The most useful range of total parts by weight of the organotin or zirconate in the total composition is on the order of about 5 to about 7 phr. In the case of organotin compound, the most useful parts are on the order of about 2 to about 3 phr. Each of the components of the system can range from 1 to 10 phr. The ratios of the components is not considered to be critically limiting among the broader aspects of the invention.
(4.) Plasticizer
In a broader mode, the vinyl halide composition is plasticized with aliphatic or aromatic esters, typically, di-octyl adipate (DOA), di-isononylester of cyclohexane dicarboxylic acid or di-isodecyl phthalate (DIDP). In its presently best mode, the aliphatic ester is used. It is presently believed that the mobility in the polymeric matrix lent by the plasticizer is important because rigid PVC samples have not demonstrated compostability.
The principles of this invention and its operating parameters will be further understood with reference to the following detailed examples which serve to illustrate the types of specific prodegradants and their amounts as used in typical vinyl halide polymer resin formulations and the compostabilities displayed by the essential combination of the prodegradant system components of this invention. These examples are considered to be exemplary of this invention and should not be considered as limiting, especially in view of applicant's broad disclosure of the principles of this invention.
In each of the examples, standard resin formula was employed which contained 100 parts by weight polyvinyl chloride homopolymer (Geon 121 PVC by B.F. Goodrich). Included in the standard formula was a plasticizer such as di-octyl adipate (DOA) or di-isodecyl phthalate (DIDP).
The compostability of the PVC compositions of the examples was determined by following ASTM D 5526-94 (reapproved 2002), Standard Test Method for Determining Anaerobic Biodegradation of Plastic Materials Under Accelerated Landfill Conditions. Using the standard test, a mixture was prepared comprising 60% by weight of sterilized dehydrated manure (to simulate processed household waste), 30% distilled water, and 10% fermenting inoculum from an active composter. 50 g were used in sealed Petri dishes with ½ by 1 inch samples of PVC composition or composite sheet material. All experiments were run at 97° F. in a dark incubator.
EXAMPLE 1
A plastisol was mixed consisting of 100 parts PVC (Geon 121), 80 parts di-isodecyl phthalate (DIDP), and 2 parts dibutyltin dilaurate (DBTDL) heat stabilizer; coated as a 2 mil film on release paper and fused. Samples were unchanged after 90 days exposure to the test conditions of ASTM D 5526-94. The procedure was repeated using di-octyl adipate (DOA) in place of DI DP. After 90 days, there was visible mold growth on the film but no visible evidence of decomposition. The procedure was repeated with the addition of 2.5 parts of a 4% solution of isothiazolone biocide (MICRO-CHEK 11, Ferro Corporation). In this case, there was no evidence of mold growth after 90 days.
EXAMPLE 2
The plastisol of Example 1 was mixed using DOA, DBTDL plus 5 parts of titanium neoalkanato, tri(dioctyl) pyrophosphato-O-(adduct)-N-substituted methacrylamide (Kenrich LICA 38J). Fused samples were consumed in the test landfill within 10 days, vanishing to the visible eye. The experiment was repeated adding 2.5 parts of MICRO-CHEK 11 biocide, with identical results.
EXAMPLE 3
The plastisol of Example 1 was mixed with DBTDL, LICA 38J and, replacing DOA, the di-isononyl ester of cyclohexane dicarboxylic acid (DINCH, BASF). Upon testing per ASTM D 5526-94 method, fused samples disappeared in 7 days, with or without added biocide.
EXAMPLE 4
Example 3 was repeated with the zirconate analog of LICA 38J (Kenrich NZ 38J). Upon testing per ASTM D 5526-94 method, fused samples disappeared within 10 days.
EXAMPLE 5
The plastisol was mixed using DINCH, LICA 38J and dibutyltin maleate ester heat stabilizer (PLASTISTAB 2808, Halstab) in place of DBTDL. Upon testing per ASTM D 5526-94 method, fused samples disappeared within 10 days.
EXAMPLE 6
The plastisol was mixed using DINCH, LICA 38J, and 2 parts of a liquid calcium/zinc stabilizer (PLASTISTAB 3002, Halstab) in place of DBTDL organotin. After 90 days, the fused sample had heavy mold growth and had fragmented but was still visibly of the same dimensions.
EXAMPLE 7
Control samples were run for comparison. Upon testing per ASTM D 5526-94 method, samples of untreated filter paper showed mold growth within week and were consumed in 30 days. A sample of polylactic acid (PLA) 2 mil film was completely consumed in seven days. A sample of 1 mil low density polyethylene (LDPE) film was unchanged after 90 days.
EXAMPLE 8
A plastisol was mixed consisting of 100 parts Geon 121 PVC, 80 parts DOA, 2 parts DBTDL stabilizer and 5 parts of LICA 38, which is the titanate LICA 38J without the methacrylamide adduct. After 30 days at 97° F. per ASTM D 5526, there was no visible sign of decomposition. The same result was found with NZ 38, the zirconate bases for NZ 38J, and with 5 parts of methacrylamide itself. These tests establish that the methacrylamide adduct of the organotitanate or zirconate is necessary for compostability.
EXAMPLE 9
A plastisol was mixed consisting of 100 parts PVC, 80 parts DOA, 5 parts LICA 38J organotitanate-methacrylamide adduct, and 2 parts of dibutyltin di-isothioglycolate (SP1002, Ferro Corporation). After 30 days, there was only minor decomposition. This probably reflects the antioxidant capability of organotin mercaptides. It also presently establishes the preferred organotin carboxylates in the prodegradant system.
EXAMPLE 10
Example 9 was repeated using the following stabilization system: epoxidized soybean oil (ESO)—2 parts; phenyl di-iso-decyl phosphite—2 parts; zinc stearate—0.2 parts. After 30 days, there was no visible compostability, probably due to the antioxidant capability of the phosphite that would be used in most mixed metal stabilizer systems. In this case there was, however, notable mold growth, so it is possible that there might be eventual decomposition (period of years). Repetition using ESO containing 4% isothiazolone biocide led to no mold growth.
EXAMPLE 11
As described previously, plastisol was mixed consisting of 100 parts Geon 121 PVC, 80 parts DOA, 2 parts DBTDL, and 5 parts of Kenrich LICA 38J reactive titanate. To this was added 5 parts of VULCABOND MDX (Akzo Nobel) bonding agent. The plastisol was coated on polyester fabric and fused to a coating of about 5 mils thickness.
A sample of this coated fabric with the inventive prodegradant system and a control sample of a commercial finished product of the same construction (without the prodegradant system) were exposed at 90° F. per ASTM D5526 conditions. After two weeks exposure, the control sample was essentially unchanged. The inventive sample has lost almost all trace of plastisol to the landfill, the only remnants being that which penetrated intersections of the fabric mesh. The fabric shows evidence of some decomposition and it is anticipated that the polyester will slowly decompose.
Having described this invention in its various embodiments and parameters, other variations will become apparent to a person of ordinary skill in the art.
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Compositions of vinyl halide polymers such as PVC are rendered compostable by a prodegradant system of an organotitanate or zirconate and an organotin. PVC sheets and composites are compostable in landfills.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of optical waveguides and optical devices incorporating optical waveguides.
BACKGROUND TO THE INVENTION
[0002] It is increasingly recognised that integrated optical circuits have a number of advantages over electrical circuits. However, it has been difficult to produce integrated optical circuits which are comparably small, primarily due to the difficulty in producing waveguides which can include tight bends without large signal losses. It has also been difficult to produce integrated optical circuits including signal processing devices based on photonic band structures which can be easily coupled to current optical fibres, owing to a difference in the refractive index of the material used for optical fibres and those materials typically used for integrated optical devices, whilst still maintaining compact sizes.
[0003] Photonic crystals comprising a lattice of air holes formed in a core material, typically silicon or silicon nitride, have been fabricated, which exhibit a photonic band structure and typically a bandgap. Alternatively, a lattice of dielectric rods in air can be used. By not including some holes or rods in the lattice a line defect waveguide can be formed. Confinement of light within the waveguide is provided by using light within the photonic bandgap wavelength range. However, it has been found that devices of this type suffer from large losses, mainly due to the escape of light from the waveguide in a vertical direction.
[0004] Similarly, optical devices using this type structure for signal processing, such as filtering, suffer from large losses. This limits their usefulness.
SUMMARY OF THE INVENTION
[0005] According to a first aspect of the present invention, an optical waveguide structure comprises a core layer having a first refractive index n core , an array of sub-regions within the core having a second refractive index n rods , the array of sub-regions extending longitudinally along the waveguide and giving rise to a photonic band structure experienced by an optical mode travelling through the waveguide structure, and a cladding layer adjacent to the core layer having a refractive index n cladding , wherein:
n core >n rods ≧n cladding and n core −n rods >0.1.
[0006] Preferably, the array of sub-regions gives rise to a photonic bandgap.
[0007] As is well known in the field of photonic crystals, in order to give rise to an appreciable band structure an absolute refractive index contrast of greater than 0.1 must be present between the main body of material and the sub-regions ,which are typically holes. Indeed, typically, high refractive index such as silicon (n=4) have been used with a lattice of air holes (n=1) to provide a complete photonic bandgap. Accordingly, written grating structures, such as Bragg gratings, which have a refractive index contrast of less than 0.1 cannot be considered to be photonic crystals. Written grating structures do not interact with light in the same way as photonic crystals and so cannot be used to achieve the same functionality. Written structures only interact with the evanescent field of optical signals which gives rise to much weaker interaction.
[0008] The optical waveguide structure may be a planar structure. In this case, the waveguide guide structure preferably further includes a buffer layer having a refractive index n buffer , wherein the core layer is positioned between the buffer layer and the cladding layer and wherein:
n core >n rods ≧n buffer .
[0009] Alternatively, the waveguide structure may be an optical fibre structure, wherein the cladding layer surrounds the core layer.
[0010] The present invention provides advantages over conventional photonic crystal devices which include an array of rods in air or an array of air holes formed in a core layer. In these conventional structures there is a large amount of loss for optical signals passing through them, especially out of the plane of propagation. The structure of the present invention is less lossy than prior waveguide structures having photonic bandstructure regions. The out of plane divergence of light in the sub-regions is reduced as compared with air holes which are typically used in photonic crystal structures. As a result more light is coupled back into the core at the sub-region/core interface. In the planar case, coupling of light into the buffer layer is also reduced. Furthermore, there are added advantages over the prior art associated with the fabrication of these structures.
[0011] The refractive index contrast between the core and the sub-regions affects the nature of the band structure. For some applications, such as filtering and dispersion compensation the difference in refractive index can be extremely small i.e. a difference in the third decimal place of the refractive index. However, other applications such as 90° bends in waveguides require a bandgap which overlaps in different propagation directions. This requires a much larger refractive index contrast. Preferably, the core layer has a refractive index between 1.4 and 4. Preferably, the sub-regions have a refractive index between 1.3 and 1.6. Preferably, the cladding has a refractive index between 1.3 and 1.6. In the planar case, preferably the buffer layer has a refractive index-between 1.3 and 1.6.
[0012] Preferably, the sub-regions are formed from silicon oxynitride. Preferably, the core layer is formed from silicon nitride, doped silica, tantalum pentoxide or doped tantalum pentoxide. The cladding layer is preferably formed from silicon dioxide. In the planar case the buffer layer is preferably also formed from silicon dioxide.
[0013] The sub-regions may extend through the cladding layer as well as the core layer and partially or fully into the buffer layer. Alternatively, the cladding layer may include sub-regions corresponding to the sub-regions in the core layer having a refractive index which is greater than or equal to the refractive index of the cladding layer but which is less than or equal to the refractive index of the sub-regions in the core. Furthermore, in the planar case, the buffer layer may include sub-regions corresponding to the sub-regions in the core layer having a refractive index which is greater than or equal to the refractive index of the buffer layer but which is less than or equal to the refractive index of the sub-regions in the core.
[0014] The present invention is applicable to waveguides connecting integrated optical circuits as well as to individual optical devices which are used in integrated optical circuits. Any device incorporating waveguide bends in a glassy core layer can be improved by use of the present invention. Such devices include Arrayed Waveguide Gratings (AWGs), Mach Zehnder interferometers, directional couplers, dispersion compensators, splitters/multiplexers, polarisation compensators, optical switches, optical delay elements and filters.
[0015] Preferably, the core layer includes a lateral waveguiding region having no sub-regions. Preferably, the waveguiding region includes a waveguide bend.
[0016] According to a second aspect of the invention, a method of manufacturing a optical waveguide structure comprises the steps of:
[0017] providing a core layer having a first refractive index n core ;
[0018] providing an array of sub-regions within the core having a second refractive index n rods , the array of sub-regions giving rise to a photonic band structure experienced by an optical mode travelling through the waveguide structure; and
[0019] providing a cladding layer adjacent to the core layer having a refractive index n cladding ; wherein:
n core >n rods ≧n cladding .
[0020] The optical waveguide may be planar, the method further including the step of providing a buffer layer having a refractive index n buffer on the opposite side of the core layer to the cladding layer, wherein:
n core >n rods ≧n buffer .
[0021] Alternatively, the optical waveguide may be an optical fibre, the method further including the steps of:
[0022] providing the cladding layer surrounding the core layer.
[0023] According to a third aspect of the present invention, a method of guiding an optical signal comprises the step of passing an optical signal through a waveguiding region of an optical waveguide structure comprising a core layer having a first refractive index n core , an array of sub-regions within the core layer having a second refractive index n rods , the array of sub-regions giving rise to a photonic band structure experienced by an optical mode travelling through the waveguide structure, and a cladding layer adjacent the core layer having a refractive index n cladding , wherein:
n core >n rods ≧n cladding .
[0024] The optical waveguide structure may be a planar structure. In this case, the waveguide guide structure preferably further includes a buffer layer having a refractive index n buffer , wherein the core layer is positioned between the buffer layer and the cladding layer and wherein:
n core >n rods ≧n buffer .
[0025] Alternatively, the waveguide structure may be an optical fibre structure, wherein the cladding layer surrounds the core layer.
[0026] According to a fourth aspect of the present invention, an optical waveguide structure comprises a core layer having a first refractive index n core , a 2-dimensional array of sub-regions within the core layer having a second refractive index n rods , the array of sub-regions extending longitudinally along the waveguide and giving rise to a photonic band structure within the core layer, and a cladding layer adjacent to the core layer having a refractive index n cladding , wherein:
n core >n rods ≧n cladding .
[0027] The preferred features of the first aspect are all equally applicable to the fourth aspect of the present invention. Furthermore, preferably n core −n rods >0.1.
[0028] According to a fifth aspect of the present invention, a method of manufacturing a optical waveguide structure comprises the steps of:
[0029] providing a core layer having a first refractive index n core ;
[0030] providing a cladding layer adjacent to the core layer having a refractive index n cladding ,
[0031] forming a 2-dimensional array of holes in the core layer extending longitundinally along the wave guide structure; and
[0032] filling the holes with a material having a second refractive index n rods , wherein:
n core >n rods ≧n cladding .
[0033] The preferred features of the second aspect are all equally applicable to the fifth aspect of the present invention. Furthermore, preferably n core −n rods >0.1.
[0034] According to a sixth aspect of the present invention, a method of guiding an optical signal comprises the step of passing an optical signal through a waveguiding region of an optical waveguide structure comprising a core layer having a first refractive index n core , a 2-dimensional array of sub-regions within the core layer extending longitudinally along the waveguide having a second refractive index n rods , the array of sub-regions giving rise to a photonic band structure within the core layer, and a cladding layer adjacent to the core layer having a third refractive index n cladding , wherein:
n core >n rods ≧n cladding .
[0035] The preferred features of the third aspect are all equally applicable to the sixth aspect of the present invention. Furthermore, preferably n core −n rods >0.1.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Examples of the present invention will now be described in detail with reference to the accompanying drawings, in which:
[0037] [0037]FIG. 1 is a schematic cross sectional view of a photonic crystal embedded in a waveguide structure in accordance with the prior art;
[0038] [0038]FIG. 2 a is a schematic cross sectional view of a photonic crystal embedded in a waveguide structure in accordance with the present invention;
[0039] [0039]FIGS. 2 b and 2 c are schematic cross sectional views of other examples of photonic crystals embedded in a waveguide structure in accordance with the present invention;
[0040] [0040]FIG. 3 shows a waveguide design in accordance with the present invention;
[0041] [0041]FIG. 4 shows a waveguide bend formed with a waveguide design in accordance with the present invention;
[0042] [0042]FIG. 5 is a schematic illustration of a optical device in accordance with the present invention;
[0043] [0043]FIG. 6 shows an optical fibre incorporating a structure in accordance with present invention;
[0044] [0044]FIG. 7 shows schematically a photonic device incorporating a photonic element suitable for use in a telecommunications system;
[0045] [0045]FIG. 8 shows schematically another photonic device incorporating a photonic element suitable for use in a biosensor arrangement; and,
[0046] [0046]FIG. 9 shows schematically a further photonic device incorporating a photonic element suitable for use in an optical pick-up unit.
DETAILED DESCRIPTION
[0047] Photonic crystal waveguide structures are based on some perturbation in dielectric constant in the core of a planar waveguide structure. This has most commonly been performed by the etching of air rods into the core layer of the waveguide. As light propagates through the core it interacts with the dielectric constant modulation and, in some structures, in a manner analogous to electrons in a semiconductor, certain electromagnetic fields are forbidden to propagate in the core. The forbidden electromagnetic fields form a photonic bandgap. More detail on the nature of the band structure of photonic crystals of this sort can be found in WO986/53351 (BTG International Limited).
[0048] [0048]FIG. 1 illustrates the interaction of the electric field (E-field) of an optical mode with the core 1 in a photonic crystal according to the prior art. The light is travelling through the core 1 from left to right. A profile of the E-field within the core 1 , cladding 2 and buffer 3 layers is shown. It can be seen that in the photonic crystal region the mode confinement is reduced and there is out of plane loss. When the light reaches the first air/core interface, the light diverges strongly in the vertical direction, introducing loss. Once the light is in the air region 4 there is no confinement and light escapes from the top of the structure and into the buffer layer 3 , which is of a higher refractive index than air. Furthermore, owing to the fact that the structure is not symmetric, and light is not well confined in the vertical direction, light leaks into the buffer layer 3 from the air rods 4 .
[0049] Vertical loss in the waveguide structure is very significant and limits the usefulness of the structure in practical devices, especially in confinement applications such as in waveguide bends.
[0050] [0050]FIG. 2 a shows a waveguide structure according to one aspect of the present invention. The waveguide structure shown in FIG. 2 comprises a core layer 10 , having a refractive index n core , an array of rods 11 in the core layer 10 having a refractive index n rods , and buffer 12 and cladding layers 13 having a refractive index n buffer and n cladding , respectively. In this example the rods 11 extend through the cladding layer 13 and partially into the buffer layer 12 . However, alternatively, the rods may be formed solely in the core layer or solely in the core layer and cladding layer. The refractive indices satisfy the inequality:
n core >n rods ≧n cladding and n buffer
[0051] This condition provides greater vertical confinement of the E-field of an optical signal passing through the waveguide. The higher refractive index of the rods 11 reduces the tendency of the light to leak into the buffer layer 12 and reduces losses from the top of the structure and into the substrate. The arrow 15 indicates the longitudinal direction of the waveguide from which it can be seen that the array extends longitudinally along the waveguide.
[0052] [0052]FIG. 2 b shows an another example of a waveguide structure. The structure is identical to the structure shown in FIG. 2 a in that it has substrate 14 , buffer 12 , core 10 and cladding 13 layers. The only difference is that the rods 15 extend through the cladding 13 and the core 10 , but not into the buffer 12 . Similarly, FIG. 2 c shows a waveguide structure with substrate 14 , buffer 12 , core 10 and cladding 13 layers but in this example the rods 16 exist only in the core layer 10 .
[0053] The core 10 material of the structure of FIG. 2 a is a few microns in thickness and may be formed of silicon nitride (n=2.02). The rods 11 may be composed of silicon oxynitride (n=1.6).The cladding 13 and buffer 12 layers are formed of silicon dioxide (n=1.46). The buffer 12 and cladding 13 layers need not be formed of the same material as long as they satisfy the inequality above. The materials described above are examples only and it should be appreciated that other materials may be used. The benefit of the invention will be realised as long as the inequalities are satisfied. However, for structures which are easily coupled to typical optical fibres and devices it is preferred that the core layer has a refractive index between 1.4 and 4 and more preferably between 1.4 and 2.5, the rods have a refractive index between 1.3 and 1.6 and the cladding and buffer layers each have a refractive index between 1.3 and 1.6.
[0054] The waveguide of FIG. 2 a also includes a substrate layer 14 underneath the buffer layer 12 . The waveguide structure of FIG. 2 a may be fabricated as follows. The buffer layer 12 is put on the substrate by thermal oxidation, HIPOX or plasma enhanced chemical vapour deposition (PECVD) depending on whether a thin or thick oxide is being deposited. The core layer is put down next by PECVD, CVD or sputtering. The cladding layer is then deposited by PECVD, CVD or sputtering. The position of the rods 11 is then defined, for example, by etching into the core 10 . Wet or dry etching may be used but dry etching is preferred. The position of the rods may be either direct-written using an e-beam, or transferred from a mask. The material filling the rods, in this case silicon oxynitride, is then deposited into the etched holes using any suitable technique, such as PECVD, chemical vapour deposition (CVD), molecular beam epitaxy (MBE) or sputtering. Any silicon oxynitride on top of the waveguide can be removed preferably by dry etching, but alternatively by controlled wet etching or chemical mechanical polishing. Alternatively, the rods can be grown or etched from the substrate and a waveguide structure grown around the rods.
[0055] In the case described above both the filling material and the cladding are different materials. In order to simplify fabrication, the material filling the rods may be the same as the cladding. With a core of silicon nitride (n=2.02) and rods of silicon oxynitride (n=1.6), the silicon oxynitride (n=1.6) on top of the waveguide during fabrication can be retained. This provides a filling material which is identical to that of the cladding, which satisfies n core >n rods =n cladding . Alternatively, rods can be grown or etched from the substrate and a waveguide structure grown around the rods.
[0056] Additionally, it is possible to include a different material to define the rods in the buffer and cladding layers, with a refractive index n rods in cladding and buffer . In this instance the following inequality applies:
n core >n rods in core >n rods in cladding and buffer >n cladding and n buffer
[0057] This type of structure improves transmittance but is more difficult to fabricate. The buffer layer 23 is deposited on a substrate 25 , the rods are defined and etched partially into the buffer. A low index silicon oxynitride is deposited into the rods. The remaining silicon oxynitride is removed. The core layer 20 is deposited and the rods are defined and etched into the core. A slightly higher index silicon oxynitride is deposited into the rods 21 in the core 20 and the remaining silicon oxynitride is removed. The cladding layer 24 is then deposited and the rods are defined again. The rods are etched into the cladding and filled with a lower index silicon oxynitride. This results in the structure shown in FIG. 3. An example of refractive indices for this embodiment is n core =2.02, n rods in core =1.6, n rods in cladding and buffer =1.58 and n cladding and n buffer =1.46.
[0058] As shown in FIG. 4, waveguides in accordance with the present invention can include tight waveguide bends. The waveguide structure comprises an array of silicon oxynitride rods 30 extending. through a cladding layer 31 and a core layer 32 and partially into a buffer layer 33 , formed on a substrate 34 . A number of rods are missing from the array forming a waveguide which includes a 90° bend. Clearly, the waveguide could take any shape and could, for example, include a bifurcation to form a splitter. The reduced vertical loss from the waveguide means that light within the bandgap of the photonic crystal region is confined with the waveguide and is forced to propagate around the bend. This allows integrated optical circuits to be fabricated over a much smaller area with greatly reduced loss (of the order of 10 dB) and optical devices incorporating waveguide bends to be made smaller. For example, waveguide bends in an arrayed waveguide grating (AWG) are typically of the order of a couple of millimetres. They can be reduced using the present invention to be of the order of a couple of microns, with minimal loss of light.
[0059] Other devices may also be made incorporating a photonic band structure in an optical waveguide in accordance with the present invention, such multiplexers, demultiplexers and dispersion compensators. These devices are formed in the same manner as described in WO98/53351 (BTG International Limited) referenced above, but with materials chosen to satisfy n core >n rods ≧n cladding . FIG. 5 is a schematic illustration of such an optical device 35 , including an optical input 36 and an optical output 37 . The device 35 typically includes a photonic band structure region in the optical path of an input optical signal which acts to process the signal in some way, such as dispersion compensating.
[0060] The present invention can be applied to any glass technology, whether it is planar or fibre. For example, as shown in FIG. 6, conventional fibre 40 could be flattened or planarised and an array of filled holes 41 incorporated into the flattened region through the cladding 42 and the core 43 . The structure as a whole remains in-fibre.
[0061] The material forming the high index rods is not necessarily silicon oxynitride, it may for example be a non-linear material of suitable refractive index, providing the possibility of a tuneable device, for example a tuneable filter.
[0062] The present invention provides a waveguiding structure having a photonic band structure with lower loss than prior structures of the same type. This means that a larger number of rows of rods, equating to conventional holes, can be used in a device structure for the same amount of loss. High losses in prior structures has limited the effect of the band structure. With the present invention it is feasible to produce longer structures for the same loss, and hence longer time delays and higher resolution filters and demultiplexers.
[0063] Waveguiding structures according to the present invention may be used in photonic elements in many different applications. Photonic elements, including those of the present invention, may be implemented in telecommunications systems, in biosensor devices, and in optical storage media.
[0064] [0064]FIG. 7 illustrates the general arrangement of a photonic device 3000 incorporating a photonic element 3002 . The illustrated photonic device 3000 is suitable for use in a telecommunications system. A light signal typically propagates along a waveguiding structure 3050 , such as an optical fibre. The photonic device 3000 includes: at least one Light On Light Off (LOLO) device 3004 , 3024 ; at least one waveguide element 3006 , 3026 ; a mode converter 3008 ; the photonic element 3002 ; a further mode converter 3012 ; at least one further waveguide element 3016 , 3020 ; and at least one further LOLO device 3018 , 3022 .
[0065] The LOLO device 3004 couples the waveguiding structure 3050 to other components of the photonic device 3000 , in the process converting the mode of the telecommunications waveguiding structure 3050 (which is typically large, approximately 8 mm in diameter) into a much smaller (approx. 1 to 2 mm in diameter) planar waveguide mode that can propagate along the photonic device 3002 with minimal loss. In many cases, several channels need simultaneous processing and multiple fibre inputs are provided.
[0066] Following the coupling of light from the external waveguiding structure 3050 to the photonic device 3002 , horizontal confinement of the mode is commonly provided by at least one waveguide element 3006 . Waveguide elements 3006 such as rib or ridge waveguides are often implemented in high refractive index contrast planar material systems. Other waveguide elements 3006 include waveguide splitters and bends. By means of these waveguide elements 3006 (defect state waveguides, ribs, ridges, splitters and/or bends), light from the LOLO device 3004 is transported from one region of the device to another.
[0067] The mode converter 3008 is required to provide efficient coupling of light from the waveguide into the photonic element 3002 . Examples of wave converters include tapers, multi-mode interference slab couplers, and star couplers. Efficient coupling requires attention to appropriate propagation modes and angles in the photonic element 3002 , in order to minimise reflections and loss from the interface of the element 3002 . Following the conversion of the mode, the light is processed by, and propagates through, the photonic element 3002 .
[0068] The operation of photonic element 3002 may be altered in a number of ways, including the application of an optical and/or an electrical control signal. The means for altering the operation of the photonic element 3002 is represented in the Figure as an (optional) controller element 3010 . Examples of suitable controller elements 3010 include optical control signal sources, electrical control signal sources, and optical pumps, depending on the functionality of the photonic element.
[0069] The mode is converted back again into a mode for propagation along the waveguide by the further mode converter 3012 . Optionally, additional photonic elements 3014 can be inserted to provide extra functionality and to increase the integration capabilities of the photonic device. The additional photonic elements 3014 , when provided, may be associated with a corresponding variety of connecting optical components, including further waveguide devices and/or splitters. As the reader will appreciate, the connecting optical components may themselves be formed as integrated photonic elements as well as conventional waveguides joining the photonic elements. The optional, additional photonic element feature in the Figure represents the presence of at least one photonic element and the concomitant connecting optical components in order to provide a highly integrated optical device.
[0070] Finally, at least one further waveguide element 3016 (ribs, ridges, splitters and/or bends) is used to guide the light along to the further LOLO device 3018 . In this arrangement, the light is coupled back out into an output waveguiding structure 3060 . Multiple waveguide elements 3016 , 3020 and LOLO devices 3018 , 3022 can be used for applications such as demultiplexers.
[0071] It is further noted that the further waveguide elements 3016 , 3020 and further LOLO devices 3018 , 3022 may be one and the same as the LOLO devices 3004 , 3024 and waveguide elements 3006 , 3026 .
[0072] [0072]FIG. 8 illustrates the general arrangement of another photonic device 3100 incorporating a photonic element 3102 . The illustrated photonic device 3100 is suitable for use in a biosensor arrangement.
[0073] The photonic device 3100 includes: at least one Light On Light Off (LOLO) device 3104 , 3124 ; at least one waveguide element 3106 , 3126 ; a mode converter 3108 ; the photonic element 3102 ; a further mode converter 3112 ; at least one further waveguide element 3116 , 3120 ; and at least one detector 3136 , 3134 , 3132 .
[0074] Light from a light source 3130 , for example a laser or a light emitting device (LED), is launched into the or each waveguide element 3106 via a corresponding LOLO device 3104 . The launching of light could simply be end-facet coupling of the light into the waveguide 3106 . Again, the waveguide element 3106 , may include bends, splitters, ribs and/or ridge structured waveguides. The or each waveguide element 3106 is used to guide incoming light into different regions of the photonic device 3100 where illumination of different samples is performed.
[0075] The mode converter 3108 is required to provide efficient coupling of light from the waveguide into the photonic element 3102 .
[0076] Preferably, the or each photonic element 3102 is itself provided with sample recesses for receiving at least one sample and illumination is performed inside the photonic element 3102 . Alternatively, the photonic element 3102 is arranged to launch the light into at least one external biological sample 3140 . In some examples of biosensor arrangements, the sample is assayed not as a result of direct illumination but rather through the observed interaction of the evanescent field of light propagating in the photonic element 3102 .
[0077] Illumination of biological and/or biochemical samples can result in characteristic luminescence properties, for example fluorescence or phosphorescence. In the preferred arrangement, light emitted from the or each sample is then collected at another portion of the photonic element 3102 : whereas, in the external sample arrangement, light emitted from the or each sample is collected at another photonic element 3142 .
[0078] The operation of photonic element 3102 , and where present the other photonic element 3142 , may be altered in a number of ways, including the application of an optical and/or an electrical control signal. The means for altering the operation of the photonic element 3102 , 3142 is represented in the Figure as an (optional) controller element 3110 . Examples of suitable controller elements 3110 include optical control signal sources, electrical control signal sources, and optical pumps.
[0079] Following the collection of the light, the mode is converted into a mode for propagation along the waveguide by the further mode converter 3112 . Filtering and possible wavelength separation can then be performed using additional integrated photonic elements 3114 .
[0080] The processed light signal is then routed around at least one further waveguide element 3116 (ribs, ridges, splitters and/or bends) is used to guide the light along to at least one integrated detector 3134 . Processed light may alternatively be routed externally, a further LOLO device 3118 , 3122 providing the interface with an external detector 3132 , 3136 . Many applications require the use of multiple detectors in order to span a range of different wavelengths, for example Raman Spectroscopy, or in order to distinguish between different samples.
[0081] [0081]FIG. 9 also illustrates the general arrangement of a photonic device 3200 incorporating a photonic element 3202 . The illustrated photonic device 3200 is suitable for use in an optical pick-up unit, such as an optical disc reading head.
[0082] The photonic device 3200 includes: at least one Light On Light Off (LOLO) device 3204 , 3224 ; at least one waveguide element 3206 , 3226 ; a mode converter 3208 ; the photonic element 3202 ; a further mode converter 3212 ; at least one further waveguide element 3216 , 3220 ; and at least one integrated detector 3234 , 3238 .
[0083] Light from a light source 3230 , for instance a modulated laser or LED source, is launched into the photonic device 3200 by the LOLO element 3204 . Although not illustrated, light can also be coupled into the photonic device 3200 from an external waveguiding structure, such as an optical fibre.
[0084] Light from the LOLO element 3204 is coupled into the waveguide element 3206 . The waveguide element 3206 , may include bends, splitters, ribs and/or ridge structured waveguides. The or each waveguide element 3206 is used to guide incoming light into different regions of the photonic device 3200 .
[0085] A mode converter 3208 is required to provide efficient coupling of light from the waveguide element 3206 into the photonic element 3202 . The photonic element 3202 processes the light, for example it may serve to filter, compensate for dispersion, focus, align or modulate the incoming light.
[0086] The operation of photonic element 3202 , and where present the other photonic elements 3214 , 3244 , may be altered in a number of ways, including the application of an optical and/or an electrical control signal. The means for altering the operation of the photonic element 3202 , 3214 , 3244 is represented in the Figure as an (optional) controller element 3210 . Examples of suitable controller elements 3210 include optical control signal sources, electrical control signal sources, and optical pumps.
[0087] The processed light output by the photonic element 3202 is converted into a mode for propagation along the waveguide by the further mode converter 3212 . Filtering and possible wavelength separation can then be performed using additional integrated photonic elements 3214 .
[0088] The light is propagated into a LOLO element 3246 where the light is focussed onto an optical storage medium 3240 . The light is collected back again using another LOLO element 3248 where it is processed again with at least one further integrated photonic element 3244 . The further integrated photonic element 3244 includes photonic “building block” elements, for example dispersion compensators, focussing elements, filters and amplifiers.
[0089] The processed light from further integrated photonic element 3244 is then coupled to at least one waveguide component 3216 (ribs, ridges, splitters and/or bends) and thereby projected onto a detector 3232 , 3234 , 3236 , 3238 which can either be in the plane of the waveguide or external to the waveguide (hence requiring a LOLO element 3218 , 3222 ).
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An optical waveguide structure according to the invention comprises a core layer having a first refractive index n core , an array of sub-regions within the core having a second refractive index n rods , the array of sub-regions giving rise to a photonic band structure within the core layer, and a cladding layer adjacent to the core layer having a refractive index n cladding , wherein:
n core >n rods ≧n cladding and n core −n rods >0.1.
The structure of the present invention is less lossy than prior waveguide structures having photonic bandstructure regions. The out of plane divergence of light in the sub-regions is reduced as compared with air holes which are typically used in photonic crystal structures. As a result more light is coupled back into the core at the sub-region/core interface. Coupling of light into the buffer layer is also reduced. Furthermore, there are added advantages over the prior art associated with the fabrication of these structures.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/635,754 filed on Dec. 7, 2006, now U.S. Pat. No. 7,682,360,, the entire contents of which are incorporated herein by reference.
BACKGROUND
1,. Technical Field
The present disclosure relates to the field of tissue debriders. More particularly, the present disclosure relates to a tissue debrider that shears and cauterizes tissue and a method of using the same.
2,. Description of Related Art
Debriders are generally used by physicians to cut tissue at a tissue treatment site, e.g., during sinus or arthritis surgery. Generally, these surgical instruments utilize a cutting tube mounted within an outer cutting housing. The cutting tube is hollow and may be connected to a source of suction. The cutting tubes either rotate or reciprocate within the outer tube housing to cut tissue that is located between the two tubes. The suction source is used to remove debris, e.g., the sheared tissue, from the tissue treatment site,
After such a surgical treatment is utilized, bleeding may occur from the surgical site and it is often desirable to cauterize or coagulate tissue that has been cut. Debriders that are used in the prior art do not have the capability to coagulate or cauterize tissue. Accordingly, a separate coagulation or cautery tool is subsequently used to coagulate the tissue.
SUMMARY
The present disclosure combines the benefits of a conventional debrider and an electrosurgical instrument, such as a coagulator. As such, the apparatus and method of the present disclosure include using a single instrument, i.e., a debrider apparatus, to both shear and cauterize/coagulate tissue.
The present disclosure relates to a debrider apparatus. The debrider apparatus includes a first tubular member, a second tubular member, a first set of teeth, a second set of teeth and at least one switch. The first tubular member includes a distal portion and is adapted to connect to a first potential of an electrosurgical generator (e.g., an active electrode). The second tubular member includes a distal portion, is at least partially disposed within the first tubular member and is adapted to be connected to a second potential of the electrosurgical generator (e.g., a return electrode). At least one of the first and the second tubular member is selectively movable (e.g., rotationally or reciprocably) relative to the other. The first set of teeth is disposed around at least a portion of a periphery of the first tubular member and is adjacent its distal portion. The second set of teeth is disposed around at least a portion of a periphery of the second tubular member and is adjacent its distal portion. The at least one switch is operably coupled to at least one of the first and second tubular members and both activates movement of one of the tubular members relative to the other tubular member and supplies respective electrical potential to the first and second tubular members.
In a disclosed embodiment, the debrider apparatus includes two switches. One of the two switches is configured to activate movement of the tubular members relative to one another and the other switch is configured to supply respective electrical potentials to the first and second tubular members.
In a disclosed embodiment, about 25% to about 75% of the periphery of the first tubular member includes teeth and the remaining portion defines a non-cutting zone. In another embodiment, a distal surface of the first and second tubular members is beveled at an angle relative to a longitudinal axis defined by the first tubular member.
An embodiment of the present disclosure also includes at least one lumen defined within at least one of the tubular members. The lumen is configured to remove material from a tissue treatment site. In a disclosed embodiment, the lumen is configured to supply a solution to the tissue treatment site.
The present disclosure also relates to a method of using a single instrument to shear and cauterize tissue. This method includes providing a debrider apparatus, such as a debrider apparatus described above, placing the debrider apparatus adjacent a tissue treatment area, and activating the at least one switch to both rotate one of the first and second tubular members relative to one another and to simultaneously provide electrical energy to the first and second tubular members.
The present disclosure also relates to a system for shearing and electrosurgically treating tissue. The system includes a debrider apparatus, such as a debrider apparatus described above, and an electrosurgical generator that supplies the first tubular member with a first electrical potential and supplies the second tubular member with a second electrical potential.
DESCRIPTION OF THE DRAWINGS
Various embodiments of the presently disclosed surgical instrument are disclosed herein with reference to the drawings, wherein:
FIG. 1 is a perspective view of a debrider apparatus according to an embodiment of the present disclosure;
FIG. 2 is a top view of the debrider apparatus of FIG. 1 ;
FIG. 3 is a perspective view of a distal portion of a debrider apparatus according to an embodiment of the present disclosure;
FIG. 4 is a top view of the debrider apparatus of FIG. 3 ; and
FIG. 5 is a cross-sectional view of a distal portion of the debrider apparatus of FIGS. 3 and 4 .
DETAILED DESCRIPTION
Embodiments of the presently disclosed debrider apparatus are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As is common in the art, the term “proximal” refers to that part or component closer to the user or operator, e.g., surgeon or physician, while the term “distal” refers to that part or component farther away from the user.
Referring to FIG. 1 , an embodiment of a debrider apparatus 100 of the present disclosure is illustrated. Debrider apparatus 100 of this embodiment includes a body portion 110 , a first tubular member 120 , and a second tubular member 130 . As illustrated in FIGS. 2-5 , second tubular member 130 is at least partially disposed within first tubular member 120 . Additionally, second tubular member 130 may be moved (e.g., rotated in the direction of arrow C or arrow D or reciprocated back and forth in the direction of double-head arrow E-F, see FIG. 2 ) with respect to first tubular member 120 .
First tubular member 120 defines a first axis A-A extending therethrough and includes a first set of teeth 140 disposed at least partially around a distal portion thereof. Second tubular member 130 includes a second set of teeth 150 disposed at least partially around a distal portion thereof. Upon movement of second tubular member 130 , tissue from a tissue treatment area is sheared. Specifically, in one embodiment, tissue on the tissue treatment area that is located between first set of teeth 140 and second set of teeth 150 is sheared from rotational movement of second set of teeth 150 .
In addition to having the ability to shear tissue, debrider apparatus 100 of the present disclosure also cauterizes or coagulates tissue. Specifically, first tubular member 120 is charged with a first electrical potential, e.g., a positive charge or active electrode and second tubular member 130 is charged with a second electrical potential, e.g., a negative charge or return electrode. The first electrical potential is different from the second electrical potential, thus creating a potential difference therebetween. Thus, tissue on the tissue treatment area that is located between first set of teeth 140 and second set of teeth 150 is cauterized or coagulated during activation due to the potential difference between first tubular member 120 and second tubular member 130 .
In the embodiment illustrated in FIG. 1 , debrider apparatus 100 includes a power supply 160 (e.g., an electrosurgical generator), a hand switch 170 and a foot switch 180 . While illustrated with each of these features, it is envisioned and within the scope of the present disclosure that debrider apparatus 100 may not include one or more of these features or may include additional features. Power supply 160 is configured to provide power to debrider apparatus 100 . More specifically, power supply 160 may enable inner tubular member 130 to move (e.g., rotate or reciprocate), via a suitable motor (not explicitly shown in this embodiment), for example. Additionally, power supply 160 may be in the form of a battery that is contained at least partially within body portion 110 of debrider apparatus 100 .
Hand switch 170 and/or foot switch 180 enables a user to control the speed (e.g., speed of rotation or reciprocation) of second tubular member 130 and the amount of electrical potential of first tubular member 120 and second tubular member 130 , in a disclosed embodiment. For example, depressing hand switch 170 may control the movement of second tubular member 130 and depressing foot switch 180 may control the power supplied to the first tubular member 120 and the second tubular member 130 . It is also envisioned that hand switch 170 or foot switch 180 may operate to control both the speed and the power. Additionally, it is envisioned that at least one more switch (not explicitly shown in the illustrated embodiment) is provided to control irrigation and/or removal of material through at least one lumen, as discussed below. It is also envisioned that a single switch (e.g., hand switch 170 or foot switch 180 ) is able to control more than one of these functions.
In the embodiment illustrated in FIGS. 2-5 , an insulation layer 190 is disposed between first tubular member 120 and second tubular member 130 . Insulation layer 190 , such as an insulative sheath, coating, or bearing, allows for differences in electrical potential between first tubular member 120 and second tubular member 130 to exist while preventing a “short” therebetween. Insulation layer 190 may be made from any suitable insulative material, such as synthetic resinous fluorine-containing polymers sold under the trademark TEFLON®, for example.
With continued referenced to FIGS. 2-5 , a lumen 200 is defined within second tubular member 130 and extends the length thereof. In the illustrated embodiments, lumen 200 is disposed through the center of second tubular member 130 and may be configured to extend from a part of body portion 110 to a distal portion of first tubular member 120 or second tubular member 130 . In use, lumen 200 may be used for suction and/or irrigation. Specifically, when used for suction, lumen 200 may remove debris (e.g., sheared tissue) from the operating field or tissue treatment area. In this embodiment, suction through lumen 200 may be activated as movement of second tubular member 130 begins and/or as power is being supplied to debrider apparatus 100 . When used for irrigation, lumen 200 may provide the operating field or tissue treatment area with an amount of cleaning or sanitizing solution, such as saline. In the embodiment illustrated in FIG. 4 , secondary lumens 202 , 204 are illustrated between first tubular member 120 and second tubular member 130 (shown within insulation layer 190 ). Here, lumen 200 may be used for suction and secondary lumens 202 , 204 may be used for irrigation, or vice versa. It is envisioned that at least one secondary lumen 202 , 204 extends to a portion of debrider apparatus 100 that is located proximally of first set of teeth 140 .
Referring to FIGS. 3 and 4 , first tubular member 120 of debrider apparatus 100 is illustrated having a non-cutting zone 210 . Non-cutting zone 210 is a portion of the distal periphery of first tubular member 120 that contains no teeth from first set of teeth 140 . That is, first set of teeth 140 do not extend around the entire periphery of a distal portion of first tubular member 120 . Non-cutting zone 210 may incorporate a reasonable percentage of the periphery of first tubular member 120 , such as between about 25% to about 75%. In use, the tissue located between non-cutting zone 210 and second set of teeth 150 is not sheared. This allows a user (e.g., surgeon or physician) to selectively shear only part of the tissue located adjacent first tubular member 120 , thus potentially enabling the user to only shear tissue that is in a more concentrated field of view.
The embodiment of debrider apparatus 100 illustrated in FIG. 5 shows first tubular member 120 and second tubular member 130 having angled distal surfaces 230 , 232 , respectively. Distal surfaces 230 , 232 are defined by a second axis B-B that intersects first axis A-A at an acute angle α in this embodiment. Thus, distal surfaces 230 , 232 are beveled at an angle relative to longitudinal axis A-A. Here, angle α may be in the range from about 10° to about 80°. Angled distal surfaces 230 , 232 may enable the user to see a tip 234 of debrider instrument 100 more clearly, and thus enable the user to cut tissue more selectively. Additionally, angled distal surfaces 230 , 232 of this embodiment may be used in conjunction with non-cutting zone 210 of FIGS. 3 and 4 .
The present disclosure also relates to a method of shearing and coagulating/cauterizing tissue using a single instrument, e.g., debrider apparatus 100 . In use, debrider apparatus 100 is provided and placed adjacent a tissue treatment area. Second tubular member 130 is moved (e.g., rotated or reciprocated) with respect to first tubular member 120 , thus allowing debrider apparatus 100 to shear tissue disposed between first set of teeth 140 and second set of teeth 150 . An electrical potential is supplied to at least one of first tubular member 120 and second tubular member 130 , creating a potential difference therebetween. This bipolar quality enables debrider apparatus 100 to coagulate/cauterize tissue disposed adjacent the tissue treatment area.
It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
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A debrider apparatus is disclosed. The debrider includes a first tubular member that is adapted to connect to a first potential of an electrosurgical generator. A second tubular member is at least partially disposed within the first tubular member and is adapted to connect to a second potential of the electrosurgical generator. At least one tubular member is selectively movable relative to the other. A first set of teeth is disposed around at least a portion of a distal periphery of the first tubular member. A second set of teeth is disposed around at least a portion of a distal periphery of the second tubular member. At least one switch is operably coupled to at least one of the tubular members and activates movement of one tubular member and supplies respective electrical potentials to the tubular members.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of copending application Ser. No. 10/885,358, filed Jul. 6, 2004.
FIELD OF THE INVENTION
[0002] The present invention generally relates to flagpole winches, cleats and fastening plates, and more particularly to flagpole fastening plate assemblies and flagpole winch or cleat assemblies mounted internally to a flagpole.
BACKGROUND OF THE INVENTION
[0003] It is often desirable to substantially eliminate exposed flag halyards, especially while a flag is flying from a flagpole. There are flagpole assemblies in which the halyard remains substantially concealed from view but allows the flag to be raised and lowered. The flagpole assembly includes a hollow pole mounted at its base to a support. A first end of a halyard is connected to a winch. The winch is typically mounted near the base of the pole. The halyard passes through the hollow pole and out an exit opening at the pole tip.
[0004] Paying out the halyard from the winch causes the flag to lower as the length of the halyard extending from the exit opening in the hollow pole increases. The halyard is retracted by winding the halyard onto the winch. If the halyard has a flag attached to it, the flag is raised by this operation. If not, substantially the entire halyard is housed within the hollow pole or on the halyard winch.
[0005] A primary advantage of this design is that it simplifies raising and lowering of a flag while keeping the halyard substantially concealed. Keeping the halyard substantially concealed reduces deterioration of the halyard by preventing its exposure to the elements. It also eliminates problems caused by tangled halyards and flags.
SUMMARY OF THE INVENTION
[0006] The present invention provides a flagpole assembly including a hollow flagpole body, one or more internal fastening plates, an external fastening plate, and plural fasteners for securing the plates to the flagpole body. The embodiments of the invention may also include halyard handling mechanism disposed in the flagpole body.
[0007] The flagpole body is generally-cylindrical having a first end, a second end, a principal axis, an inner surface, an outer surface and an aperture disposed in the side thereof. The aperture extends from the inner surface to the outer surface along a radial axis substantially orthogonal to the principal axis. At least one internal fastener receiving hole or opening extends from the inner surface to the outer surface.
[0008] One or at least two internal fastening plates may be disposed at least partly within the flagpole body, and include inner surfaces, outer surfaces, an aperture disposed therein, or formed thereby, and threaded fastening holes generally aligned to fastener openings or passages in the flagpole body, respectively. The external fastening plate may be disposed at least partly outside of the flagpole body, and has an inner surface, an outer surface, an aperture disposed therein and external fastener passages generally aligned to corresponding fastener passages in the flagpole body. Threaded fasteners are disposed partly within external fastener passages, partly within internal fastener passages and partly within threaded fastener receiving holes.
[0009] In a second or alternate embodiment, the present invention provides a flagpole assembly including a flagpole body, an internal fastening plate or plates, an external fastening plate, plural threaded fasteners and a halyard engaging cleat or a winch mount. In other respects the embodiment which includes the winch mount is substantially like the embodiment mentioned hereinabove.
[0010] In a third embodiment, the present invention provides a flagpole assembly including a flagpole body, one or more internal fastening plates, an external fastening plate and door assembly and a winch mount. In the third embodiment, the external fastening plate and door assembly is disposed at least partly outside of the flagpole body, and has an inner surface, an outer surface, a door aperture having a door disposed therein and at least four external fastener passages, each external fastener passage being generally aligned to an internal fastener passage in the flagpole body. The winch mount includes an internal fastening plate and a winch secured thereto.
[0011] Those skilled in the art will further appreciate the above-mentioned advantages and features of the invention together with other important aspects thereof upon reading the detailed description which follows in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded perspective view of a flagpole assembly according to one preferred embodiment of the present invention;
[0013] FIG. 2 is an exploded section view of the flagpole assembly of FIG. 1 taken along line 2 - 2 of FIG. 1 ;
[0014] FIG. 3 is an unexploded section view of the flagpole assembly of FIG. 1 taken along line 2 - 2 ;
[0015] FIG. 4 is an exploded perspective view of a flagpole assembly according to another preferred embodiment of the present invention;
[0016] FIG. 5 is an exploded section view of the flagpole assembly of FIG. 4 taken along line 5 - 5 of FIG. 4 ;
[0017] FIG. 6 is an unexploded section view of the flagpole assembly of FIG. 4 taken along line 5 - 5 ;
[0018] FIG. 7 is a detail section view of the flagpole assembly of FIG. 4 taken along line 7 - 7 of FIG. 4 ;
[0019] FIG. 8 is a front elevation view of an external plate which may be used in the flagpole assembly of FIG. 4 ;
[0020] FIG. 9 is a top plan view of the external plate of FIG. 8 ;
[0021] FIG. 10 is a detail section view of the external plate of FIG. 9 taken along line 10 - 10 of FIG. 9 ;
[0022] FIG. 11 is a detail section view of the external plate of FIG. 8 taken along line 11 - 11 of FIG. 8 ;
[0023] FIG. 12 is a front elevation view of an internal plate which may be used in the flagpole assembly of FIGS. 1 and 4 ;
[0024] FIG. 13 is a top plan view of the internal plate of FIG. 12 ;
[0025] FIG. 14 is a transverse section view of another embodiment of the flagpole assembly;
[0026] FIG. 15 is a transverse section view of still another embodiment of the flagpole assembly;
[0027] FIG. 16 is a top plan view of another embodiment of plural internal plates which may be used with the flagpole assemblies of the present invention; and
[0028] FIG. 17 is a front elevation of the plural internal plates shown in FIG. 16 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] In the description which follows like elements are marked throughout the specification and drawing with the same reference numerals, respectively. The drawings are not necessarily to scale and certain features may be shown in somewhat schematic or generalized form in the interest of clarity and conciseness.
[0030] Flagpole assembly 100 includes a tubular flagpole body 102 having a principal central axis 104 , an inner surface 106 , an outer surface 108 and an aperture 110 disposed in its side along radial axis 112 , which is generally-orthogonal to principal axis 104 . A set of fastener receiving passages 114 , one shown in FIG. 1 , is disposed adjacent to aperture 110 .
[0031] Flagpole assembly 100 also includes an internal fastening plate 116 having an inner surface 118 , an outer surface 120 and an aperture 122 . Plate 116 has a somewhat circular segment shape in cross section as shown in FIG. 2 . A set of threaded fastener receiving holes 124 is disposed about aperture 122 . Each of the threaded holes 124 is positioned to be aligned with a corresponding internal fastener passage 114 .
[0032] Flagpole assembly 100 also includes an external fastening plate 126 having an inner surface 128 , FIG. 1 , an outer surface 130 , an aperture 132 and a somewhat circular segment shape in cross section, also as shown in FIG. 2 . A set of fastener receiving passages 134 is disposed in the external fastening plate 126 adjacent to the aperture 132 . Each of the external fastener passages 134 is positioned to be aligned with a corresponding internal fastener passage 114 and a threaded fastener receiving passage or hole 124 . A mount 138 , including a halyard cleat 140 , is secured to or formed integral with external fastening plate 126 . In alternate embodiments, a pulley, a winch or other mechanism, not shown, may be supported on mount 138 . A set of threaded fasteners 136 is operable to fasten the components described above of flagpole assembly 100 together.
[0033] Another preferred embodiment of the present invention is shown in FIGS. 4-7 and comprises a flagpole assembly 200 . Flagpole assembly 200 includes a flagpole body 202 having a principal central axis 204 , an inner surface 206 , an outer surface 208 and an aperture 210 disposed in its side along a radial axis 212 , which is generally-orthogonal to principal axis 204 . Fastener receiving passages 214 are disposed adjacent to aperture 210 , as shown and similar to the arrangement for the embodiment of FIGS. 1 through 3 .
[0034] Flagpole assembly 200 also includes a generally rectangular internal fastening plate 216 having an inner surface 218 , an outer surface 220 and an aperture 222 . A set of threaded fastener receiving holes 224 is disposed about aperture 122 . Each of the threaded fastening holes 224 is aligned with a corresponding fastener receiving passage 214 . Flagpole assembly 200 includes an external fastening plate 226 having an inner surface 228 , an outer surface 230 and a door aperture 232 . A set of external fastener receiving passages 234 is disposed in the external fastening plate 226 adjacent to the door aperture 232 . Each of the external fastener passages 234 is aligned to a corresponding fastener receiving passage 214 and a threaded fastener receiving hole 224 . A mount plate or block 238 includes an arcuate surface 239 and a threaded fastener receiving hole 238 a formed therein, FIGS. 5 and 6 . Plate or block 238 is operable for securing a winch 240 , FIG. 6 , to the flagpole body 202 . Plate 238 is adapted to be secured to body surface 206 by a fastener assembly 207 , 209 , FIG. 5 . A set of threaded fasteners 236 fastens the plates 218 and 226 of the flagpole assembly 200 together.
[0035] The internal and external plates used in flagpole assemblies may vary from one application to another. FIGS. 8 through 17 depict variations on the shapes and configurations of the internal and external plates, which may be operable in the flagpole assemblies of the present invention.
[0036] Referring to FIGS. 8 through 11 , external plate 326 has a transverse shape of a segment of a cylinder. External plate 326 has an arcuate external surface 330 , an arcuate internal surface 338 and an aperture 332 disposed in the center thereof. A set of fastener receiving passages or bores 334 is spaced about the aperture 332 in a generally rectangular pattern. In the embodiment shown in FIGS. 8-11 , the fastener receiving bores 334 are preferably countersunk.
[0037] Referring to FIGS. 12 and 13 , internal plate 316 also has the general profile or transverse cross section shape of a segment of a cylinder. Internal plate 316 has an internal surface 318 , an external surface 320 and an aperture 322 disposed in the center thereof. A set of fastener receiving holes 324 is spaced about the aperture 322 in a generally rectangular pattern. In the embodiment shown in FIGS. 8-11 , the fastener or receiving holes 324 are preferably threaded, as shown.
[0038] Alternate flagpole assemblies 400 and 500 are shown as examples of variations on the geometry of flagpole assembly 200 . Flagpole assembly 400 is shown in FIG. 14 and includes a flagpole body 402 having an internal plate 416 and a winch assembly 440 disposed therein, and an external plate 426 disposed on the outside thereof. Internal plate 416 and external plate 426 are fastened to the flagpole body 402 and to one another by fasteners 436 . Flagpole assembly 400 incorporates an operable or removable door or cover 442 covering an aperture 444 to enclose and protect winch assembly 440 or other device from the elements and unwanted tampering. Similarly, flagpole assembly 500 includes a flagpole body 502 having an internal plate 516 and winch assembly 540 disposed therein and an external plate 526 disposed on the outside thereof. Internal plate 516 and external plate 526 are fastened to the flagpole body 502 and to one another by fasteners 536 . Flagpole assembly 500 also incorporates a removable door 542 to enclose and protect the winch assembly from the elements and tampering. It can be seen that flagpole assemblies 400 and 500 employ the same basic layout as flagpole assembly 200 , although the geometry of the components varies between the three, as seen in FIGS. 6, 14 and 15 .
[0039] Referring now to FIGS. 16 and 17 , the internal plates previously described are single piece structures. However, in certain instances certain dimensions, such as the wall thickness of the flagpole body, may vary whereby the fastener receiving holes in the internal plates will not necessarily be aligned with the fastener receiving holes in the flagpole body or the external plates. Accordingly, the present invention contemplates the provision of separate but substantially identical internal plates designated by the numerals 616 in FIGS. 16 and 17 . The internal plates 616 include arcuate external surfaces 620 and may have a somewhat shallow U-shape with opposed relatively short legs 622 formed thereon, respectively, and interconnected by web portions 623 , respectively. Accordingly, the internal plates 616 have essentially the shape of the internal plates described above, in some respects. Internal plates 616 are also provided with spaced apart threaded fastener receiving holes 624 , as shown, for receiving fasteners, such as the fasteners 136 , 236 , 336 or 436 , not shown in FIGS. 16 and 17 .
[0040] The components of the flagpole assemblies described herein may be fabricated as cast metal, such as aluminum or similar metals or other materials suitable for exposure to the elements and incorporating the strength requirements of such structures.
[0041] Those of skill in the art will appreciate that flagpole assemblies 200 , 300 , 400 , 500 are only exemplary and that other geometries may be employed.
[0042] In general, although preferred embodiments have been described herein, those skilled in the art will appreciate that substitutions and modifications may be made without departing from the scope and spirit of the appended claims.
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A flagpole assembly comprising a flagpole body having an aperture disposed in the side thereof, one or two internal fastening plates, disposed within the flagpole body, an external fastening plate and door assembly and a set of threaded fasteners securing the flagpole assembly together. A cleat or winch mount may be secured to the internal fastening plate, having a winch secured thereto for securement of a flag halyard inside the flagpole body.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/292,753 filed Jan. 6, 2010, entitled “A method for effective autonomous mopping of a floor surface,” which is hereby incorporated by reference herein for all purposes.
TECHNICAL FIELD
The invention pertains to a mobile robot for cleaning a floor or other surface. In particular, the invention pertains to a robot configured to implement a class of trajectories designed to efficiently scrub or otherwise clean the floor.
BACKGROUND
From their inception, robots have been designed to perform tasks that people prefer not to do or cannot do safely. Cleaning and vacuuming, for example, are just the type of jobs that people would like to delegate to such mechanical helpers. The challenge, however, has been to design robots that can clean the floor of a home well enough to satisfy the exacting standards of the people the live in it. Although robots have been designed to vacuum floors, robots designed to perform mopping present unique challenges. In particular, such a robot should be able to dispense cleaning solution, scrub the floor with the solution, and then effectively remove the spent cleaning solution. Robots tend to perform unsatisfactorily, however, because hard deposits on the floor may require time for the cleaning solution to penetrate and removal of the dirty solution may leave streak marks on the floor. There is therefore a need for a cleaning robot able to implement a cleaning plan that enables the robot to apply cleaning solution, repeatedly scrub the floor with the solution, and leave the floor free of streak marks.
SUMMARY
The present invention pertains to a mobile robot configured to travel across a residential floor or other surface while cleaning the surface with a cleaning pad and cleaning solvent. The robot includes a controller for managing the movement of the robot as well as the treatment of the surface with a cleaning solvent. The movement of the robot can be characterized by a class of trajectories that achieve effective cleaning. These trajectories seek to: maximize usage of the cleaning solvent, reduce streaking, utilize absorption properties of the pad, and use as much of the surface of the pad as possible. In an exemplary embodiment, the trajectory may include an oscillatory motion with a bias in a forward direction by repeatedly moving forward a greater distance than backward. In the same exemplary embodiment, the cleaning pad is a disposable sheet impregnated with solvent that is then applied to and recovered from the surface by means of the trajectory.
In one embodiment, the cleaning robot includes a cleaning assembly; a path planner for generating a cleaning trajectory; and a drive system for moving the robot in accordance with the cleaning trajectory. The cleaning trajectory is a sequence of steps or motions that are repeated a plurality times in a prescribed order to effectively scrub the floor. Repetition of the sequence, in combination with the forward and back motion, causes the cleaning assembly to pass of areas of the floor a plurality of times while allowing time for the cleaning solution to penetrate dirt deposits.
The sequence repeated by the cleaning trajectory preferably comprises: (i) a first path for guiding the robot forward and to the left; (ii) a second path for guiding the robot backward and to the right; (iii) a third path for guiding the robot forward and to the right; and (iv) a fourth path for guiding the robot backward and to the left. The first path and third path result in a longitudinal displacement of the robot (movement parallel to the direction of progression) referred to as a first distance forward, and the second path and fourth path result in a longitudinal displacement referred to as a second distance backward. The first distance is greater than the second distance, preferably twice as large. In addition, the second path results in a lateral displacement (movement perpendicular to the direction of progression) which is referred to as the third distance, and the fourth path moves the robot laterally by a fourth distance that is equal in magnitude but opposite in direction from the third distance. In the preferred embodiment, the first through fourth paths are arcuate paths.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, and in which:
FIG. 1A is an autonomous mobile robot, in accordance with a preferred embodiment;
FIG. 1B is the autonomous mobile robot moving in the forward direction, in accordance with a preferred embodiment;
FIG. 1C is the autonomous mobile robot moving in the backward direction, in accordance with a preferred embodiment;
FIG. 2 is a schematic diagram of a navigation system, in accordance with a preferred embodiment;
FIG. 3 is a cleaning trajectory for scrubbing a floor, in accordance with an exemplary embodiment;
FIGS. 4A-4D depict a sequence of steps that produce the trajectory of FIG. 3 ;
FIG. 5 is a cleaning trajectory for scrubbing a floor, in accordance with another exemplary embodiment;
FIGS. 6A-6D depict a sequence of steps that produce the trajectory of FIG. 5 ,
FIG. 7 is a cleaning trajectory for scrubbing a floor, in accordance with still another exemplary embodiment; and
FIGS. 8A-8B depict a sequence of steps that produce the trajectory of FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Illustrated in FIG. 1A is an autonomous mobile robot 100 configured to clean or otherwise treat a floor or other surface using a trajectory designed to repeatedly scrub the floor. In the preferred embodiment, the mobile robot 100 includes a housing with a controller and navigation system (not shown) for generating a path to clean the entire floor, a drive system 110 configured to move the robot around a room or other space in a determined trajectory, and a cleaning assembly 120 A pivotably attached to the robot housing by means of a hinge 130 . The cleaning assembly 120 A preferably includes a curved bottom surface 122 configured to press a cleaning sheet to the floor. The mobile robot in the preferred embodiment is based on the cleaning robot taught in pending U.S. patent application Ser. No. 12/429,963 filed on Apr. 24, 2009, which is hereby incorporated by reference herein.
The cleaning component in the preferred embodiment is configured to scrub the floor with a disposable cleaning sheet, preferably a wet cleaning sheet impregnated with cleaning solution. In other embodiments, the cleaning assembly is configured to dispense cleaning solution directly on the floor and then scrub the floor with a dry cleaning sheet. In still other embodiments, the cleaning assembly is configured to employ cleaning components for brushing, dusting, polishing, mopping, or vacuuming the floor, which may be a wood, tile, or carpet, for example.
Illustrated in FIG. 2 is a schematic diagram of the navigation system in the preferred embodiment. The navigation system 200 includes a navigation module 210 configured to maintain an estimate of the robot's current pose while it navigates around its environment, preferably an interior room bounded by walls. The pose 212 , which includes both the position and orientation, is based on multiple sensor readings including wheel odometry 214 provided by encoders integrated into the wheels 110 , orientation readings 216 from a gyroscope (not shown) on board the robot, and position coordinates from an optical sensor configured to sense light reflected from the room's ceiling. The optical sensor may include one or more photo diodes, one or more position sensitive detectors (PSDs), or one or more laser range finders, for example. The optical sensor employed in the preferred embodiment is taught in U.S. Pat. No. 7,720,554, which is hereby incorporated by reference herein.
The navigation system further includes a path planner 220 for generating or executing logic to traverse a desired trajectory or path 222 to scrub the entire floor with no gaps. In path 222 designed by the path planner 220 is a combination of a first trajectory from a room coverage planner 222 and a second trajectory from a local scrub planner 226 , which are discussed in more detail below. Based on the current pose 212 and the desired path 222 , the motion controller generates motion commands 232 for the robot drive 240 . The commands in the preferred embodiment include the angular velocity for each of a pair of wheels 110 , which are sufficient to control the speed and direction of the mobile robot. As the robot navigates through its environment, the navigation module 210 continually generates a current robot pose estimate while the path planner 220 updates the desired robot path.
The first trajectory is designed to guide the robot throughout the entire room until each section of the floor has been traversed. The second trajectory is a pattern including a plurality of incremental steps that drive the cleaning assembly both forward and backward, and optionally left and right. The first trajectory ensures every section of the floor is traversed with the cleaning assembly while the second trajectory ensures each section of floor traversed is effectively treated with cleaning solution and scrubbed with multiple passes of the cleaning assembly.
The first trajectory may take the form of any of a number of space-filling patterns intended to efficiently traverse each part of the room. For example, the first trajectory may be a rectilinear pattern in which the robot traverses the entire width of the room multiple times, each traversal of the room covering a unique swath or row adjacent to the prior row traversed. The pattern in repeated until the entire room is covered. In another embodiment, the robot follows a path around the contour of the room to complete a loop, then advances to an interior path just inside the path traversed in the preceding loop. Successively smaller looping patterns are traversed until the center of the room is reached. In still another embodiment, the robot traverses the room in one or more spiral patterns, each spiral including a series of substantially concentric circular or substantially square paths of different diameter. These and other cleaning contours are taught in U.S. patent application Ser. No. 12/429,963 filed on Apr. 24, 2009.
The second trajectory scrubs the floor using a combination of forward and backward motion. The step in the forward direction is generally larger than the step in the backward direction to produce a net forward movement. If the second trajectory includes lateral movement, the steps to the left and right are generally equal. The repeated forward/backward motion, in combination with hinge 130 , causes the orientation of the cleaning assembly to oscillate between a small angle forward or a small angle backward as shown in FIGS. 1B and 1C , respectively. When driven in the forward direction, the cleaning assembly 120 B pivots forward which presses the front half of the cleaning pad against the floor while lifting the back half away from the floor. When driven in the reverse direction, the cleaning assembly 120 C pivots backward to press the back half of the cleaning pad against the floor while lifting the front half away from the floor. As a result, the front half of the cleaning sheet (1) scrubs the floor with the cleaning sheet impregnated with cleaning solution and (2) captures/collects dirt and debris as the robot advances in the forward direction (see FIG. 1B ). On the other hand, the back half of the cleaning sheet, which remains generally free of debris, scrubs the floor with cleaning solution released from the cleaning sheet. This serves to: (i) evenly apply cleaning solution, (ii) recover the cleaning solution mixed with dissolved dirt, (iii) produce an elapse time between application and recovery of the cleaning solution, (iv) mechanically agitate the cleaning solution on the floor, and (v) produce little or no visible streak marks on the floor. In the exemplary embodiment, the cleaning sheet is impregnated with a cleaning solution that is transferred to the floor by contact. In another embodiment the mobile robot includes a reservoir with at least one nozzle configured to either spray cleaning solution on the floor surface in front of the cleaning assembly or diffuse the cleaning solution directly into the upper surface of the sheet through capillary action.
Illustrated in FIG. 3 is an example of a second trajectory for scrubbing a floor. The trajectory is produced by repetition of the sequence of steps shown in FIGS. 4A-4D . The solid line 310 represents the path traced by the midpoint of the leading edge of the cleaning assembly 120 while the shaded region 320 represents the region of floor scrubbed by the cleaning assembly. When this sequence is employed, the robotic cleaner oscillates in the forward direction of motion as well as laterally. For each oscillation, the forward displacement (defined as the “fwd_height”) exceeds the backward displacement (defined as the “back_height”) so the robot advances in a generally forward direction (defined as the “direction of progression”). The robot also moves left and right equal amounts (defined as the fwd_width) which causes the robot to travel in a generally straight line.
The trajectory shown in trajectory in FIG. 3 is produced by repetition of the sequence of steps illustrated in FIG. 4A-4D in the prescribed order. Each step or leg comprises a motion with an arcuate path. The first leg 410 of the sequence shown in FIG. 4A advances the robot forward by fwd_height and to the left. In the second leg 420 shown in FIG. 4B , the robot moves backward by back_height and to the right. In the third leg 430 shown in FIG. 4C , the robot moves forward by fwd_height and to the right. In the fourth leg 440 shown in FIG. 4D , the robot moves backward by back_height and to the left. The forward arcing motions have a larger radius than the back motions such that the robot is oriented parallel to the direction of progression upon completion of the backward motion.
Trajectories that include arced or arcuate paths can provide several benefits over trajectories having only straight paths. For example, the trajectory shown in FIG. 3 , which consists of arcuate paths, causes the robot to continually turn or rotate while in motion. This rotation, in turn, is detected by the on-board gyroscope and monitored by the navigation system for purposes of detecting slippage of the wheels 110 . When the detected rotation is different than the rotation associated with the curvature of the path, the robot can confirm slippage due to loss of traction, for example, and correct the robots course accordingly. In contrast, trajectories with straight paths make it difficult to detect slippage when, for example, both wheels slip at the same rate which cannot be detect with the gyro.
For the trajectory shown in FIGS. 3 and 4 A- 4 D, the parameters are as follows:
(a) fwd_height: the distance traveled in the direction of progression on the forward legs or strokes has a value of approximately 1.5 times with width of the cleaning assembly 120 , the width being measured in the direction perpendicular to the direction of progression; (b) back_height: the distance traveled in the direction opposite the direction of progression on the backward legs or strokes has a value of approximately 0.75 times the width of the cleaning assembly 120 ; and (c) fwd_width: the distance traveled orthogonal to the direction of progression on the forward legs or strokes has a value of approximately 0.3 times the width of the cleaning assembly 120 .
In general, however, fwd_height may range between one and five times the width of the cleaning assembly 120 , the back_height may range between one third and four times the width of the cleaning assembly 120 , and the elapse time of a cleaning single sequence may range between five second and sixty seconds.
Where the cleaning sheet is a Swiffer® Wet Cleaning Pad, for example, each sequence of the trajectory is completed in a time between 15 to 30 seconds, which enables the cleaning solution to remain on the floor long enough to dissolve dirt but not so long that it first evaporates.
Illustrated in FIG. 5 is another example of a second trajectory for scrubbing a floor. The trajectory is produced by repetition of the sequence of steps shown in FIGS. 6A-6D . The solid line 510 represents the path traced by the midpoint of the leading edge of the cleaning assembly 120 while the shaded region 520 represents the region of floor scrubbed by the cleaning assembly. When this sequence is employed, the robotic cleaner oscillates in the forward direction of motion as well as laterally. For each oscillation, the forward displacement (“fwd_height”) exceeds the backward displacement (“back_height”) so the robot advances in a generally forward direction (“direction of progression”). The robot also moves left and right equal amounts (fwd_width) which causes the robot to travel in a generally straight line.
The trajectory shown ion trajectory in FIG. 5 is produced by repetition of the sequence of steps illustrated in FIG. 6A-6D . Each step or leg comprises a motion with an arcuate path. The first leg 610 of the sequence shown in FIG. 6A advances the robot forward by fwd_height and to the left with a predetermined radius. In the second leg 620 shown in FIG. 4B , the robot moves backward by back_height and to the right along the same radius as leg 610 . In the third leg 630 shown in FIG. 6C , the robot moves forward by fwd_height and to the right with the same predetermined radius. In the fourth leg 640 shown in FIG. 6D , the robot moves backward by back_height and to the left with the same radius as above. The forward arcing motions progress a greater distance than the back motions so that the robot generally progresses in the forward direction.
For the trajectory shown in FIGS. 5 and 6 A- 6 D, the parameters are as follows:
(a) fwd_height: the distance traveled in the direction of progression on the forward legs or strokes has a value of approximately 1.5 times with width of the cleaning assembly 120 , namely the direction perpendicular to the direction of progression; (b) back_height: the distance traveled in the direction opposite the direction of progression on the backward legs or strokes has a value of approximately 0.75 times the width of the cleaning assembly 120 ; and (c) radius: the radius of each arc is approximately equal to the diameter of the mobile robot, although the radius may range between 0.5 and 3 times the width of the cleaning assembly.
Illustrated in FIG. 7 is another example of a second trajectory for scrubbing a floor. The trajectory is produced by repetition of two legs that are both straight and parallel, as shown in FIGS. 7A-7B . The solid line 710 represents the path traced by the midpoint of the leading edge of the cleaning assembly 120 while the shaded region 720 represents the region of floor scrubbed by the cleaning assembly. When this sequence is employed, the robotic cleaner oscillates in the forward direction but not laterally. For each oscillation, the forward displacement (“fwd_height”) of the forward leg 810 exceeds the backward displacement (“back_height”) of the back leg 820 , so the robot advances in a generally forward direction.
In some embodiments, the robot further includes a bump sensor for detecting walls and other obstacles. When a wall is detected, the robot is configured to make a U-turn by completing a 180 degree rotation while moving the robot to one side, the distance moved being approximately equal to the width of the cleaning assembly. After completing the turn, the robot is then driven across the room along a row parallel with and adjacent to the preceding row traversed. By repeating this maneuver each time a wall is encountered, the robot is made to traverse a trajectory that takes the robot across each portion of the room.
The trajectory is preferably based, in part, on the pose of the robot which is tracked over time to ensure that the robot traverses a different section of the floor with each pass, thereby avoiding areas of the floor that have already been cleaned while there are areas still left to be cleaned.
One or more of the components of the mobile robot, including the navigation system, may be implemented in hardware, software, firmware, or any combination thereof. Software may be stored in memory as machine-readable instructions or code, or used to configure one or more processors, chips, or computers for purposes of executing the steps of the present invention. Memory includes hard drives, solid state memory, optical storage means including compact discs, and all other forms of volatile and non-volatile memory.
Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention.
Therefore, the invention has been disclosed by way of example and not limitation, and reference should be made to the following claims to determine the scope of the present invention.
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A mobile robot configured to travel across a residential floor or other surface while cleaning the surface with a cleaning pad and cleaning solvent is disclosed. The robot includes a controller for managing the movement of the robot as well as the treatment of the surface with a cleaning solvent. The movement of the robot can be characterized by a class of trajectories that achieve effective cleaning. The trajectories include sequences of steps that are repeated, the sequences including forward and backward motion and optional left and right motion along arcuate paths.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/213,774, filed on Aug. 19, 2011, now U.S. Pat. No. 8,303,526, which is a continuation of U.S. application Ser. No. 13/007,090, filed on Jan. 14, 2011, now U.S. Pat. No. 8,007,452, which is a continuation of U.S. application Ser. No. 12/843,478, filed on Jul. 26, 2010, now abandoned, which is a continuation of U.S. application Ser. No. 11/159,988, filed on Jun. 23, 2005, now U.S. Pat. No. 7,762,969, which is a continuation of U.S. application Ser. No. 10/092,872, filed on Mar. 7, 2002, now U.S. Pat. No. 6,953,428, which claims the benefit of U.S. Provisional Application No. 60/274,843, filed on Mar. 9, 2001 and U.S. Provisional Application No. 60/286,863 filed on Apr. 26, 2001, the entire contents of which are incorporated by reference herein.
TECHNICAL FIELD
This invention generally relates to surgical mesh for use as a medical sling, such as a pelvic floor repair mesh, methods of making such mesh, kits including such mesh, and methods of treating or reinforcing a damaged, prolapsed, weakened or herniated portion of a patient's body using such mesh.
BACKGROUND INFORMATION
Surgical prosthetic mesh has been used to treat or reinforce tissues or organs which have been damaged, prolapsed, weakened, or otherwise herniated, such as in the conditions rectocele, cystocele, enterocele, vaginal prolapse, and protocele, for example. A prolapse refers to the slipping down of an organ or organ part from its normal position. For example, a prolapse of the rectum refers to the protrusion of the inner surface of the rectum through the anus. Rectocele is the prolapse of the rectum into the perineum. A prolapse of the uterus refers to the falling of the uterus into the vagina due to stretching and laxity of its supporting structures. Vaginal vault prolapse refers to the prolapse of the cephalad extreme of the vaginal canal toward, through, and beyond the introitus. Cystocele (i.e., vesicocele) is a hernia formed by the downward and backward displacement of the urinary bladder toward the vaginal orifice, due most commonly to weakening of the musculature during childbirth. However, any abnormal descent of the anterior vaginal wall and bladder base at rest or with strain is considered cystocele. Enterocele is a hernia of the intestine, though the term is also used to refer specifically to herniation of the pelvic peritoneum through the rectouterine pouch (i.e., posterior vaginal, rectovaginal, cul-de-sac, or Douglas' pouch hernia).
Surgical mesh may also be used to suspend tissues or retract body organs temporarily, e.g., during surgery. For example, U.S. Pat. No. 4,973,300 describes the use of a cardiac sling for supporting the heart during surgery; and U.S. Pat. No. 5,362,294 describes the retraction of body organs such as the uterus or bowel during laparoscopic surgery; U.S. Pat. No. 6,102,921 describes the use of a medical anastomosis sling for the use in repair or regeneration of nerves.
Synthetic mesh materials utilized as slings for the treatment or reinforcement of patient tissues for these and many other conditions can cause patient complications such as erosion, due at least in part to the sharp tangs on the edges of the mesh, which are formed during the manufacturing process or afterward (for example, when a physician cuts or shears or otherwise shapes the material). These tangs can cause an irritative effect which can lead to an erosion when they contact surrounding tissue. Thus, a need exists for a sling which minimizes irritation and erosion of the tissue surrounding the tissue which it supports.
Stress urinary incontinence (SUI), which primarily affects women, is a condition which is successfully treated using surgical slings. Stress urinary incontinence is generally caused by two conditions that may occur independently or in combination, namely, intrinsic sphincter deficiency (ISD) and hypermobility. In ISD, the urinary sphincter valve, located within the urethra, fails to close properly (coapt), causing urine to leak out of the urethra during stressful actions. Hypermobility is a condition in which the pelvic floor is distended, weakened or damaged, causing the bladder neck and proximal urethra to rotate and descend in response to increases in intra-abdominal pressure (e.g., due to sneezing, coughing, straining, etc.), resulting in insufficient response time to promote urethral closure and, consequently, in urine leakage and/or flow.
Biological factors that can affect hypermobility include: poor endopelvic fascia muscle tone (from age or limited activity), endopelvic fascia muscle stretch/tear from trauma (e.g. childbirth), endopelvic fascia/arcus tendenious (muscle/ligament) separation (lateral defect), hormone deficiency (estrogen), concombinant defects (cystocele, enterocele, ureteral prolapse), and vaginal prolapse. Traditional treatment methods include bladder neck stabilization slings in which a sling is placed under the urethra or bladder neck to provide a platform preventing over distention. An emerging alternative treatment is the placement of a mid-urethral sling. Such a sling placement takes advantage of the hypermobillty condition by providing a fulcrum about which the urethra and bladder neck will rotate and provide a “urethral kink” to assist normal urethral closure.
Slings are traditionally placed under the bladder neck to provide a urethral platform limiting endopelvic fascia drop while providing compression to the urethral sphincter to improve coaptation. The mid-urethral placement location provides mechanical stability to a less moveable anatomical structure. Bladder neck slings have traditionally been affixed in the desired location using a bone anchoring method. Mid-urethral slings, being placed in a low mobility area, have demonstrated the effectiveness of an anchorless approach. Recognizing that minimal tension, if any, is necessary, a physician need only place the sling under the mid-urethra secured through the endopelvic fascia to permanently secure the sling in position. The sling permits immediate tissue security through the mesh openings and mesh tangs to initially maintain sling stabilization. As healing occurs, the endopelvic fascia and rectus fascia tissue re-establish vascularity and regrow into and around the knit pattern of the mesh. The sling in this procedure provides a fulcrum about which the pelvic floor will drop (taking advantage of the hypermobility condition of the patient) and a urethral “kink” or higher resistance to obstruct urine flow during high stress conditions.
Thus, while tangs can contribute beneficially to SUI treatment, they can also cause patient complications such as erosion of the vagina or urethra.
SUMMARY OF THE INVENTION
The present invention relates to surgical mesh or slings with a non-tanged (i.e., tangs are unformed, smoothed, rounded, or removed) section disposed on a portion of the sides of the mesh, methods of making such mesh, medical kits including such mesh, and methods of treating a damaged, weakened, sagging, herniated or prolapsed portion of a patient's body using such mesh.
The benefits of such a sling according to the invention include decreased tissue irritation from a non-tanged section when it is in contact with tissue, such as urethral and vaginal tissue, while promoting rapid scar tissue formation around the tanged portion of the sling. The formation of scar tissue generally adds bulk that compresses the tissue to which it is applied (e.g., the urethra), provides support to improve patient continence and inhibits or prevents movement of the placed sling following placement.
In one aspect, the invention involves a sling for use in a medical application. The sling is made of a mesh material that includes first and second opposed ends (i.e., disposed opposite and away from each other) along a longitudinal axis. The mesh material also includes first and second opposed sides separated by a distance along an axis perpendicular to, or substantially perpendicular to, the longitudinal axis. The perpendicular axis intersects the longitudinal axis at the midpoint, or substantially at the midpoint, of the perpendicular axis. A portion of the first and second sides and the first and second ends of the material contains tangs. A portion of the first and second sides does not contain tangs (e.g. tangs on the first and second sides are unformed, smoothed, rounded or removed), creating a non-tanged section. The first and second sides may each have, for example, a non-tanged section about 1 cm to about 5 cm in length, centered along the longitudinal axis.
The sling of the invention may have a shape suitable for a medical application; e.g., it may be rectangular or substantially rectangular. Alternatively, the sling may be octagonal, hexagonal, trapezoidal, elliptical, or some other shape that is suitable to the sling's intended placement location within the body.
In another aspect, the invention relates to a method of making a sling by direct manufacturing with a non-tanged section or by smoothing, rounding or removing the tangs on a portion of the sling to create a non-tanged section.
The sling material provided may be derived from synthetic materials or a combination of mammalian tissue(s) and synthetic material(s). The method of making the sling can further comprise sterilizing the sling material according to methods known in the art so that the sling is suitable for use in various medical applications, and may include packaging the sling in a sterile holder. The sling material may be enclosed within a sleeve to assist in handling the sling and/or to adjust the sling during surgical placement, or to prevent the sling from stretching or becoming misshapen due to handling prior to placement within the body of the patient.
In a further aspect, the invention involves a method of treating a damaged portion of a patient's body using a sling with a non-tanged section. The sling is placed inside the body of a patient such that its perpendicular axis lies substantially along a portion of the patient's body, such as the mid-urethra, bladder, rectum, vagina, blood vessel, nerve, heart, etc.; the material supports a portion of the patient's body in a manner which does not erode the surrounding tissue. The sling may be centered at the damaged portion of a patient's body using the perpendicular axis of the sling as a guide. Pressure may be distributed evenly on a portion of a patient's body with the secured sling material. A surgical fastener such as a suture, a clip, a bone anchor, a staple, or other suitable fastener, may be employed to secure the sling to anatomical structures.
The sling material may be implanted to treat female urinary incontinence according to transvaginal, transabdominal, or combined transvaginal and transabdominal procedures. For example, the method may be employed to treat a patient with SUI, the non-tanged section of the sling placed adjacent the patient's mid-urethra.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to scale, but rather illustrate the principles of the invention.
FIG. 1 is a plan view of a rectangular embodiment of a sling having a non-tanged section on either side of the perpendicular axis.
FIG. 2 is a close-up diagram of sling material with a non-tanged section.
DESCRIPTION
Referring to FIG. 1 , a sling 20 in accordance with the present invention can be made of one or more materials 22 , and includes a first end 24 and a second end 26 . The second end 26 is disposed opposite and away from the first end 24 along a longitudinal axis 28 . The material 22 also includes a first side 30 and a second side 32 . The second side 32 is disposed opposite and away from the first side 30 along a perpendicular axis 34 . The axis 34 is perpendicular to, or substantially perpendicular to, the longitudinal axis 28 , and intersects the longitudinal axis 28 at the midpoint, or substantially the midpoint, of the axis 28 . The longitudinal axis 28 of the sling 20 may range from about 2.5 cm to about 45 cm in length, while the perpendicular axis 34 may range from about 1.0 cm to about 3.0 cm. The sling is preferably 20 to 30 cm in length and 1 to 3 cm wide, though larger and smaller slings are contemplated depending upon the size of the patient and the surface area of the body part that requires support.
The sling 20 and 21 can be rectangular, as illustrated in FIG. 1 , or substantially rectangular in shape (e.g., octagonal). Alternatively, the sling may have another shape (e.g., trapezoidal, hexagonal, or elliptical) suitable to its intended placement location within the body. Exemplary shapes are described in U.S. Pat. No. 6,042,534, the disclosure of which is incorporated herein by reference.
The thickness of the sling material 22 can be uniform over the entire piece of the material or it can vary at one or more different locations. The thickness of sling material 22 may range from about 0.02 to about 0.10 cm, but typically will be about 0.07 cm and have a uniform thickness. The material construction may impact the material thickness and uniformity; for example, a weave may have thicker regions where the fibers intersect.
The mesh may have any of a number of knits, weaves, or braids, such as those described in U.S. Pat. Nos. 5,569,273; 5,292,328; 5,002,551; 4,838,884; 4,655,221; 4,652,264; 4,633,873; 4,520,821; 4,452,245; 4,347,847; 4,193,137; 5,124,136; 3,054,406; and 2,671,444 the disclosures of which are hereby incorporated by reference.
The mesh material may be fabricated from any of a number of biocompatible materials such as nylon, polyethylene, polyester, polypropylene, fluoropolymers, copolymers thereof, combinations thereof, or other suitable synthetic material(s). The material may be, for example, a synthetic material that is absorbable by the patient's body. Suitable absorbable synthetic materials include polyglycolic acid, polylactic acid, and other suitable absorbable synthetic materials. The mesh material may be fabricated from one or more yarns, which yarns may be made from one or more materials. The mesh may be produced according to numerous fabrication processes, and may be designed to permit rapid tissue revascularization and tissue in-growth by having large interstitial spaces. For example, each yarn of the mesh may have void areas between yarn filaments and the fabrication process may create crevices. An exemplary weave is a tricot knit with two yarns per needle, as illustrated in FIG. 2 . In a preferred embodiment, the mesh is composed of polypropylene monofilament yarns.
Absorbable synthetic materials may also be suitable for use in accordance with the invention. Such absorbable synthetic materials include, for example, polyglycolic acid (PGA), polylactic acid (PLA), and other available absorbable synthetic materials. A suitable PGA material is available under the trade designation DEXON, from TYCO. Other suitable polymeric and non-polymeric synthetic materials may be employed in accordance with the invention. Exemplary materials as set forth above are found in U.S. Pat. Nos. 6,090,116; 5,569,273; 5,292,328; 4,633,873; 4,452,245; 4,347,847; 3,124,136; 3,054,406; and 2,671,444, and Inglesia, C. B. et al. (1997) Int. Urogynecol. J. 8:105-115, the entire disclosures of which are incorporated by reference.
Alternatively, the sling material 22 may be derived from a combination of mammalian tissue(s) and synthetic material(s). The mammalian tissue source may be, for example, human, human cadaveric, or tissue-engineered human tissue. The mammalian tissue may alternatively be from an animal source such as porcine, ovine, bovine, and equine tissue sources. Such combinations may also include materials that include both synthetic polymers and animal cells that are treated so as to cross-link the collagen or other commonly antigenic fibers of the animal cells. In one embodiment, at least a portion of the mesh portion of the sling which contacts the patient's tissue comprises a synthetic material requiring smoothness of the tangs.
The tangs (i.e., sharp projections or frayed edges) 40 that form when the material 22 is cut, chopped, torn, frayed or otherwise manufactured may be located along any edge of the material 22 . The tangs 40 are generally useful for encouraging tissue growth into the material 22 . However, it is found that some tangs 40 may erode the adjacent tissue when the sling 20 is inserted into a patient's body. Accordingly, a portion of the tangs 40 located on sides 30 and 32 (e.g., in some embodiments to within about 1 cm to about 5 cm of either side of the perpendicular axis 34 ) are therefore unformed, smoothed, rounded or removed to form a non-tanged section 42 . By removing these irritative projections, which will be in close proximity to the urethra and anterior vaginal wall, the erosion effects are reduced.
With continued reference to FIG. 1 , in one version of the sling, a line 36 is disposed along the perpendicular axis 34 of a rectangular sling 20 . The line 36 may be formed by, for example, applying surgical ink along the perpendicular axis 34 of the material 22 . Preferably, the approximate midpoint of the non-tanged sections 42 of sides 30 and 32 intersects with line 36 . Thus, line 36 may be employed as a visual guide to evenly align the non-tanged sections 42 with the portion of the patient's body that the sling 20 is employed to support.
Any process which will smooth, round or remove the tangs 40 to remove their sharp edges is suitable. For example, the tangs 40 may be heat smoothed by burning or melting. Such a heat process causes melting of the sharp tangs 40 back to the woven knot 44 forming a non-tanged section 42 , as shown best in FIG. 2 . The non-tanged section 42 may be located on both sides 30 and 32 , occupying, for example, about 1 to 4 cm on either side of the perpendicular axis 34 . The tangs may be removed, for example, along a 5, 6, 7, 8, 9 or 10 cm portion of the side of the mesh material.
An exemplary method of making a sling 20 of the invention from a material 22 , for example, includes manufacturing a sling material 22 and forming a non-tanged section 42 on a portion of a material 22 at sides 30 and 32 adjacent the perpendicular axis 34 . The sling 20 may be formed from the cutting to size of a larger piece of sling material 22 . The tangs 40 on a portion of each side 30 and 32 are unformed, smoothed, rounded or removed (e.g., to the woven knots) to form a non-tanged section 42 . The non-tanged section 42 may span a segment of sides 30 and 32 having a length up to about 4 cm, but usually at least about 1 cm, and the segment is preferably centered on the perpendicular axis 34 . In alternative embodiment, the non-tanged section 42 may span a segment of sides 30 and 32 having a length of 5, 6, 7, 8, 9 or 10 cm. In one version of the method, the tangs 40 are smoothed, rounded or removed by exposing the tangs to a source of heat (i.e., by contact or by bringing the heat source into close proximity to the tangs). In an alternative method, a straight blade edge that is heated to a sufficient temperature to simultaneously cut and smooth the tangs 40 may be employed.
The sling 20 may be surrounded by or enclosed within a sleeve or envelope as described in the U.S. patent application entitled “System for Implanting an Implant” co-filed with the instant application, which is hereby incorporated by reference in its entirety. The co-filed application also contains methods for installing slings enclosed within an envelope.
Referring to FIG. 1 , the sling 20 may be pre-soaked in a prescribed drug prior to implantation in a patient's body. Exemplary drugs include neomycin, sulfa drugs, antimicrobials, and antibiotics, generally. In some embodiments, the hydrophilic material, the drug, or both when used in combination, release the drug to patient tissues upon contact. Thus, the drugs that are delivered to the patient tissue surfaces when accessing and inserting the sling 20 are active upon contact with the patient's tissue during implantation of the surgical device.
Alternatively, the sling 20 is made of a non-wettable material such as a polypropylene, polyethylene, polyester, polytetrafluoroethylene, TYVEK®, MYLAR®, or co-polymers thereof. Polytetrafluoroethylene, which is suitable for use in accordance with the present invention, is available from DuPont (Wilmington, Del., under the trade designation TEFLON®). Such non-wettable materials do not take up any liquids, for example, drugs in solution. In order to permit drugs to bond or absorb to these non-wettable material surfaces, the sling 20 can be treated with a substance that is wettable such as, for example, a wettable coating composition. The wettable coating composition maybe a synthetic coating (e.g., polyvinylperilidone or PVP), a natural coating (e.g., collagen) or a physically absorbent material (e.g., sponge comprising cellulose or open celled polyurethane). The wettable coating composition may be hydrophilic, so as to pick up or absorb hydrophilic drugs. Suitable hydrophilic coatings may be water soluble and include, for example, Hydroplus (Boston Scientific Corp., Natick, Mass.), Hydropass (Boston Scientific Corp., Natick, Mass.), hyoscymine sulfate, which is available under the trade designation CYTOSPAZ from Polymedica (Woburn, Mass.), and ketrodac frometharnine, which is available under the trade designation Toradol from Roche Pharmaceuticals (Nutley, N.J.). Hydrophilic drugs that may be employed in accordance with the invention include oxybutynin chloride, lidocaine, ketorolac, and hyoscymine sulfate, for example.
Similarly, a hydrophobic coating may be employed on one or more surfaces of the sling 20 . Suitable hydrophobic coatings include but are not limited to hydrophobic coatings that may be employed in accordance with the invention include polytetrafluoroethylene, silicon, and Pyrelene. Such hydrophobic coatings may be used in conjunction with and absorb hydrophobic drugs. Suitable hydrophobic drugs include but are not limited to suitable hydrophobic drugs include ibuprofen, ketoprofen, diclofenac, and lidocaine in hydrophilic form. Where the bonding between these coatings and drugs is weak, the drug that is absorbed will readily release to be delivered to the surfaces it contacts. Alternatively, a stronger bonding affinity may provide a slower timed release of the drug.
Where the coating applied to the surface of the sling 20 has an ionic charge, drugs comprising a complementary charge will bond to the coating when the coating and the drug are exposed to one another. The strength of any bonding will impact how readily the drug is released from the surface of the sling 20 . Where the ionic bonding between the coating and the drug is weak, the drug will release more readily. In embodiments where rapid drug release is desirable, covalent bonding between the surface coating and the drug should be avoided.
Alternatively, the sling 20 may be coated with hydrophilic coating 75 . The sling 20 , coated with hydrophilic coating 75 , may be dipped into a solution containing a hydrophilic drug just prior to surgery. In another embodiment, the hydrophilic coating and the hydrophilic drug are mixed to form a single coating. This coating may be disposed on the surface of the sling 20 .
Methods of sling delivery and installation, e.g., to treat female stress incontinence include but are not limited to transvaginal, transabdominal (percutaneous), and combined transvaginal and transabdominal procedures.
Variations, modifications, and other implementations of what is described herein will occur to those of ordinary skill in the art without departing from the spirit and the scope of the invention. Accordingly, the invention is not to be limited by the preceding illustrative description.
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A medical sling made from material that is suitably shaped for use in a medical application has sides, portions of which are smoothed to prevent abrasion of surrounding tissue.
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TECHNICAL FIELD
The present invention relates in general to simple network management protocol (SNMP) and in particular to methods and systems for generating a management information base (MIB) such that a network entity (NE) that is not SNMP compliant can communicate traps (error messages) to one or more specific managers in accordance with existing SNMP standards.
BACKGROUND
As networks have grown in size, the networks have become more difficult to manage (ie. monitor and maintain). It was determined that a network management protocol needed to be developed. A protocol initially developed as a quickly designed "temporary" solution to management difficulties was designated simple network management protocol (SNMP). Although improvements have been made to the original SNMP, improvement protocols, such as SNMPv2, still embody many of the essential features of the original SNMP.
While SNMP was designed as a temporary answer to communications problems between different types of networks, no better choice became available and SNMP became the network management protocol of choice. As a result, a large number of network entities (NE) are designed to be SNMP compliant. That is the NE acts as an agent that can receive messages from a network manager and supply responses to the received requests. These network information exchange messages are known in the art as protocol data units (PDUs).
Although there are several types of PDU messages, this invention is concerned with trap messages that are initiated by agents and are used for monitoring various network events such as terminal start-ups, shut-downs and other entity, typically software, events. In many instances, when such a trap message is received by a manager, an error defining message is displayed on a monitor in human readable form so that suitable action may be taken where action is appropriate.
If an NE is not designed as a SNMB compliant entity, the trap event or error messages must be translated to a common format that the SNMB managers can correctly interpret. An SNMP manager may be required to interact with many types of NEs such as routers, servers, repeaters and the like. The trap message is coded so as to be very compact and thus PDUs from two different NEs that appear to be identical may be indicative of entirely different events. To this end, a plurality of trap definitions are incorporated in management information bases (MIBs) that are used by a manager to correctly interpret the trap message being received. Typically a manager accesses a different MIB for each different type NE.
The writing of an MIB is a tedious process that requires one to follow a very stringent set of rules in developing the definition. For an NE that has many events that need to be monitored, the manual preparation of such a file takes thousands of hours. Since an SNMP manager will totally reject an MIB file that incorporates any type of format or syntactical error, many additional hours are often required to debug a defective MIB.
It would thus be desirable to be able to automatically generate an MIB having trap definitions for each of the alarms or logs for which trap messages are to be supplied by a given NE wherein the MIB is free of format or syntactical errors.
Sometimes an entity requires monitoring of new events or presently monitored events may require assignment of different interpretations. In such instances, it would be desirable to generate a new MIB with a minimum of effort and replace the MIB file in the appropriate SNMP managers.
SUMMARY OF THE INVENTION
The present invention comprises a method of and apparatus for generating a management information base (MIB) that can be used by an SNMP manager to properly interpret a trap message.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and its advantages, reference will now be made in the following Detailed Description to the accompanying drawings, in which:
FIG. 1 is a block diagram of a network monitoring and SNMP management system;
FIG. 2 is a block diagram used to describe the process used to generate an MIB;
FIG. 3 comprises a listing for illustrating the type of material in a template library of FIG. 2;
FIG. 4 is a partial listing of an MIB file constructed in accordance with the teachings of this invention; and
FIG. 5 is a flow diagram to be used in conjunction with the process of describing the method of generating an MIB.
DETAILED DESCRIPTION
In FIG. 1, a monitored block 10 is labeled NETWORK and there is a further indication that an example of such a network might be a telephone switch. Network 10 is connected via a network communication system 12 to a block 14. Block 14 is connected via a further network communications system 16 to an SNMP manager labeled 18. Systems 12 and 16 would be capable of transferring digital messages. Within block 14 there is shown a block 20 labeled networks monitor, an SNMP interface block 22 and an MIB generator 24.
As will be explained in more detailed later, the monitor 20 receives various alarms and logs from network 10. These alarms and logs are translated according to standardized protocols to a form that can be utilized by an SNMP manager and transmitted over communication network 16 to block 18. If it becomes appropriate to generate a new MIB file, this file can be downloaded using existing file transfer protocol (FTP) procedures into the SNMP manager 18 over the same communication network 16 as was used to transmit the alarms and logs to manager 18. The SNMP manager 18 can then immediately start interpreting incoming data according to the new MIB file.
In FIG. 2 an MIB generator 30 is designed to retrieve data or otherwise receive inputs from a base definition library 32, a template library 34 and a network element generated alarm/logs block 36. The generator 30 transmits the generated output to an MIB block 38 comprising a resultant MIB file.
In FIG. 3, lines 1 through 13 illustrate the contents of the format or template library 34 for one embodiment of the present invention. The first line is the name of the trap. Line number 2 sets forth the name of the particular set of traps to which this particular trap message belongs. Lines 3 through 10 list variables that might be contained in a trap message and which comprise part of the base definitions library 32. Line 12 is a descriptive and human readable presentation of the alarm or log to be displayed on a monitor, while line 13 is utilized for setting forth a given trap identifying number. Thus FIG. 3 sets forth the format or template used by generator 30 in assembling each of the trap elements of the MIB file from data obtained from the database of block 36.
In FIG. 4, an abbreviated example of an MIB file is presented. The omitted lines 1-11 and 19-24 contained explanatory remarks not pertinent to the invention. The omitted lines 48-123 included further field definitions and trap types not pertinent to the explanation of operation of the invention or the MIB file.
As previously indicated, the generator 30 assembles a resultant MIB file using data from various sources. It first retrieves a base definition from block 32. Lines 12-18 and 25-27 comprise identifying data used by SNMP manager 18 to define the source of the received alarm. Lines 31 through 46 define two of the object types or variables listed in the template of FIG. 3. Although, the definitions of the remaining variables shown in FIG. 3 would comprise part of the library 32 and be in the MIB file, these definitions were omitted from FIG. 4 for simplification, as shown by the three vertically spaced dots. In the example used to generate the MIB file of FIG. 4, only a few alarms were used in block 36. The last two of these alarms are defined in lines 124-136 and 138-150. The command END at line 152 instructs the SNMP manager that there are no more trap types defined in this file.
The database 36 in the embodiment shown includes a trap type number, such as 13821, to differentiate that alarm or log from other error messages. For the trap type 13821, line 138 comprises the name of the trap, line 149 comprises the human readable description and line 150 comprises a numerical identifying designation for that trap. Thus the database in block 36 only contains the data in a few lines of each trap definition, such as in lines 149 and 150, even though the definition requires 12 lines to be generated in the MIB file.
Thus the generator 30 generates a traptype similar to that shown in lines 138-150 for each of the designated error message sources to be monitored by the SNMP manager 18 and compiled in the database of block 36. When generator 30 determines that the final data entry has been transformed to a traptype, the final MIB file entry "END" of 152 is supplied and the MIB file in block 38 is deemed complete.
The system set forth is designed to provide a flexible approach to generating an MIB file. However, the addition of further variables to the base definition library 32 and to the template library 34 may introduce errors to an automatically generated MIB file. Thus the generator 30 may include software components such as a syntax checker, semantics checker and template validation apparatus to assist in the detection of material in the libraries that would prevent the generation of an error free MIB file.
The flow diagram of FIG. 5 shows the steps followed by the MIB generator 30 of FIG. 2 in generating to a MIB file of FIG. 4. Prior to the generation of the MIB file, the data in each of the libraries 32 and 34 must be manually assembled along with the data in the list of identification elements of block 36. Once all the information in these three data files, lists or libraries is complete, the generation of the MIB file 38 can commence.
As shown in block 50, the first step of a computer program operating to perform the functions of MIB generator 30 is to retrieve header and field definitions from the base definition library 32 and insert this information into a data file as represented by block 38 in FIG. 2. This header and field definition information is substantially identical to that shown in FIG. 4 in lines 12-18 and 25-47. As previously indicated there are more objects defined than what is shown but the two objects shown in lines 31 through 46 are representative of other objects or variables. The next step, as set forth in block 52, is to retrieve field layout data from the template library 34 of FIG. 2. A counter must be set within the list 36 to the first set of identification elements in this list. Typically when such a list is first accessed, an internal pointer is situated at the first item. However, pointers can always be forced to a given list position such as the first element. Such a step is shown in block 54. At this time the set of identification elements identified by the pointer are retrieved from the list of identification elements. Such a step is shown in block 56. The program then proceeds to block 58 where a trap definition is generated in accordance with the layout data obtained from the template library 34. The program than proceeds to block 60 where the trap definition is inserted into the MIB data file. Such a trap definition might be such as shown in lines 124 through 136 of FIG. 4. At this time the counter or pointer in the list 36 is incremented as shown in block 62. A decision is made at this time as to whether or not all the identification elements have been retrieved as is shown by decision block 64. If there are still identification elements that have not been retrieved and processed, the program returns to block 56 and retrieves the next set of identification elements. Otherwise, a final or closing set of commands, such as the END command as listed on line 152 of FIG. 4, is added to the MIB file and the MIB file is closed as set forth in block 66.
In summary, network 10 provides output signals indicative of various alarms and logs that are received by the networks monitor block 20. Since block 20 is not SNMP compliant, the alarms and logs or other messages that are to be transmitted to SNMP manager block 18 must first be passed through the SNMP trap interface 22. The manager block 18 must, however, have a definition of each of the types of received messages from its agent 14. The definition used by block 18 to interpret incoming signals is obtained from the previously mentioned MIB file.
The MIB file can be quickly generated by generator 30, of FIG. 2, by first retrieving SNMP formatted definitions for each of the fields found in the trap definition or base library 32. As indicated previously these definitions may be customized by the vendor for particular circumstances. Thus they can be modified in to accommodate additional variables as required. The template library 34 is then accessed by generator 30 to add a properly formatted trap type definition for each one of the sets of elements in the assembled database of block 36. When the error messages are received by manager 36, the trap name as set forth in line 1 of FIG. 3, the variables as set forth in lines 3 through 10, and the descriptive information can then be properly interpreted by the manager 18.
The network 10 may be expanded such that added alarms or logs need to be monitored. When this happens, the additional data can be added to the database of block 36, the generator 30 can be activated and a new MIB file can be completed. This MIB file can then be transferred to manager 18, over network 16 using standard FTP protocol downloading techniques known to those skilled in the art. With the computing power available today, the assembly of an error free MIB file, even where the number of element sets in block 36 is in the order of tens of thousands, can be completed in a few seconds. The transfer of the file to manager 18 and installation therein may also be completed in a short period of time to quickly accommodate any required changes in error message management.
Although the invention has been described with reference to a specific embodiment, these descriptions are not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore, contemplated that the claims will cover any such modifications or embodiments that fall within the true scope and spirit of the invention.
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Disclosed is an apparatus for quickly generating an error free MIB file of the type used by a SNMP manager to manage and display error and log trap messages received from agents reporting to said manager. This is accomplished by retrieving data from definition and template libraries to be used in conjunction with a network element database to correctly generate, element by element, a completed MIB file.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part application of Ser. No. 07/808,795, filed Dec. 16, 1991 entitled "THREE-DIMENSIONAL IMPEDANCE IMAGING PROCESSES", which is incorporated here by reference and now U.S. Pat. No. 5,284,142.
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates in general to electrical impedance tomography and in particular, to a new and useful method for obtaining sets of current patterns which are used for producing a three-dimensional impedance image of the interior of a body.
The present invention has applications in medical imaging, clinical monitoring, non-destructive evaluation, process control and the imaging of multiphase fluid flow.
Although superficially similar to X-ray computed tomography or positron emission tomography, electrical impedance tomography (EIT) encounters fundamentally different problems when attempting to create an image. In X-ray computer tomography, for example, the paths of photons through the body are essentially straight lines. In contrast, current paths in EIT are functions of an unknown resistivity distribution. This gives rise to a non-linear reconstruction problem.
The physiological basis for EIT, relies on the fact that biological tissues contain free charge carriers that permit them to act as relatively poor electrical conductors. This ability to conduct electricity varies substantially among the various body tissues. Some typical values for resistivity of biological tissues are disclosed in Table 1. The goal of EIT is to compute and display the spatial distribution of resistivity inside the body.
TABLE 1______________________________________ ResistivityMaterial (ρ) ohm-cm______________________________________Blood 150Plasma 63Cerebrospinal Fluid 65Urine 30Skeletal muscle 300Cardiac muscle 750Lung 1275Fat 2500Copper 1.724 × 10.sup.-6______________________________________
The present invention is related to the subject matter of U.S. Pat. No. 4,920,490 issued to one of the co-inventors of the present application and incorporated here by reference.
This invention is also related to U.S. patent application Ser. No. 07/727,075 entitled A LAYER STRIPPING PROCESS FOR IMPEDANCE IMAGING, which is also incorporated here by reference and which discloses mathematical theories and manipulations which are useful in understanding the present invention. For additional disclosure concerning hardware useful in practicing the present invention, see U.S. patent application Ser. No. 07/734,591 entitled CURRENT PATTERNS FOR ELECTRICAL IMPEDANCE TOMOGRAPHY which is also incorporated here by reference.
Additionally, the present invention relates to trigonometric current patterns such as those described by Cheney et al., NOSER: An Algorithm For Solving the Inverse Conductivity Problem, 2 Int'l. J. Imaging Systems and Technology, 66-75 (1990).
The present invention also relates to Walsh function patterns such as those disclosed by U.S. patent application Ser. No. 07/591,615 entitled CURRENT PATTERNS FOR IMPEDANCE TOMOGRAPHY, now U.S. Pat. No. 5,272,624, which is incorporated herein by reference.
SUMMARY OF THE INVENTION
The present invention pertains to a method for obtaining sets of current patterns for three-dimensionally imaging the interior of a body having an internal resistivity using electrical impedance tomography. The method according to the present invention utilizes various current patterns such as trigonometric current patterns and Walsh function patterns for application to an impedance imaging system.
According to the present invention, the method comprises providing an array of electrodes arranged in a plurality of groups for an impedance imaging system. A current for each electrode in the groups is provided for establishing a current pattern. After which, a linearly independent set of current patterns is also established for forming a basis for each group. A constant pattern is then adjoined to each basis for forming an augmented basis for each group. A tensor product is then taken of the augmented basis for forming a tensor product basis. Finally, the constant pattern from the tensor product basis is removed in order to establish an applied basis of current patterns for being applied to the array of electrodes.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which the preferred embodiments of the invention are illustrated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a method for obtaining useful sets of current patterns which are used for three-dimensional imaging systems for imaging the interior of a body having an internal resistivity using electrical impedance tomography.
The present invention is applicable to various imaging systems. For illustration purposes, suppose an impedance imaging system has L electrodes arranged in an array with M rows and N columns, where M×N=L. A "current pattern" is defined as a set of L currents, one for each electrode. A "basis" of current patterns is a linearly independent set of current patterns that has the property that every possible current pattern can be written as a linear combination of these basis patterns. A basis of current patterns contains L-1 current patterns. That is, L, the number of electrodes, minus one, is the basis of current patterns.
The present invention provides a method for systematically selecting current patterns as a basis which are then applied to a full array of electrodes.
The first step is to choose a basis of current patterns for a linear arrangement of M electrodes. For example, such a basis could be a set of trigonometric current patterns or a set of Walsh function patterns. The second step is to choose a basis of current patterns for a linear arrangement of N electrodes. The third step is to adjoin the constant pattern to each basis. The constant pattern is not an allowed pattern for a simple linear arrangement, because the current being injected is not being extracted anywhere. The resulting basis is the "augmented" basis. The fourth step is to take the product of each pattern in the first augmented basis with every pattern in the second augmented basis. The resulting set of patterns is the "tensor product" of the augmented bases. The patterns in the tensor product are possible patterns for the M×N array of electrodes. The fifth and final step is to delete the constant pattern (which arises from multiplying together the two constant patterns, one from each augmented basis) from the tensor product of the augmented basis. The resulting set of patterns is a basis for the M× N array.
By way of example, suppose there are three electrodes in the horizontal direction, i.e. first group of electrodes, and two electrodes in the vertical direction, i.e. second group of electrodes. Both groups constituting a full array of electrodes.
The first step is to choose a basis for the three-electrode array which may be {(1,-1,0), (1,0,-1) }. The first current pattern, (1,-1,0), corresponds to applying 1 mA on the first electrode, -1 mAon the second electrode, and no current on the third electrode. A second current pattern, (1,0,-1), corresponds to applying 1 mAon the first electrode, no current on the second electrode, and -1 mA on the third electrode.
Any other current pattern on the three electrodes can be expressed as a linear combination of these two current patterns listed above. For example, the pattern (0,-2,2) is equal to
2*(1,-1,0)-2*(1,0,-1).
Thus, there can only be two linearly independent patterns because the currents in each pattern must sum to zero, due to the conservation of charge principle.
The second step is to choose a basis of current patterns for the two-electrode array, for instance, {(1,-1)}.
The third step is to adjoin a constant pattern to each basis for establishing augmented bases. The augmented bases, for the example above, are then
{(1,-1,0), (1,0-1), (1,1,1)}
and
{(1,-1), (1,1)}.
Note that (1,1,1) is the constant pattern for the first basis and (1,1) is the constant pattern for the second basis.
The fourth step is to take the tensor product of the augmented bases. This results in the basis:
______________________________________1 -1 0 1 0 -1 1 1 1-1 1 0 -1 0 1 -1 -1 -11 -1 0 1 0 -1 1 1 11 -1 0 1 0 -1 1 1 1______________________________________
The fifth and final step is to remove the constant pattern. This deletion gives the final result
______________________________________1 -1 0 1 0 -1 1 1 1-1 1 0 -1 0 1 -1 -1 -11 -1 0 1 0 -11 -1 0 1 0 -1______________________________________
In accordance with the present invention, the final basis is a basis of 3*2-1=5 current patterns that can be applied to the full 3 by 2 electrode array. In order to produce an image, one must apply all five of these current patterns (one after the other), measure the corresponding voltage patterns, and use all this data to make an image in a manner taught in one or more of the above-identified applications which are incorporated here by reference.
The requirement, according to the present invention, of obtaining linear independence of a set of vectors, can be found, for example, in the reference Introduction to Linear Algebra With Applications, Friedberg et al., Prentice-Hall, pgs. 132-136.
Although the present invention relies heavily on mathematical manipulations, it is more than simply an algorithm and more than simply utilizing an algorithm in a particular technological environment. The present invention, does not preempt an algorithm, but instead defines a method of first obtaining sets of currents and then applying the obtained sets of currents to a multi-dimensional array of electrodes for the purpose of creating an EIT image. The method of applying currents to electrodes, followed by reading voltages resulting from those applied currents and thereafter creating an image using the voltages, is statutory subject matter and the method of the present invention provides an advancement in the field of EIT which is both useful and advantageous.
Another more general example of forming the tensor product of two current patterns, which is part of the present invention, can be expressed as follows.
The M×N array of electrodes are positioned:
______________________________________ (1,1) (1,2) (1,3) (1,4) (2,1) (2,2) (2,3) (2,4) (3,1) (3,2) (3,3) (3,4) (4,1) (4,2) (4,3) (4,4) (5,1) (5,2) (5,3) (5,4)______________________________________
Suppose a current pattern in the horizontal direction is (A, B, C, D) and a current pattern in the vertical direction is:
b
c
d
e.
Then the corresponding tensor product pattern for the full array would be:
______________________________________ Aa Ba Ca Da Ab Bb Cb Db Ac Bc Cc Dc Ad Bd Cd Dd Ae Be Ce De.______________________________________
If, for example, A=2 mA and d=-3 mA, then the current on electrode (4,1) would be Ad=-6 mA.
The current pattern in the horizontal direction is (A=2, B=0, C=-2, D=0), and the current pattern in the vertical direction is (a=0, b=l, c=0, d=-3, e=2) where all numbers are in milliamps. Then the tensor product of these two current patterns would be:
______________________________________0 0 0 02 0 -2 00 0 0 0-6 0 6 04 0 -4 0.______________________________________
Note that this would be only one current pattern in the required basis of 4*5-1=19 patterns. A second, linearly independent pattern could be constructed from (A=0, B=1, C=0, D=-1) and (a=1, b=0, c=-2, d=0, e=l). The tensor product of these two is:
______________________________________0 1 0 -10 0 0 00 -2 0 20 0 0 00 1 0 -1.______________________________________
To provide an better intuitive basis for explaining what is meant by linearly independent sets of current patterns, and in addition to the above-identified standard reference concerning linear algebra, a set of vectors is linearly independent if it is not possible to express one of the vectors in term of the others.
For example, the set of vectors {(1,0,0), (0,1,0), (0,0,1)} is linearly independent, but the set of vectors {(1,0,0), (0,1,0), (1,1,0)} is not, because the sum of the first two in the set, equals the third.
The phrase "adjoining the constant pattern" in the present application means to include the constant pattern into the set of basis vectors. For example, if we denote the constant vector by C, and if the original basis vectors are A1, A2, A3, then the augmented basis would be {A1, A2, A3, C}.
Further, explaining the fifth step of the invention, assume the original two bases are {A1, A2, A3} and {B1, B2, B3}. After adjoining the constant pattern C1 to the first basis and the constant pattern C2 to the second basis, the two bases would be {A1, A2, A3, C1} and {B1, B2, B3, C2}. Different letters are used for the two constant patterns because they might be vectors with different numbers of entries. After taking the product, one of the product vectors, namely (C1)(C2), will be the product of the two constant patterns, which will itself be a constant pattern. For example, suppose one electrode array has 3 electrodes and the other has 2. Then a constant pattern (C1) for the 3-electrode array would be (1 mA, 1 mA, 1 mA); a constant pattern (C2) for the 2-electrode array would be (1 mA, 1 mA). Note, however, that these patterns violate the conservation of charge, and cannot actually be applied. The pattern (C1)(C2 ) would, however, be
______________________________________1mA 1mA 1mA1mA 1mA 1mA.______________________________________
This pattern also violates conservation of charge, which is why we need to remove it from the tensor product basis for the full array.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A method for obtaining sets of current patterns for three-dimensionally imaging the interior of a body having an internal resistivity using electrical impedance tomography comprises providing an array of electrodes arranged in a plurality of groups for an impedance imaging system. A linearly independent set of current patterns is also established for forming a basis for each group. A constant pattern is then adjoined to each basis for forming an augmented basis for each group. A tensor product is then taken of the augmented basis for forming a tensor product basis. Finally, the constant pattern from the tensor product basis is removed in order to establish a basis of current patterns for being applied to the array of electrodes.
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RELATED APPLICATIONS
The present application is based on and claims priority from International Application Number PCT/JP2008/061941, filed Jun. 25, 2008, the disclosure of which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for forming plasma-sprayed thermal barrier coatings over the surfaces of the metal bodies such as the combustor transition pieces, turbine rotor blades, and turbine stator blades as to the industrial gas turbines.
2. Background of the Invention
Gas turbines are used for the emergency power generating facilities, as the gas turbines need neither cooling water nor long start-up time; gas turbines are used for the combined cycle power plants (gas-turbine steam-turbine combined cycle power plants) of a large scale because of the high efficiency of the combined cycle power generation.
The gas turbine is a centrifugal, axial or radial turbo machine that includes three major configuration parts, namely, a compressor, a combustor, and a turbine. In the gas turbine, the air compressed by the compressor is supplied to the combustor(s) in which the fuel is injected so as to be burnt; thereby, the combustion gas of a high temperature and a high pressure is generated; and, the combustion gas flows into the centrifugal, axial or radial turbine so as to drive the gas turbine (so as to make the gas turbine rotate). In general, the turbine is directly connected (without gear connections) to the compressor, transferring the power needed for compressing the air to be supplied to the compressor.
In order to improve the efficiency of the gas turbine, it is desirable to enhance the turbine inlet temperature (TIT); thus, TIT has been increased in the field of the gas turbine. The TIT for the gas turbines operated in the actual thermal power plants is usually at a level within a range around from 1300 to 1500° C.
The parts that form the combustor, the combustor transition piece that guides the high temperature/pressure combustion gas from the combustor to the turbine, the turbine rotor blades, and the turbine stator blades are exposed to the combustion gas of the temperature around from 1300 to 1500° C.; these gas turbine components are provided with the thermal barrier coatings (often abbreviated as TBC) so as to achieve high durability. For instance, the patent reference 1 (JP patent 2977369) discloses a rotor or stator blade with the surface TBC comprising a first layer that is made of NiCrAlY (nickel.chrome.aluminum.yttrium) alloy or CoNiCrAlY (cobalt.nickel.chrome.aluminum.yttrium) alloy, the layer being formed by means of the low pressure plasma spray coating; a second layer that is made of ZrO 2 -Y 2 O 3 material, the layer being formed by means of the atmospheric pressure plasma spray coating; a third layer that is made of fine ceramics and forms oxygen-permeable layer, the layer being formed by means of the chemical vapor deposition or the low pressure plasma spray coating.
In forming the TBC on the parts configuring the gas turbine as described in the above, a robot comprising a plasma spray gun is used in order that the coating material is sprayed from the spray gun toward the to-be-coated surface or the whole surface of the to-be-coated part in response to the predetermined plasma spray conditions, while the robot is moved toward a predetermined direction at a predetermined speed. The referred plasma spray conditions depends on the shape, the to-be-coated part material and so on; thus, before performing the spray coating by use of the robot, it becomes necessary to instill (teach) how to spray plasma coating in (to) the robot. It is hereby noted that the term “(robot) teaching” mean to teach the robot how to move and work hereafter in this specification.
The conventional robot teaching for establishing the plasma spray coating conditions is a manner in which a test plasma spray coating is performed to a to-be-spray-coated part, and the inspection of the coated part is executed, on the premise that the part is inexpensive; namely, if the inspection result is negative (not satisfactory), the same process (modified coating test on an equivalent part) is repeated until the inspection result becomes satisfactory. In other words, the tested parts until the inspection result becomes satisfactory are thrown away.
In a case where the to-be-spray-coated part is expensive, the robot teaching method in which the throwaway practice as described above is incorporated is not feasible from the economical point of view; in fact, the above referred parts such as the combustor transition pieces, turbine rotor blades, and turbine stator blades are the examples of expensive parts. In particular, the combustor transition pieces are made of the expensive Ni-base alloy as the patent reference 2 (JP patent 3067416) discloses; further, the transition pieces are provided with a plurality of fine through-holes for cooling the combustion gas flow film (boundary layer), the fine holes being not easily machined; and, the manufacturing cost of the combustor transition pieces currently reach several millions yen per gas turbine. Therefor, the robot teaching method in which the throwaway practice is not feasible at all.
Thus, in the conventional robot teaching (method) for performing the plasma spray coating, the inner surface of the combustor transition pieces is masked with double or triple layers of tape so that foreign substances do not clog the fine through-holes; then, on the layers of tape, the test specimens are paved with a space of approximately five centimeters between a piece (specimen) and the adjacent piece (specimen), the test specimens being made of the same material as that of the combustor transition pieces; further, the trailer parts (end edge areas) of the test specimens are fixed to the layers of tape (the masking tape), by use of the tape of the same material as that of the layer tape (the masking tape); then, the plasma spray coating test is performed so as to execute the robot teaching.
In addition, the tape can be, for example, PTFE tape that is made of fiber glass impregnated with polytetrafluoroethylene resin, one side of the tape having an adhesive coating of silicon (silicon-base material); or, the tape can be the tape comprising silicon rubber, aluminum foil and fiber glass, the tape material being able to be used for the plasma spraying.
Further, the patent reference 3 (JP1993-111666) discloses a masking method for forming a (hard) resist film on the to-be-plasma-splayed area on which the hardened film can be formed by use of a method such as photo-curing or heat curing, the film being made of resin that is able to be resistant against plasma spraying (heat) as well as to be removed after plasma alloy spraying, the resin being applied or printed on the to-be-plasma-splayed area in a liquid condition, dried on the area and hardened by light or heat.
As for the above-described robot teaching (method) by use of the test specimens fixed on the to-be-plasma-sprayed (metal) part with the layers of tape, the plasma spraying heat sometimes scorch the tape in the test plasma spraying; thus, the surface of the metal part is exposed and plasma material clogs the fine through-holes of the tested part. Further, the heat scorches the tape fixing the pieces so that the test specimens sometimes move from the predetermined positions or the TBC plasma spray reaches the backside of the tested part. Moreover, the masking method by use of the tape is so difficult that even skilled craftsmen need a lot of man-hours to perform the method.
Even if the masking method accompanies the approach for forming a (hard) resist film on the to-be-plasma-splayed area of the inner surface of the transition piece as disclosed by the patent reference 3, it is necessary to use the tape to fix the test specimens; thus, the problem that the tape may be scorched remains unsolved.
DISCLOSURE OF THE INVENTION
In view of the hitherto unsolved subjects as described above, the present invention aims at providing a plasma spray coating method whereby the masking work is easily performed, and the conditions as to the plasma spray coating can be established so that the test specimens are surely placed on the surface of the to-be-plasma-sprayed apparatus.
In order to solve the above subjects, the present invention discloses a plasma spray coating method for forming a thermal barrier coating by performing a plasma spraying on a metal surface of heat resistant apparatus, the method comprising:
the step of establishing the plasma spraying conditions that sequentially includes the processes of:
forming a heat resistant resin coating film on the whole metal surface to be plasma-sprayed, placing test specimens made of the same material as the material of the heat resistant apparatus so that the specimens stick to the heat resistant apparatus, plasma-spraying the thermal barrier coating material on the surface of the test specimens, removing the test specimens from the heat resistant resin coating film, and confirming the plasma spraying conditions so as to establish a production plasma spraying conditions; and
the step of forming the thermal barrier coating by plasma-spraying the thermal barrier coating material on the metal surface under the established conditions regarding the plasma spraying.
Incidentally, the to-be-plasma-sprayed surface is heated up to a temperature level of 150 to 200° C. at most; thus, the resin cured with dry air, the resin cured with light such as the resin cured with ultraviolet rays, or the resin cured with heat can be used, for example, in the above method, thereby the resin can form a hardened film from a liquid state. Moreover, an inexpensive resin such as silicon sealant that can form nonflammable filler can be used.
According to the method as disclosed above, a heat resistant resin coating film is formed on the metal surface to be plasma-sprayed as to the heat resistant apparatus; thus, the formed heat resistant resin coating film prevents the thermal barrier coating from being formed on the metal surface of the heat resistant apparatus during the trial plasma spray coating for establishing the conditions regarding the plasma spraying; further, the heat resistant resin has the heat resistant properties so that the resin is free from scorching or melting during the plasma spraying test (robot teaching). Moreover, the work for forming the heat resistant resin coating film can be performed in a relatively brief period of time; accordingly, the time needed for establishing the plasma spraying conditions can be reduced.
Preferably in the above-described disclosure, the present invention further provides the plasma spray coating method whereby the heat resistant resin coating film is made of a resin cured with ultraviolet rays in a liquid state, the ultraviolet rays being a photo-curing resin that makes the resin cure by polymerization in response to the specific wavelength of the rays; the liquid resin cured with ultraviolet rays is applied to the whole metal surface to be plasma-spray-coated; the test specimens are placed on the resin cured with ultraviolet rays and the resin is radiated with ultraviolet rays so as to be hardened; the hardened resin forms a resin film covering the metal surface, and the test specimens are bonded to the resin film.
In addition, the resin cured with ultraviolet rays or visible light can be used, thereby the resin in which the polymerization reaction in the resin has proceeded to a 10% level of the full polymerization (before being coated) is used so that the polymerization hardening speed is restrained. Further, in the embodiment described later, the resin cured with ultraviolet rays will be focused on; however, the present invention is not limited to the resin cured with ultraviolet rays. The resin cured with visible light can be also applied to the present invention; in the resin cured with light, the polymerization hardening reaction proceeds by not only ultraviolet rays but also visible light out of the ultraviolet zone. It is noted that the (light) sensitizing agent that absorbs larger energy in the visible light zone is combined with the light polymerization initiator agent that reacts to electron beams or ultraviolet rays, in the resin cured with light. The present invention may use the resin cured with the light which promotes the polymerization reaction in the resin even though the light is out of visible zone.
The ultraviolet curing resin in a liquid state may be applied to the to-be-applied surface, and ultraviolet rays may be radiated to the surface; thus, the resin film can be simply formed in a short time. In addition, by radiating ultraviolet rays after placing the test specimens on the ultraviolet curing resin in the liquid state, the test specimens are bonded to the metal surface via the hardened ultraviolet curing resin; thus, the test specimens can be simply arranged.
In addition, the radiated ultraviolet rays cannot penetrate through the test specimens; thus, the ultraviolet curing resin on the backside of the test specimens remains not in a hardened state but in a liquid state, even after radiating ultraviolet rays. The ultraviolet curing resin has weak adhesion properties; thus, there is no apprehension that the test specimens come off from the coated resin film, even though the metal surface on which the test specimens are placed is extended to the upper side area, the left and right side area, and the bottom side area of the inner space of the heat resistant apparatus such as the transition piece of the gas turbine.
Preferably in the above-described disclosure, the present invention further provides the plasma spray coating method whereby the metal that forms the heat resistant apparatus is provided with a plurality of fine through-holes; the thermal barrier coating is formed in the process of forming the heat resistant resin coating film (in the step of establishing the plasma spraying conditions), under the condition that the penetrating holes are filled with the heat resistant resin.
According to the above, the fine through-holes are free from being clogged during the blast finishing process (the abrasive blasting process) or the undercoat treatment process for the metal surface, either of the processes being performed prior to the plasma spray coating process.
Preferably in the above-described disclosure, the present invention further provides the plasma spray coating method whereby the heat resistant resin comprises an incombustible (a nonflammable) filler of the size not exceeding the (minimum) diameter of the penetrating holes.
According to the above, an incombustible (a nonflammable) filler of the size not exceeding the (minimum) diameter of the penetrating holes can be used. Since the holes are filled with the filler during the plasma spraying process or the abrasive blasting process, the holes are finally free from being clogged with the metal powders or the like.
Preferably in the above-described disclosure, the present invention further provides the plasma spray coating method whereby the test specimens are provided with at least one groove on the specimen surface that faces the heat resistant resin coating film.
According to the above, the test specimens are provided with at least one groove on the backside of the specimens, the backside facing the weakly adhesive resin film; thus, there is no apprehension that the test specimens fall off from the resin film, even though the air or the monomer gas included in the resin on the backside of the test specimens expands so as to separate the specimens from the film, as the expanded air or gas is absorbed in the air of the groove space. Or the expanded air or gas is discharged out of the groove in a case where the groove reaches the end side of the specimen so as to be open toward the outside.
According to the present invention as described above, the masking of the surface to be plasma spray-coated of the to-be-manufactured part (the to-be-plasma-sprayed apparatus) is easily performed; further, the conditions as to the plasma spray coating can be established on the premise that the plasma spraying is performed on the surface of the to-be-manufactured part, the test specimens being surely placed on the masking film on the to-be-plasma-sprayed surface of the part (apparatus).
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in greater detail with reference to the preferred embodiments of the invention and the accompanying drawings, wherein:
FIG. 1 shows a part of the bird view as to a transition piece of the gas turbine according to a first embodiment of the present invention, the plasma spray coating being performed on the inner surface of the transition piece;
FIG. 2 shows a part of the outline cross-section as to a neighborhood area of the to-be-plasma-coated surface in establishing the plasma spray conditions;
FIG. 3 shows a flow chart for establishing the plasma spray conditions as well as performing the plasma spray coating as per the established conditions;
FIG. 4(A) shows a side view of a test specimen;
FIG. 4(B) shows an A-A cross-section of FIG. 4(A) .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereafter, the present invention will be described in detail with reference to the embodiments shown in the figures. However, the dimensions, materials, shape, the relative placement and so on of a component described in these embodiments shall not be construed as limiting the scope of the invention thereto, unless especially specific mention is made.
(First Embodiment)
The gas turbine comprises three components: a compressor of at least one stage, a turbine of at least one stage, and a plurality of combustors; wherein, the air compressed by the compressor is supplied to the combustor into which fuel is controllably sprayed so that the combustion of the fuel generates combustion gas of a high pressure and a high temperature; the generated combustion gas is supplied to the turbine of a centrifugal, an axial or radial type so as to rotate the gas turbine. In order to enhance the thermal efficiency of the gas turbine configured as described above, it is preferable to enhance the turbine inlet temperature (the gas inlet temperature) to as high a degree of temperature as possible; the turbine inlet (gas) temperature reaches a level within a temperature range from 1300 to 1500° C. during the operation of an industrial gas turbine.
In the gas turbine, the transition piece that leads the combustion gas in to the turbine is exposed to the high pressure combustion gas of a high temperature from 1300 to 1500° C.; thus, the inner surface of the transition piece is provided with the thermal barrier coating (TBC) to ensure the durability of the transition piece. However, the TBC sometimes falls off in a case where the operation hours of the gas turbine reach certain duration in time. Thus, it becomes necessary to provide the thermal barrier coating again, at regular time intervals or every time when the TBC falls off; in a case where the TBC is performed again, a robot comprising a plasma spray gun is used in order that the coating material is sprayed from the spray gun toward the to-be-coated surface or the whole surface of the to-be-coated part (apparatus) in response to the predetermined plasma spray conditions, while the robot is moved toward a predetermined direction at a predetermined speed. The referred plasma spray conditions depends on the shape and the material of the to-be-coated part, and so on; thus, before performing the spray coating by use of the robot, it becomes necessary to instill (teach) how to spray plasma coating in (to) the robot. It is hereby noted that the term “(robot) teaching” means to teach the robot how to move and work in this specification.
By use of FIG. 3 , how to establish the plasma spraying conditions is now be explained with reference to FIGS. 1 , 2 and 4 .
FIG. 1 shows a part of the bird view as to the transition piece of the gas turbine according to the first embodiment of the present invention, the plasma spray coating being performed on the inner surface of the transition piece.
As shown in FIG. 1 , the transition piece 1 is provided with a large number of fine through-holes 2 (e.g. for cooling the combustion gas flow film or the resin film). A heat-resistant thin coating (resin film) 11 and a test specimen 12 are explained later. In addition, the transition piece 1 is made of a nickel-base alloy.
FIG. 2 shows a part of the outline cross-section as to a neighborhood area of the to-be-plasma-coated surface in establishing the plasma spray conditions; FIG. 3 shows a flow chart for establishing the plasma spray conditions as well as performing the plasma spray coating as per the established conditions.
FIG. 4(A) shows a side view of the test specimen 12 explained later; FIG. 4(B) shows an A-A cross-section of FIG. 4(A) . As shown in FIGS. 4(A) and 4(B) , the test specimen 12 is provided with a groove 12 a of a U-shaped cross section.
The plasma spray coating is performed as per the established plasma spray conditions, after the transition piece 1 is removed from the gas turbine that is in a shutdown state and sufficiently cooled.
In the flow chart of FIG. 3 , the step S 1 denotes the beginning of the processes as to the plasma spray coating; in the next step S 2 , the inner surface of the transition piece 1 is cleaned. In cleaning the surface, no special conditions may be required so long as neither the transition piece 1 is damaged nor the inner surface is deteriorated; a worker may clean the inner surface in the transition piece 1 either by hand or by use of a high-pressure water-jet.
When the step S 2 of cleaning the inner surface is finished, the step 2 is followed by the step S 3 where a liquid ultraviolet curing resin (a liquid resin cured with ultraviolet radiation) is applied to the inner surface of the transition piece 1 with a brush so that the resin forms a film of a thickness from 100 to 200 μm; the ultraviolet curing resin can be commercially available; for example, a resin of the trade name “SpeedMASK” produced by Dymax Corporation can be used as the resin of this kind.
Further, instead of the above-described ultraviolet curing resin, a resin that can form a hardened film from a liquid state may also be used in the step S 3 ; namely, the resin may be cured with dry air, cured with light, or cured with heat. Moreover, the heat resistant material, namely, a heat resistant silicon sealant that can form nonflammable filler made of a material such as mica may be used; thereby, the size regarding the clusters of the heat resistant silicon sealant may be less than the diameter of the fine through-holes.
Incidentally, it is required that the resin cured with ultraviolet radiation be not burnt by the heat during the plasma spraying; the explanation will be given later about the detail as to the plasma splaying.
After the ultraviolet curing resin is applied on the inner surface of the transition piece in the step S 3 , the test specimens 12 are placed on the applied liquid resin (the ultraviolet curing resin) in the step S 4 . In the present embodiment, the material of the test specimens 12 is the same as the material of the transition piece; namely, the material is a nickel-base alloy; and, the size of the specimen 12 is 100 mm in length, 50 mm in width and 1 mm in thickness; further, the specimens are paved on the inner surface of the transition piece 1 with a space of 50 mm between a specimen and the adjacent specimen.
Further, it is required that the area (footprints) and the number of the test specimens 12 placed on the inner surface (the surface of the ultraviolet curing resin applied on the inner side of the transition piece) be arranged so that the plasma spraying conditions can be confirmed over the whole inner surface of the transition piece 1 .
After the test specimens are placed in the step S 4 , the step S 4 is followed by the step S 5 where at least one ultraviolet lamp is located in the inner space of the transition piece 1 and ultraviolet rays are radiated toward the surface of the ultraviolet curing resin applied on the inner side of the transition piece; and, the ultraviolet curing resin is hardened so as to form a heat-resistant (thin coating) film 11 .
With reference to FIG. 2 , the hardening of the ultraviolet curing resin is now explained. Being radiated with the ultraviolet rays, the ultraviolet curing resin is hardened at the area 11 a where the test specimens 12 are not placed. On the other hand, the ultraviolet curing resin is not hardened at the area facing the backside 11 b of the test specimens 12 , as the test specimens made of the nickel-base alloy cutoff the ultraviolet rays. Further, as shown in FIG. 2 , the ultraviolet rays enter the resin that is beneath the test specimens (the area 11 b facing the backside of the specimens) as well as in the neighborhood of the end sides of the test specimens (the area within approximately 2 mm from the end sides); and, the resin which the ultraviolet rays enter is also hardened. Thereby, a plurality of adhesion parts 11 c where the test specimens adhere to the ultraviolet curing resin film 11 is formed along the end sides of the test specimens 12 .
Thus, the heat-resistant (thin coating) film 11 is formed at the area 11 a where the test specimens 12 are not placed; further, the test specimens 12 are bonded (connected) to the inner surface of the transition piece 1 via the adhesion parts 11 c and the heat-resistant (thin coating) film 11 .
The test specimens are placed on the whole areas of the inner surface of the transition piece 1 , namely on the upper area, the lower area and the side area of the inner surface; the test specimens do not fall off, even when the specimens are placed on the upper area or the side area, as there is non-hardened resin on the backside of the specimens and the ultraviolet curing resin (e.g. “SpeedMASK” produced by Dymax Corporation) has adhesion properties, though weak.
In a case where fluid resin capable of forming hardened coating film other than the ultraviolet curing resin is used, the hardened film is formed in this step S 5 .
After the heat-resistant (thin coating) film 11 is formed by radiating ultraviolet rays in the inner side of the transition piece 5 in the step S 5 , the step S 5 is followed by the step S 6 where the robot teaching is performed toward a robot (not shown) equipped with a thermal spraying gun 21 ; further, in the step S 6 , the trial plasma spray coating is performed under the robot teaching conditions (i.e. the conditions that is instilled in the robot) like the production plasma spray coating is performed. More concretely in this embodiment, an under-coating layer made of a CoNiCrAlY alloy is formed throughout the whole inner surface of the transition piece 1 , by a plasma spraying in which the plasma spraying temperature does not exceed 300° C., after an abrasive blasting (process) is performed on the inner surface. Further, a top-coating layer of a 500 to 700 μm thickness made of ZrO 2 and 8Y 2 O 3 is formed over the whole inner surface of the transition piece 1 , by a plasma spraying in which the plasma spraying temperature does not exceed 300° C. During the plasma spraying process, the distance between the thermal spraying gun 21 and the test specimen is to be approximately 100 mm.
There is an apprehension that the air or the monomer gas included in the resin on the backside 11 b of the test specimens 12 expands because of the heat by plasma-spraying and the expanded air or gas makes the test specimen fall off from the resin film; thus, the test specimen 12 is provided with at least one groove 12 a of a U-shaped cross-section as depicted in FIGS. 4(A) and 4(B) , so that the expanded air or gas can be discharged outside. In this way, the apprehension regarding the separation of the specimen 12 is eliminated.
Moreover, as depicted in FIG. 2 , the fine through-holes 2 are filled with the ultraviolet curing resin; therefore, there is no apprehension that the fine holes are clogged with the alloy materials or the metals (slug) during the under-coating treatment or the abrasive blasting process.
After the trial plasma spray coating is performed in the step S 6 , the step S 6 is followed by the step 7 where the test specimens 12 are peeled off, and the transition piece 1 and the plasma spray state (the plasma sprayed results) on the specimens 12 is examined. Since the specimens are bonded to the inner surface of the transition piece 1 by the week adhesion properties of the ultraviolet curing resin via the heat-resistant thin coating film 11 on the backside of the specimens, the test specimens 12 can be peeled off by hand. In examining the test specimens 12 , it is checked whether or not the plasma spray condition at each location on the inner surface of the transition piece is satisfactory in view of the plasma coating requirements (or predetermined specifications).
After the examination has been performed in the step S 7 , the step S 7 is followed by the step S 8 where it is decided whether the process returns back to the step S 3 via the step S 9 or goes to the step S 10 . If the examination result is not satisfactory, the step S 8 is followed by the step S 9 where the ultraviolet curing resin on the inner surface of the transition piece 1 is removed. Further, the plasma spraying conditions are changed (adjusted) and the process returns back to the step S 3 from the step S 9 ; namely, the process loop passing the steps S 3 , S 8 , and S 9 is repeated till the examination result is judged to be satisfactory in the step S 8 and proper plasma spraying conditions are established.
If the examination result is satisfactory in the step S 8 , the step S 8 is followed by the step S 10 where the ultraviolet curing resin is removed. Further, the plasma spraying conditions for the robot teaching is established as per the conditions which are (finally) used in the step S 6 . Then, in the following step S 11 , the production plasma spray coating for the inner surface of the transition piece 1 is performed according to the established plasma spraying conditions (instilled in the robot). After the step S 11 , the plasma spraying procedure finishes in the step S 12 .
In addition, it is most advantageous to remove the ultraviolet curing resin by hand or by use of a spatula in the steps S 9 and S 10 . In a case where the ultraviolet curing resin cannot be sufficiently removed, the resin may be removed by burning the resin or by dissolving the resin with a suitable solvent. Further, in a case where the resin can be easily taken off from the metal surface after being hardened, the resin may be removed by hand.
Further, in the step S 11 , the fine through-holes that are (if any) not clogged by the suitable clogging materials are filled with the resin; then, the plasma spraying is performed under the condition that the whole fine holes are filled with the resin or the suitable clogging materials. Since the transition piece is placed into an active combustion test after the production plasma spray coating is completed and the resin or the suitable clogging materials are burnt off, there is no apprehension that the resin or the suitable clogging materials remain in some of the fine through-holes. In other words, there is no apprehension that the diameters of the fine holes decrease because of the plasma spraying material adhesion, as the resin or the suitable clogging materials left in the fine holes hinder the plasma spraying material from entering the fine holes; and the resin or the suitable clogging materials are burnt off due to the high temperature of the combustion gas.
According to the above-described embodiment, the coating film of the ultraviolet curing resin can be easily formed on the metal surface at the inner side of the transition piece that is the to-be-plasma-sprayed subject; moreover, the plasma spray coating can be performed on the inner surface of the transition piece, under predetermined plasma spraying conditions.
Industrial Applicability
According to the present invention, a plasma spray coating method for forming a plasma spray coating film on the surface of the part (member) of an industrial products can be provided whereby the masking of the surface to be plasma spray-coated of the to-be-manufactured part is easily performed, and the conditions as to the plasma spray coating can be established on the premise that the plasma spraying is performed on the surface of the test specimens surely placed on the masking film on the to-be-plasma-sprayed surface of the part.
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A thermal spraying method includes forming a coating layer of heat resistant resin on the whole spray area of the metal surface, securely fixing a test piece of the same material as that of the metal as a constituent of heat resistant equipment on the surface of the coating layer, spraying a heat shield coating material onto the test piece, detaching the test piece from the surface of the coating layer, inspecting the condition of spray and setting spray conditions, removing the coating layer and, under the above set spray conditions, spraying the heat shield coating material onto the metal surface to thereby form a heat shield coating layer.
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FIELD OF THE DISCLOSURE
The present disclosure generally pertains to restraining a vehicle at a loading dock and more specifically to a wheel chock system.
BACKGROUND OF RELATED ART
When a truck, trailer or some other vehicle is parked at a loading dock, often some sort of vehicle restraint is used to keep the truck from inadvertently moving away from an elevated platform of the dock. This allows a forklift truck to safely drive between the dock platform and the truck for the purpose of loading or unloading the cargo inside the truck.
There are a variety of vehicle restraints available that can be installed at a loading dock for engaging the truck's RIG (Rear Impact Guard), also known as an ICC bar. An ICC bar is a beam that extends horizontally across the rear of a truck, just below the truck bed. Its primary purpose is to prevent an automobile from under-riding the truck in a rear-end collision. However, not all trucks have an ICC bar that can be readily engaged by an ICC-style restraint. Moreover, ICC bars are not prevalent outside the United States, so in those cases a wheel restraint can be used for blocking one or more of the truck's wheels.
Perhaps the most common wheel restraint is simply a wheel chock that wedges between the driveway and the underside of the wheel. However, wheel chocks often slip out of position on driveways that are slippery due to oil, rain, ice, sand, gravel or dirt. Moreover, wheel chocks usually are loose items that do not permanently attach to the loading dock area, so they often get misplaced.
One solution to these problems is disclosed in U.S. Pat. No. 7,032,720, which shows a wheel chock that is coupled to the loading dock by way of an articulated arm. To help prevent the chock from slipping out of its wheel-blocking position, the chock can be placed in mating engagement upon a serrated base plate that is anchored to the driveway. Although such a system can be effective, it does have some drawbacks.
First, a counterweight spring on the arm tends to prevent the wheel chock from resting its full weight upon the base plate. Second, the length to which the arm must extend to reach the wheel can adversely affect the angular relationship (about a vertical axis) between the mating surfaces of the chock and base plate. Third, although the '720 device includes a sensor for detecting the presence of a wheel, the sensor does not indicate whether the chock is fully engaged with the serrations of the base plate. And fourth, dirt, ice and other contaminants could hinder the engagement between the chock and the base plate, thus reducing the effectiveness of the chock.
Consequently, a need exists for a wheel chock system that overcomes the limitations and drawbacks of current systems.
SUMMARY
In some embodiments, a wheel chock for restraining a vehicle at a loading dock is supported by a spring loaded articulated arm, wherein the spring force can be released.
In some embodiments, a wheel chock is supported by an articulated arm that includes a pivotal joint where the arm connects to the chock, wherein the joint permits the chock to rotate relative to the arm about a vertical axis.
In some embodiments, a wheel chock includes a sensor that detects whether the chock is fully engaged with a lower support surface.
In some embodiments, a manually manipulated wheel chock is coupled to a hydraulic cylinder that can forcibly draw the chock against a vehicle's wheel.
In some embodiments, a wheel chock can be manually placed upon a mating base plate, and a hydraulic cylinder can move the plate to force the chock against a vehicle's wheel.
In some embodiments, a set of hooks or latches selectively engage and release a wheel chock from a lower support surface that is anchored to the ground. In some embodiments, a manually operated wheel chock includes a cleaning system that inhibits debris, ice and other contaminants from accumulating on a surface upon which the chock is placed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view a wheel restraint in a holding position.
FIG. 2 is a perspective view of the wheel restraint of FIG. 1 but showing the restraint in a release position.
FIG. 3 is a perspective view of a wheel chock being lowered upon a mating base.
FIG. 4 is an end view looking toward the dock face and showing a wheel chock being lowered upon a base.
FIG. 5 is a perspective view similar to FIG. 1 but showing another embodiment.
FIG. 6 is a side view of a wheel chock in a release position.
FIG. 7 is a side view similar to FIG. 6 but showing the chock in a holding position.
FIG. 8 is an end view similar to FIG. 4 but showing another embodiment.
FIG. 9 is a side view similar to FIG. 7 but showing the wheel chock of FIG. 8 .
FIG. 10 is a top view of a cleaning system for the base of a wheel restraint system.
FIG. 11 is a top view similar to FIG. 10 but showing a brush sweeping across the base.
FIG. 12 is a top view similar to FIGS. 10 and 11 but showing the wheel restraint system in a holding position.
FIG. 13 is a top view similar to FIG. 10 but showing an alternate embodiment of a cleaning system.
FIG. 14 is a top view similar to FIG. 13 but showing yet another embodiment.
FIG. 15 is a top view similar to FIG. 14 but showing the wheel restraint system in a holding position.
DETAILED DESCRIPTION
FIGS. 1 and 2 show a wheel restraint system 10 for restraining at least one wheel 12 of a vehicle 14 at a loading dock 16 . Restraint 10 is shown in a holding position in FIG. 1 and is shown in a release position in FIG. 2 . In the holding position, restraint 10 helps hold vehicle 14 adjacent to a dock face 18 so that cargo can be safely conveyed on and off of vehicle 14 . In some cases, a conventional dock leveler 20 can be used to facilitate the loading and unloading operations. An upper section of vehicle 14 is shown in phantom lines to more clearly show the subject invention.
Wheel restraint 10 includes a wheel chock 22 that may, for example, rest upon a base 24 (lower support surface) when restraint 10 is in the holding position of FIG. 1 . To limit the wheel chock's horizontal movement (particularly in a forward direction away from dock face 18 ) base 24 and/or chock 22 may include an interlocking feature such as a tooth 26 or 28 that engages a mating feature in the opposing surface, as shown in FIGS. 3 and 4 . The various shapes, sizes, quantities and positions of tooth 26 and 28 are too numerous to mention, and it will be appreciated by those of ordinary skill in the art that the number of possible designs is unlimited.
To assist the repositioning of chock 22 between the holding and release positions, an elevated articulated arm 30 couples chock 22 to an anchor 32 that is attached to dock 16 . Various joints of arm 30 , anchor 32 and/or chock 22 enable chock 22 to be moved in three-dimensional space. To ensure that chock 22 can rest flat upon base 24 , a joint 34 coupling arm 30 to chock 22 , as shown in FIG. 4 , permits chock 22 to rotate about a substantially horizontal axis 36 that is substantially parallel to dock face 18 . To ensure the horizontal footprint of chock 22 can lie square to base 24 regardless of the chock's distance from dock face 18 , joint 34 also allows chock 22 to rotate about a second axis 38 that is perpendicular to or at least traverses an imaginary horizontal plane 40 . Joint 34 could be any multi-axis joint including, but not limited to, a universal ball joint.
To further assist the manual repositioning of chock 22 , a spring 42 coupled to arm 30 helps offset the weight of chock 22 and arm 30 . Counteracting the weight of arm 30 and chock 22 can be helpful while positioning chock 22 ; however, counteracting that weight is not always desired. The weight of arm 30 and chock 22 , for instance, can actually be useful in holding chock 22 solidly against base 24 . Thus, a spring release device 44 might be added so that spring 42 can be selectively stressed ( FIG. 2 ) and released ( FIG. 1 ). In the relaxed position of FIG. 1 , the stress in spring 42 is reduced but does not necessarily have to be reduced to zero. In some examples, device 44 is a lever that can be toggled over center by rotating the lever about a pivot point 46 . To limit the rotation of the lever, an end stop 48 on device 44 engages arm 30 .
When chock 22 is in the holding position of FIG. 1 , a sensor 50 mounted to chock 22 can be used determine whether chock 22 is actually fully engaged with base 24 . Sensor 50 can be any device that can provide a signal 52 in response to proper engagement between chock 22 and base 24 . Examples of sensor 50 include, but are not limited to, a proximity switch (e.g., Hall effect sensor), electromechanical switch, photoelectric eye, etc. Signal 52 can be transmitted via wires through arm 30 or can be transmitted wirelessly to control one or more signal lights 54 .
FIG. 5 shows another example wherein a hydraulic cylinder 56 (hydraulic arm) replaces articulated arm 30 . By controlling or stopping the flow of hydraulic fluid using conventional techniques, cylinder 56 can help hold wheel chock 22 at its holding position, as shown in FIG. 5 . An anchor 58 with a pivotal joint 60 allows repositioning of cylinder 56 and chock 22 . Similar to spring 42 of wheel restraint 10 , a spring 62 can be used to help offset the weight of cylinder 56 and chock 22 .
FIGS. 6 and 7 show a wheel chock 64 and a sliding base 66 with an alternate tooth design. This wheel restraint system includes a linear actuator 68 (e.g., a hydraulic cylinder, lead screw, etc.) that is held in place by an anchor 70 fixed to the loading dock. Actuator 68 can draw chock 64 tightly up against wheel 12 by pulling base 66 towards dock face 18 , as indicated by arrow 72 . To release wheel 12 , actuator 68 extends to push base 66 and chock 64 away from dock face 18 . Once chock 64 is no longer tightly up against wheel 12 , chock 64 can be manually lifted from base 66 . The mechanism for maintaining the chock in position shown in FIGS. 6 and 7 could be used with a manual chock, or one connected to a mechanism for facilitating chock placement such as that shown in FIGS. 1 and 2 . The same holds true for the remaining examples or concepts described herein.
FIGS. 8 and 9 show a wheel chock 72 resting upon a stationary base 74 . To limit the chock's movement away from dock face 18 , one or more hooks or latches 76 are pivotally connected to chock 72 or base 74 . For the illustrated example, a hinge 78 connects each latch 76 to base 74 such that selected latches 76 can be pivoted upward to limit the movement of chock 72 . Although it is generally more important to limit the chock's movement away from dock face 18 , latches 76 and their mounting configuration to base 74 or chock 72 could be such that latches 76 restrict the chock's movement in other directions as well.
FIGS. 10 , 11 and 12 show a wheel chock system 80 that includes a cleaning system 82 for inhibiting contaminants, such as dirt and ice, from accumulating on a base 84 . To prevent ice from accumulating, a heating element 86 , such as electrical resistive wire or some other heat-generating source, is installed in proximity (i.e., in heat exchange relationship) with base 84 .
A brush 88 mounted to a movable arm 90 can be used to sweep dirt from base 84 . One end 92 of arm 90 is pivotally coupled to an anchor 94 . An opposite end 96 of arm 90 provides a cam surface 98 against which wheel 12 can push so that as a vehicle backs into the loading dock, the engagement of wheel 12 against cam surface 98 forces brush 88 to sweep across base 84 . When the vehicle departs, a spring 100 can be used to pull arm 90 back to its position of FIG. 10 . Alternatively, arm 90 could be power actuated. A linearly movable brush is also well within the scope of the invention.
FIG. 13 shows an alternative cleaning system 102 that includes one or more nozzles 104 that discharges a fluid 106 (e.g., air, water or an ice-thawing liquid) to clear contaminants from a base 108 or some other lower support surface. Fluid discharge can be triggered manually, or it can be triggered automatically in response to a timer or a sensor responsive to a vehicle or the presence of a contaminant.
FIGS. 14 and 15 show a cleaning system 110 wherein one or more covers 112 help shelter unused portions of base 108 . For the illustrated example, covers 112 are moved manually by simply lifting the covers on or off of base 108 . Alternatively, covers 112 can be hinged to base 108 so that covers 112 can be pivoted on and off.
Although the invention is described with respect to various examples, modifications thereto will be apparent to those of ordinary skill in the art. Many of the wheel restraint features disclosed herein are interchangeable among the various examples. The scope of the invention, therefore, is to be determined by reference to the following claims:
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A wheel restraint for restraining a vehicle at a loading dock includes various features such as, a wheel chock supported by a spring loaded articulated arm with a spring that can be selectively tightened or released, a sensor that detects whether the chock is solidly against a base plate or floor, a bi-directional pivotal joint between the articulated arm and the wheel chock to ensure that the chock can sit squarely on a mating base plate, a wheel chock that meshes with a hydraulically actuated base plate, pivotal or otherwise movable backstops that prevent a wheel chock from sliding out of position, and a base plate cleaning system. The cleaning system might include a vehicle-actuated brush, fluid spray nozzles, electric heater and removable cover plates.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application No. 61/278,043 filed on Oct. 2, 2009, incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention concerns induction hardening which is widely used in industry to harden such parts as cam shafts, crank shafts, etc. In this process an inductor surrounds a section of the part, and a high frequency voltage is applied to the inductor. This induces a current in the surface of the part (to a variable depth set by design), rapidly heating the same to a desired temperature. A flow of quenching coolant is then directed at the part, thereby hardening the surface of the part to the hardness and depth desired.
[0003] In the conventional arrangement, the inductor (typically a single turn coil) is constructed in two halves in order to allow positioning of the part within the coil by a clam shell opening of the inductor closed around the part when the ends of each half are pivoted together. The coil halves can also be separated by linear motion and then brought together to surround the part. In this arrangement it is necessary to make an electrical connection between the inductor half coil ends in order to complete the circuit and cause current to flow through both coil halves.
[0004] Power from a high frequency power source is applied to the inductor to cause a high frequency current to flow through the connected inductor coil halves.
[0005] Such electrical connections must be made with care to insure a proper flow of power through the complete inductor coil, slowing the process of loading the part. Such connections are subject to wear and present a maintenance burden in this application. This requirement makes automation of part loading somewhat impractical.
[0006] Another problem often encountered is the formation of gaps in the electric field induced around the inductor which would create unevenness in the hardening obtained in the part, necessitating rotation of the part in the inductor coil in order to prevent this, complicating the equipment needed and slowing the completion of the hardening part heating cycle.
[0007] It is an object of the present invention to provide an arrangement and method of powering an inductor formed of two half coils which does not require the making and breaking of an electrical connection between the two inductor half coils.
[0008] It is a further object of the invention to provide such arrangement and method which does not create gaps in the electrical field created by the inductor coil to and thereby not require any rotation of the part during the induction hardening process.
SUMMARY OF THE INVENTION
[0009] The above recited objects and other objects which will be understood upon a reading of the following specification and claims are achieved by an inductive coupling in common simultaneously to both inductor coil half sections of a two part inductor coil allowing separation to position a part therein, inducing a high frequency voltage in each inductor coil half section, while not requiring a direct electrical connection between the inductor coil half sections. This is accomplished by applying the power to primary conductor loop which is positioned between respective secondary conductor loops connected to the respective inductor coil half sections below these half coil sections.
[0010] Thus, the necessity for an electrical connection between the inductor coil half sections is eliminated and the sections can be quickly moved apart and back again together for loading and unloading of the part or for shifting the part to bring another area of the part into the inductor coil. This feature facilitates automation of the process and allows simultaneous treatment of many or all of the areas of work pieces such as cam shafts and crank shafts by a plurality of inductor coils to greatly speed the cycle times.
[0011] In addition, it has been found that no gaps in the induced electrical currents result such that the part need not be rotated, further simplifying the equipment necessary.
DESCRIPTION OF THE DRAWING FIGURES
[0012] FIG. 1 is a partially exploded end view of an induction hardening arrangement with a diagrammatic depiction of a primary power source.
[0013] FIG. 2 is a side view of the arrangement shown in FIG. 1 in the operative position of the main components.
[0014] FIG. 2A is a pictorial end view of the components shown in FIG. 2 .
[0015] FIG. 3A is a separated view of the inductor coils and primary loop components included in the arrangement shown in FIG. 1 .
[0016] FIG. 3B is a pictorial view of the components shown in FIG. 3 .
[0017] FIG. 4 is an enlarged pictorial view of the primary loop component shown in FIGS. 3 and 3A .
[0018] FIG. 5 is a side view of the components of FIGS. 3 and 3A in the position assumed during induction heating of a part.
[0019] FIG. 6 is an end view of the components shown in FIG. 5 .
DETAILED DESCRIPTION
[0020] In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.
[0021] Referring to the drawings and in particular FIG. 1 , an arrangement 10 according to the invention includes a pair of inductor half coils 12 A, 12 B, each held in recesses in a respective cooling block 14 A, 14 B in the manner well known in the art.
[0022] During use, coolant is directed under pressure into inlets 16 A, 16 B which passes into an array of radial internal passages 18 A, 18 B which open into the semicircular recesses 20 A, 20 B adjacent spaced apart partially circular segments 22 A, 22 B to quench the part 24 after induction heating to create a case in the well known manner. The inner coil sections 22 A, 22 B are spaced apart to allow the entrance of quenching coolant via passages 18 A, 18 B.
[0023] The inductor coil half sections 12 A, 12 B also include outer partially circular segments 24 A, 24 B more widely spaced apart to accommodate the passages 18 A, 18 B respectively.
[0024] The segments 22 A, 22 B are formed of copper and partially circularly shaped to encircle the part 25 when brought into a position next to each other as seen in FIG. 2A and 6 . The configuration will vary to match any particular shape and area size of the part 25 as known in the art.
[0025] The lower ends of each of the segments 22 A are integral with a conductive connector leg 26 A, 26 B descending to a connection with one side of a pair of generally square secondary inductor loops 28 A, 28 B which are split at 30 A, 30 B with insulator strips 31 A, 31 B inserted therein to preclude any electrical contact or arcing between the two ends thereof. An insulator strip 32 is also adhered to one leg 26 A to insulate the two legs 26 A, 26 B when brought together during induction heating of a part 25 .
[0026] The outer return segments 24 A, 24 B are connected at their lower ends to conductor legs 34 A, 34 B joined to the inductor loops 28 A, 28 B at the other side of splits 30 A, 30 B from the side connected to legs 26 A, 26 B.
[0027] The upper ends of segments 22 A, 22 B, 24 A, 24 B are connected together by joining pieces 36 A, 36 B, with in insulator strip 38 adhered to upper straight ends of the inner coil segments 22 A to prevent any contact or arcing. Insulator strips 40 A, 40 B are interposed between legs 26 A, 34 A and 26 B, 34 B for the same purpose.
[0028] Each side of each inductor loop 28 A, 28 B has secured thereto a flux concentrator lamination 42 A, 42 B using a thin iron or FLUXTROL™ laminations of a thickness (such as 0.003 inches) suited to the particular part hardening application in the manner well known in the art.
[0029] Each secondary inductor loop 28 A, 28 B has coolant inlets and outlets 44 A, 44 B to allow circulation of coolant in hollows therein (not shown).
[0030] Both of the secondary inductor loops 28 A, 28 B are aligned with a single primary inductor loop 46 split at 48 with in interposed insulator strip 50 . The primary loop 46 has an insulator coating (typically 0.015 to 0.020 inches thick) as of nylon applied in a dip process which is durable to withstand wear. Each side is integral with a connector leg 52 A, 52 B joined to a respective terminal bar 54 A, 54 B in turn connected to a primary AC power source 60 such as to apply 30 Khz thereto as shown diagrammatically.
[0031] The terminal bars 54 A, 54 B have coolant entry/exit ports 56 A, 56 B allowing circulation of coolant through passages in the terminal blocks 54 A, 54 B and loop 46 . An insulator strip 58 interposed between the terminal blocks 54 A, 54 B to prevent contact or arcing.
[0032] Accordingly, a single primary loop inductively powers two electrically isolated coils without any electrical connection between the two coils. All that is required is that they be moved in to be immediately adjacent a respective side of the primary loop 46 .
[0033] Additional turns could be provided of the primary loop 46 , as necessary to achieve a desired power level but a one-to-one equal area of the primary loop 46 and secondary loops 28 A, 28 B has successfully been operated as described.
[0034] The two assemblies 12 A, 12 B can be mounted for linear in and out movement to capture a part section which allows axial movement of the part to locate a different area for hardening between the coil sections or pivoted to allow a clam shell opening motion. Multiple coil section units can be used to simultaneously harden multiple sections of a part simultaneously. Turn table arrangements can also be used to bring variously configured inductor section pairs together for different sections of the part.
[0035] It has been found that by inductively powering two electrically isolated coil halves y the arrangement shown, dead spots are avoided so that rotation of the part is not necessary.
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An arrangement for induction hardening a part including a pair of separate inductors electrically isolated from each other and configured to substantially surround a part when brought into close juxtaposition with each other. The inductor sections are powered by respective secondary inductor loops brought into close juxtaposition with a primary inductor loop connected to an ac power source which induces an ac current in each inductor section.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a division of application Ser. No. 507,792, filed Sept. 20, 1974 now U.S. Pat. No. 3,951,282; which is, in turn a division of application Ser. No. 409,297, filed Oct. 24, 1973, and now abandoned.
BACKGROUND OF THE INVENTION
In the processing of naturally occurring fibers, such as cotton, it is the usual practice to mix fibers from a plurality of bales to improve uniformity. Commonly, this is done by removing segments from a plurality of bales and dumping these segments into the hopper of a fiber feeder.
If this operation is performed by hand, it is extremely laborious, hot and dirty work. Thus, several attempts have been made in the prior art to mechanize this operation. Exemplary of such attempts are U.S. Pat. No. 3,577,599 to Golddammer, entitled "Apparatus for Mixing Fibrous components." The Goldammer patent discloses a wheeled fiber plucking mechanism movable between a row of bales arranged behind bale openers. The fiber plucking mechanism in the Goldammer patent is selectively engageable with successive bales for the purpose of plucking quantity of fibers therefrom. Movement of the Goldammer fiber plucker is limited to travel in the space between rows of bales and behind the group of openers.
An improved apparatus permitting removal of fibers from a greater number of bales, and thus permitting greater uniformity of mixing, is disclosed in application Ser. No. 275,942, filed July 28, 1972, by Alex J. Keller, now U.S. Pat. No. 3,777,908. Basically, the mechanical hopper feeder apparatus disclosed in the Keller application comprises a fiber plucker having a vertically extendable pickup head. The fiber plucker is supported by and movable along a first pair of horizontal overhead tracks which are, in turn, supported at their ends upon a second pair of horizontal overhead tracks positioned tranversely with respect to the first pair of tracts. Thus, by movement of the fiber plucker along the first pair of tracks and movement of the first pair of tracks along the second pair of tracks, the fiber plucker is positionable at any point within a rectangular area defined by the spacing of overhead tracks. In operation, the fiber plucker can be moved over any one of a large number, e.g. 40 or so, bales within the processing area to remove a mass of fibers therefrom and then transport the fibers to the hopper of one of several fiber feeding machines positioned alongside the bale area.
In employing a mechanical means such as described, for example, in the aforesaid Keller application, it is of critical importance that the fiber bales be precisely locted within plus or minus 3 inches in either direction at predetermined locations in order that the pickup head will descend into the central portion of the bale during fiber plucking. Such positioning is of particular importance when the fiber plucker has been electrically programmed to move from one location to another in accordance with a predetermined program, or limit switches or cams associated with the apparatus. To date, this placement has required careful location of the bales by hand within the processing area or careful spacing and positioning of the bales upon a conveyor which then transports the bales into the processing area.
Summary of the Invention
The present invention relates to a bale handling system for use in conjunction with mechanical fiber plucking apparatus, and in particular relates to a system for readily and accurately positioning fiber bales at predetermined locations within a bale assembly area. While the preferred embodiment of the invention will be described in relation to an apparatus of the type disclosed in the aforesaid Keller application, it will be understood that the particular embodiment may be readily adapted to be used in conjunction with similar or other types of apparatus.
In accordance with the present invention, bales of fibers to be processed are placed upon bale supporting means which are then moved along guide means or guide ways into the bale assembly area.
It is an object of the present invention to provide a system for uniformly positioning fiber bales within the bale assembly area of a mechanical fiber plucker.
It is another object to provide a fiber bale handling and positioning apparatus comprised of a plurality of parallel tracks and a plurality of bale supporting means movable upon and guided by said tracks.
It is yet another object of the invention to provide a fiber plucking apparatus comprised of a mechanical fiber plucker movable to predetermined positions over a bale assembly area and means for moving bales to predetermined locations within said area.
Other objects of the present invention, if not specifically set forth herein, will be obvious to the skilled artisan upon a reading of the detailed description of the invention which follows, particularly when taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a bale assembly area and its associated apparatus, with parts broken away.
FIG. 2 is a perspective view with parts broken away, of one embodiment for moving bales within the bale assembly area.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In general, the present apparatus comprises a plurality of parallel guide ways, or guide means, extending across the bale area of a mechanical fiber plucking apparatus and plurality of bale supporting means adapted to move along, and be guided by, said track ways. In the following description, the apparatus is described in conjunction with the fiber plucker apparatus claimed in the aforementioned Keller application. It is to be undertood however that the present apparatus may also be suitably employed as part of the other systems.
Referring now to the illustrated embodiment, a first set of trackways comprising a track 10 and a track 11 are suitably supported or suspended about 8 or 12 feet above the floor F of a fiber processing plant. In the illustrated embodiment, the tracks 10 and 11 are supported by posts 12 and 13 at the ends of track 10 and by posts 14 and 15 at the ends of track 11. Track 10 is supported above and extends across a group of fiber feeding machines sometimes called bale breakers, two of which are shown and identified by the reference numerals 16a and 16b. There may be any number of bale breakers served by the fiber plucker apparatus, six breakers being an average number. Only two are shown here for purposes of illustration. Each of the openers may be like that shown and described in the Lytton U.S. Pat. No. 3,132,709 or of any other suitable construction. Each opener includes a hopper 17 into which fibers are deposited for processing within the opener and thereafter delivered to a conveyor 20 extending transversely along the row of openers. The conveyor 20 comprises an endless belt which transports fibers from the openers to a pneumatic conveyor not shown, which transports the fibers to a carding machine or the like.
The track 10 is supported above the group of breakers and extends transversely of the path of the fibers through the breakers. Track 11 is supported in the same horizontal plane as track 10 but spaced rearwardly therefrom a sufficient distance to define an assembly area wherein fiber bales B are located. A distance of about 25 feet has been found sufficient for this purpose. Each of the breakers is about 3 feet in width and if the track 10 overlies six breakers, the tracks 10 and 11 may, therefore, be conveniently about 40 feet long.
A plurality of bales B of fibers, such as cotton, are arranged in the assembly area behind the breakers and between the tracks 10 and 11, by means to be hereinafter described in detail. The bales are of rectangular configuration and may be arranged on the floor in any desired predetermined pattern, but as illustrated are arranged with two longitudinal rows behind each breaker with the longest dimension of the bales extending longitudinally of its row. This arrangement has been found advantageous in conserving floor space and thereby permitting a large number of bales to be assembled within the assembly area between and beneath the tracks 10 and 11.
If desired, all of the bales in a row behind a given breaker, such as the breaker 16a, may contain a fiber of a given kind which is different from the fibers in the remaining bales in the assembly area. Similarly, the bales behind another breaker, such as 16b, may contain fibers different from the fibers in the rest of the bales in the processing area. Alternatively, any bale or bales behind the hoppers and within the assembly area may contain fiber which is different from the fiber in other bales within the assembly area. Still another alternative would be for all of the bales in the processing area to contain the same kind of fiber. The point is that the bales within the assembly area may or may not contain different fibers and bales with fibers different from the fibers in other bales may be arranged in any desired pattern. The invention is equally applicable to all arrangements of bales containing the same or different kinds of fibers. Any desired mixing of fibers is accomplished after the fibers are deposited in the hoppers, the only function of the hopper feeder being to deliver fibers to the hoppers -- not to mix them.
Extending between the tracks 10 and 11 is a wheeled frame broadly indicated at 21 and including a rectangularly shaped longitudinally extending carriage 22 having wheels 23 journalled at the ends thereof and rotatably mounted for reciprocal movement along the tracks 10 and 11. The frame 21 supports a pair of transversely space longitudinally extending tracks 24, upon which is mounted for reciprocal movement therealong a wheeled carriage broadly indicated at 25.
The carriage 25 supports a fiber plucker or tongs broadly indicated at 26 and comprising a vertically reciprocable support shaft 27 and a pair of cooperating tongs or prongs 30 operatively connected to the lower end of the support shaft 27. The prongs 30 are selectively movable toward and away from each other to close upon a quantity of fibers in a bale within the assembly area and to release the fibers plucked fromthe bale into one of hoppers 17.
The sequence of operations may be controlled through a control circuit including a manually operated or computer operated console operatively connected to the electric, hydraulic, or air motors energizing the movement of the carriage 22 along tracks 10 and 11, carriage 25 along tracks 24, and the raising and lowering the support shaft 27 and the opening and closing of the tongs 30. The console may also include appropriate programming for sensing the volume of fibers within each of the hoppers 17, and be responsive to a volume less than a predetermined minimum to cause the fiber plucker to move an appropriate kind of fiber from one of the bales in the assembly area to the hopper requiring replenishment.
The apparatus for positioning bales with the assembly area at predetermined locations is comprised of a plurality of guide means, shown generally at 33A, 33B, 33C, 33D . . . . Each guide means is comprised of a pair of spaced parallel angle irons 34, each angle iron 34 having a horizontal outwardly extending foot 35 and an upright portion 36; the angle irons or rails forming each guide means being spaced a first given dimension transversely of the path of movement of bales along the guide means. At spaced positions along alternate angle irons 34 are hinged arms 37 secured to each alternate as by hinge 38 and adapted to be moved from an inoperative vertical position as shown at 37A in FIG. 2 to a horizontal operative position extending between proximate rails 34. Arms 37 are spaced longitudinally of the path of movement of bales along the guide means a second given dimension. The angle irons and hinged arms are positioned such that the first and second dimensions define the limits of a predetermined zone within the assembly area for the positioning of successive bales B.
Bales B are supported upon movable support means, which comprises a pallet 42 having an upper surface with dimensions approximating those of bale B. Pallet 42 is supported upon a plurality of wheels 43 or casters. Spacers 44 are secured on each side of pallet 42. In the preferred embodiment, spacers 44 comprise laterally projecting tubular members which are welded to the sides of pallet 42. Removable side walls 45 are insertable between spacers 44 and the sides of the pallet members to hold bale B on pallet 42. The dimensions of the pallets 42 is such that the dimension across the pallet from the outer edge of opposed spacers 44 slightly less than the space between the angle irons 34 forming the guide means, so that the pallets may be rolled between proximal angle irons 34. The longitudinal dimension of pallet 42 is slightly less than the distance between adjacent hinged arms or spacer bars 37, so that when two bars are positioned across proximal angle irons 34 such as guide means 33A, pallet 42 therebetween will be precisely located in a predetermined position within the assembly area for access by the fiber plucker 30, which may be programmed to stop only at designated points within the assembly area. Once properly positioned the pallet 42 will be prevented from longitudinal or transverse movement.
In operation, a bale B is positioned onto a first pallet 42 and wheeled between proximal angle irons 34, such as guide means 33A until it rest against a first arm 37 adjacent the hopper 17. The next successive or second arm 37 is then moved from its vertical inoperative position across the angle irons and behind pallet 42 to precisely position the first pallet and form a forward stop for the next succeeding pallet. The next pallet 42 and its bale between the angle irons 36 defining guide means 33A and brought into contact with the second arm. A third arm is then brought in position behind the bale support means and the sequence of steps is continued until the desired number of bales is positioned along the guideway. A similar sequence of events is carried out along each guide means until the desired number of bales have been positioned within the processing area.
It is to be understood that the essence of the present invention is an apparatus for positioning bales of fibrous material within an assembly area at predetermined locations which comprises a plurality of bale support means which are adapted to travel along a plurality of parallel guideways to predetermined positions within the assembly area. For example, the objects of the present invention may be accomplished by a plurality of parallel grooves within the floor of the processing area, and bale support means having pins projecting downwardly therefrom for engagement with the groove. It is also within the spirit of the invention to eliminate the hinged arms 37 and use a fixed stop adjacent the hoppers to locate the first pallets in each guide means. The rest of the pallets will be positioned against the first pallets in each row and against each other and properly dimensioned to precisely position their respective bales at predetermined points in the assembly area.
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A system is provided for accurately positioning bales of fibrous material in relation to a mechanical means for transporting fibers from said bales to the hoppers of fiber feeders.
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CLAIM OF PRIORITY
[0001] The present application claims the benefit as a continuation of U.S. application Ser. No. 12/965,355 filed Dec. 10, 2010 which claims the benefit and foreign priority under 35 U.S.C. 119 from Great Britain patent application No. GB 0921668.0, filed Dec. 10, 2009. The entire contents of the aforementioned applications are hereby incorporated by reference as if fully set forth herein.
FIELD
[0002] This invention relates to enhancing the performance of media traffic over the Internet Protocol. It is particularly suitable, but by no means limited, to implementation as a realtime transport protocol (RTP) performance enhancing proxy for an IP (internet protocol) router carrying VoIP (Voice over IP) traffic.
BACKGROUND
[0003] Within the digital network systems of today, and in particular the often congested telephony infrastructure of the public switched telephone network (PSTN), it is becoming increasingly popular to route voice communications over the internet, specifically, that is to use VoIP. This is particularly useful when there is no PSTN infrastructure at either the originator or the recipient of a voice communication, such as in a less developed country or a remote location, or where a dedicated network is to be set up for a specific purpose, for example for reasons of data security and integrity. In this event, it is often desired to use a dedicated satellite network.
[0004] Typically, RTP is used for the transfer of audio and video data across an IP network. In general, IP networks suffer from occurrences of network outage, congestion and varying network delays which influence the latency experienced by packets of data travelling across the network. In turn, this may affect the quality of the voice delivered to the recipient as the packets must be recombined at the receiver. If certain packets have been corrupted, lost, or delayed, the packets available for recombination may be insufficient such that, for a given bandwidth, the packets available for recombination cannot provide an acceptable quality level of voice communication.
[0005] In particular, satellite networks tend to suffer from large latency. Packet switched satellite networks also suffer large variations in data packet delay, also known as data packet jitter.
[0006] RTP has a built-in jitter compensation capability, but implementations are not always capable of buffering for the amount of jitter experienced in large latency networks such as satellite networks. Typically, RTP implementations struggle to accommodate jitter of hundreds of milliseconds. This larger jitter that is often present in packet switched satellite networks is manifested as a perceived drop in the audio quality of the transmitted conversation due to insufficient packets being available for recombination at the receiver.
[0007] Therefore, a common problem with media traffic, in particular when traversing a network comprising a satellite link, is the perceived quality of the transmitted voice, which greatly affects quality and user satisfaction, and the network bandwidth required in order to provide sufficient packets at the receiver in order to achieve an acceptable level of quality of the transmitted voice. In addition, it is often the case that the terminal device, such as a VoIP telephone, negotiates its codec bandwidth without knowledge of the network capacity.
[0008] It would therefore be beneficial to provide a performance enhancement for an IP router, especially such a router deployed to carry media traffic over satellite networks, that enables the router to cope with a transmission network that experiences low bandwidth or high jitter/latency network conditions such as those often present in satellite networks. Media traffic such as VoIP packets on the network could be optimised for both network bandwidth efficiency and the perceived quality of the recombined digital audio or other data contained within the data packets traversing the network may also be maintained.
SUMMARY
[0009] The invention is as set out in the Claims.
[0010] By adding an additional timestamp to data packets that have been identified as members of a data session, jitter compensation can be performed such that the packets may be re-constituted at the same time and frequency as they arrived at the transmission router and in the correct sequence. The perceived quality of audio transmitted within these packets once reconstituted at the recipient can be maintained.
[0011] By removing requests for non-required codecs, such as codecs with a high-bandwidth requirement, the data traffic requires less bandwidth, and also by identifying packets containing silence and removing those packets from the data session, the data packets may be transmitted in a more efficient manner.
[0012] By identifying and removing replicated data from the header of a data packet, the bandwidth requirement of transmitting those packets can be reduced.
[0013] Any or all of these techniques can be used in combination such that both bandwidth may be reduced and quality levels may be maintained in an IP network carrying media data traffic over IP.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Embodiments will now be described, by way of example only, and with reference to the drawings in which:
[0015] FIG. 1A illustrates an overview of a typical IP network;
[0016] FIG. 1B illustrates a typical LAN to WAN network;
[0017] FIG. 2 illustrates a data path through an IP router according to the invention for LAN to WAN IP routed data;
[0018] FIG. 3 illustrates the data path of FIG. 2 with an additional RTP Performance Enhancing Proxy Stage;
[0019] FIG. 4 illustrates a data path through an IP router according to the invention for WAN to LAN IP routed data;
[0020] FIG. 5 illustrates the data path of FIG. 4 with an additional RTP Performance Enhancing Proxy Stage;
[0021] FIG. 6A shows a flow diagram according to the invention at a conversation originating LAN; and
[0022] FIG. 6B shows a flow diagram according to the invention at a recipient LAN.
[0023] In the figures, like elements are indicated by like reference numerals throughout.
DETAILED DESCRIPTION
[0024] By way of overview, and as is illustrated in FIGS. 1A and 1B , two media devices 2 , 3 communicate over an IP network 1 . The IP network comprises, for example, Networks A, B and C. Typically, Networks A and C comprise relatively high bandwidth/low jitter networks such as LANs 10 and 11 of FIGS. 1B and 2 to 5 . Network B (such as WAN 14 of FIG. 1B ) would typically comprise a low bandwidth/high jitter network, for example a satellite network. Network B is, in effect, an impaired network that imposes capacity and quality constraints upon the data traffic it carries.
[0025] As shown in FIG. 1B , local area network (LAN) 10 is coupled via an IP router 12 to a wide area network (WAN) 14 and the internet. Multiple LANs may be connected together in this manner.
[0026] A point-to-point or pseudo point-to-point link (known as an aggregate) is initiated to join LANs across a network such as that of FIG. 1 . This network may involve the use of satellite transmission. Specific data packet traffic may be routed across an aggregate via a dedicated point-to-point data tunnel (known as a tributary). Tributaries can be multiplexed across aggregates from LAN to LAN via the IP routers and the WAN. In its simplest form, a tributary is a point-to-point tunnel endpoint for transferring packets between the LANs over the intermediate WAN.
[0027] As discussed in more detail below, a standard embedded IP router, such as IP Router 12 in a multiplexer platform is equipped with a performance enhancing proxy for VoIP traffic, which, when enabled, gives an enhanced RTP gateway to the WAN 14 . More specifically, the processing of IP tributary data undergoes the additional steps of:
Header compression for RTP traffic Session Initiation Protocol (SIP) filtering, such as SDP (Session Description Protocol) 64 kbit/s codec filtering Jitter buffering for RTP traffic Filtering out of certain small samples in G729B codec (a speech coding algorithm providing audio data compression)
[0032] Packets that will traverse any one tributary in a particular direction and that are identified, at an originating IP router, as a session such as a conversation, are compressed, filtered and buffered according to the above. Corresponding data manipulation is performed at the recipient IP router for subsequent recombination into a standard RTP form. This technique can allow a reduction in the bandwidth requirement for their successful transmission at an acceptable level of quality, and compensate for the network jitter experienced. Data packet delivery can be guaranteed over the aggregate by way of sequencing, (that is identifying the position of a packet in a sequence) and hence identifying missing packets from the sequence, and also by the use of checksums to identify packet errors. Packets containing errors, for example those caused by corruption or significant delay in the network, may be discarded.
[0033] Hence the quality of VoIP conversations across networks such as satellite networks with, for example, large jitter, can be maintained, and the bandwidth requirement to tunnel these conversations across an IP network may be reduced.
[0034] By utilising the above additional steps in combination with the awareness of conversation context within the multiplexer platform, the jitter buffering can additionally utilise a small proportion (by adding a small timestamp to each voice data packet) of the significant bandwidth savings achieved by the other three steps. As a result of the additional timestamp, the quality of an RTP stream can be preserved across bandwidth-sensitive networks which suffer from large variations in latency (packet-to-packet delays) by providing additional jitter compensation as described in more detail below.
[0035] This technique achieves concurrent low bandwidth usage and high perceived quality. As will be described below, individual controls are provided over each of the above elements such that bandwidth and perceived quality of the transmission may be controlled when it is implemented across a network such as a satellite network.
[0036] Turning to FIG. 2 , a data path through an IP router 12 according to the invention for LAN to WAN IP routed data within a network of FIG. 1 is illustrated. An aggregate point to point link 26 provides a data path from LAN 10 to WAN 14 to a destination LAN such as LAN 11 of FIG. 4 . The IP routed data utilises a tributary tunnel path 24 for point to point data transmission. The tributary data tunnel path used for VoIP RTP data transfer is selected via IP Route 20 and an IP Filter 22 lookup tables. The IP Route Lookup 20 selects a tributary for the LAN interface to forward a packet over via a destination IP address lookup in the IP route table. The IP Filter Lookup 22 can redirect or discard traffic based on other IP traffic attributes, for example redirecting all RTP and SIP traffic down a specific tributary.
[0037] With the performance enhancing proxy in operation, and hence the enhanced RTP gateway enabled, an additional RTP Performance Enhancing Proxy (PEP) stage 30 is performed on the SIP and RTP packets before transmission of these packets over the tributary tunnel path 26 as shown in FIG. 3 .
[0038] Within the RTP PEP stage 30 , the three steps of SIP filtering 32 , codec filtering 34 , and RTP header compression 36 are executed with an optional fourth step 38 of adding an additional timestamp to the RTP.
[0039] SIP filtering at filter stage 32 comprises stripping out any negotiation messages in the SIP session description protocol messages which request the high-bandwidth codecs such as the 64 kbit/s G.711 codecs, and forcing the audio terminals to use the much less bandwidth intensive 8 kbit/s G.729 codec instead.
[0040] Codec filter stage 34 then filters out small-sample packets which occur in G.729B when transitioning into and out of silence suppression mode. During “normal” conversations, it can be seen that some G729B devices generate smaller samples (of 10 ms) as voice/silence transitions occur. These are silence information descriptors used for comfort-noise generation during silent periods. In realworld listening trials, these packets have not been found to substantially enhance or improve the perceived voice quality. By deleting these packets, bandwidth may be saved.
[0041] Compression stage 36 comprises stripping out the constant portion of the headers of each RTP packet resulting in less header data being transmitted and hence a reduction in the required bandwidth for transmission of the RTP packet.
[0042] Timestamp stage 38 comprises adding a timestamp to each RTP voice packet. This timestamp, an additional timestamp to the standard RTP timestamp, is added to the data payload of each RTP packet and is used as a means of timing the release of the packet into the remote recipient IP network, for example LAN 11 , once the packet has traversed the impaired network. This additional timestamp enables the RTP jitter buffer mechanism to operate for all RTP data streams, since the standard RTP timestamp implementation varies according to the media stream carried. Thus, jitter caused by a high variation of latency in a network link is removed from the voice data packets. A smooth and predictable feed of voice packets is thereby provided to the remote voice terminal, for example in LAN 11 . This substantially improves the overall perceived voice quality of the conversation and due to the bandwidth savings achieved by the other three steps, even after the addition of the timestamp, the bandwidth is still reduced overall from that required by a network link not operating with the features described herein.
[0043] It will be appreciated that all, one or a sub-combination of these stages can be implemented as appropriate.
[0044] FIG. 4 shows the data path through an IP router for WAN to LAN IP routed data from a network such as FIG. 1 . Typically, the arrangement of FIG. 4 would provide the recipient part of the aggregate link 26 of FIG. 2 . Aggregate point to point link 26 provides the data path from WAN 14 to LAN 11 . The IP routed data utilises the same tributary tunnel path 24 for the point to point data transmission. The reverse process of IP Filter 22 and IP Route 20 lookup tables is used at the recipient end of aggregate link 26 .
[0045] When the performance enhancing proxy server is in operation, and hence the enhanced RTP gateway is enabled, an additional RTP PEP stage 50 is performed on the RTP packets as they are received at the endpoint of the tributary tunnel 24 before being routed to the LAN 11 as shown in FIG. 5 .
[0046] Decompression stage 52 comprises restoring the constant data that was stripped out of the header before transmission such that the original packets are reconstituted at the recipient. This enables standard network infrastructure to deal with the packets once they have arrived at the destination endpoint of tributary 24 . If a timestamp was added during RTP PEP stage 30 , the timestamp is used in conjunction with a jitter buffer 54 to time the release of the RTP packets into recipient LAN 11 and hence provide the packets to the recipient at the correct time and same frequency and order that they arrived at the transmission router.
[0047] In operation, as shown in FIG. 6A , at step 60 , a VoIP RTP conversation originates and is identified in a LAN, such as LAN 10 . Pre-filtering such that only RTP & SIP UDP traffic is sent across tributary link 24 is carried out at step 61 . In step 61 , protocol headers are interrogated to identify RTP and SIP packets.
[0048] When the RTP packets reach RTP PEP stage 30 (at step 62 ), the RTP PEP filtering mechanism on tributary 24 is carried out as shown in the following pseudo-code. Reference numerals from the figures are provided in the code.
[0000]
If valid UDP packet
{
If even port number (RTP packets are even port numbers)
{
If SIP packet [SIP filter stage 32]
Do SIP filtering
Else
{
If (G729BShortPacketFiltering)
[Codec Filter stage 34]
{
If (G729 RTP packet AND length is
less than 40bytes)
DiscardPacketAndReturn
}
RTPCompressPacket [Compress stage 36]
}
}
}
ForwardAcrossTribAsStandardIPTraffic [Route Packet step 63]
[0049] SIP packets are filtered as described in more detail in relation to SIP filter stage 32 , and all other packets are codec filtered by stage 34 and compressed by stage 36 .
[0050] If any data is stripped from a packet, the checksums are recalculated before the data is sent on across the aggregate as a standard IP routed packet at stage 63 .
[0051] When RTP data is identified in PEP stage 30 , a new transport header is used to carry this data across the tributary 24 . The transport header (see table 1 below) identifies the data as RTP PEP data, i.e. the data has been dealt with by RTP PEP stage 30 and includes a conversation identifier that allows up to 255 RTP conversations to be conveyed across each tributary link 24 . The header length for all the new RTP PEP headers is only 2 bytes.
[0000]
TABLE 1
Bits
4
4
8
Use
Type
HeaderLength
Conversation Id
[0052] The Type identification code used across IP links identifies the four new types of packet used by the protocol: RTP PEP Start, RTP PEP Start Ack, RTP PEP Compress Data and RTP PEP Nak.
[0053] According to the protocol developed in accordance with the present invention, when a conversation is first identified, data is sent uncompressed with a RTP PEP Start header including static data fields. When a recipient router receives a RTP PEP start header for a new conversation, a conversation context is created, and the static data fields from the header of the uncompressed packet are saved. An RTP PEP start ack packet is returned. Once the RTP PEP start ack packet has been received by the router that originally identified the conversation, the RTP conversation data is sent over the tributary 24 in a compressed form following passing through compressor stage 36 (without the static header fields) and with an RTP PEP compressed data header, described in more detail below.
[0054] The pseudo-code for RTPCompressPacket (compress stage 36 of FIG. 3 ) is:
[0000]
If new conversation
{
Store static data
Send uncompressed with RTP PEP Start header
}
Else if conversation is not yet ACKed
{
Send uncompressed with RTP PEP Start header
}
Else
{
Send compressed with RTP PEP compressed data header
}
[0055] Should compressed data be received with an unknown conversation identifier, an RTP PEP NAK packet is sent back which should cause the originator to identify the conversation again.
[0056] Additionally, before RTP data is sent across the tributary link 24 , a local 16-bit timestamp is prepended to the RTP data payload (between the header and data) if optional jitter buffering is enabled.
[0057] As shown in FIG. 6B when a packet with an RTP header is received from a tributary 24 , RTP PEP stage 50 (at step 64 ) applies the following logic:
[0000]
If RTP Start packet
{
Store static data
Send RTP Start Ack packet
}
If RTP Start Ack Packet
{
Mark conversation as known
}
If RTP compressed data packet [Decompress stage 52]
{
Decompress data with static info stored for this conversation
}
If RTPJitterBuffer configured [Jitter Buffer stage 54]
{
Strip timestamp;
Push data into jitter buffer
}
Else
{
Push packet into standard IP routing process [step 65]
}
[0058] If the packet is pushed into the jitter buffer, it is processed via the standard IP routing process at step 65 when it emerges from the jitter buffer.
[0059] The individual filter, compression and time-stamping schemes will now be described in more detail:
[0060] SIP Filter Stage 32
[0061] The SIP SDP 64 kbit/s codec filtering logic (see 32 of FIG. 3 ) searches for SDP within SIP signalling messages and strips out any PCMU and PCMA (G7111 64k codec) negotiation and their associated RTPMAP entries from these messages—this should prevent SIP devices selecting 64k codecs to use over the network. The RTPMAP is part of the RFC2327 Session Description Protocol and describes how a media format maps to RTP payload types.
[0062] For this SIP filtering to take place, the SIP signalling stream should be executing in a non-secured format over User Datagram Protocol (UDP). Preferably, SDP messages should be in the ASCII format.
[0063] Codec Filter Stage 34
[0064] When a G729B codec sends data over an RTP stream it typically generates 20 ms samples of 20 bytes (plus RTP/UDP/IP overhead). As previously described, during “normal” conversations, it can be seen that some G729B devices generate smaller samples (of 10 ms) as voice/silence transitions occur. There can be several of these per second even during, for example, “normal” speech. If these voice samples are not forwarded across the network, the perceived voice quality is not greatly affected and the bandwidth required to forward these packets is saved. These packets are silence information descriptors and are typically used for comfort noise generation. They may therefore be discarded (see 34 of FIG. 3 ) without creating an unacceptable perceived drop in voice quality.
[0065] Compress Stage 36 , Decompress Stage 52
[0066] Previously when RTP traffic was carried across a network, each RTP packet was sent between the IP tributaries as a complete IP/UDP/RTP packet. The format of this packet is:
[0000]
TABLE 2
2 bytes
20 bytes
8 bytes
12 bytes
N bytes
IPTrib
IP Header
UDP
RTP Header
RTP
Header
Header
Payload
[0067] Note that the multiplexer header and possible aggregate headers are still prepended to this data before transmission across the network.
[0068] By making assumptions about the contents of portions of the IP, UDP & RTP headers remaining constant throughout an RTP session (conversations), the router may be configured to search for these conversations occurring, inform the IP tributary peer of the contents of the headers, and then avoid sending the constant portions of the headers with each packet—instead just sending a conversation identifier. When the compressed packet arrives at the target IP tributary, the headers are reconstituted and sent on to the ultimate RTP target (for example LAN 11 ) and the RTP sequence and timestamp information is forwarded intact.
[0069] With the identified static data removed from the header (compress stage 36 of FIG. 3 ), the compressed data sent between the IP tributaries is:
[0000]
TABLE 3
2 bytes
8 bytes
N bytes
IPTrib Header
Compressed RTP Header
RTP Payload
[0070] Therefore each RTP packet appears on the aggregate 26 with 32 fewer bytes. For G729k packets, this represents a saving of 52%. In uncompressed form, each 20 byte payload is sent between the tributaries as a 62 byte packet. In compressed form, each 20 byte payload is sent between the tributaries as a 30 byte packet.
[0071] When operating, the IP tributary code must look at each packet to be sent to the peer tributary to identify valid packets (IP & UDP checksums) and known conversations. Performance limitations may result. The code will consider any UDP traffic with an even port number (except the SIP port number 5060 ) as RTP traffic. Service management filters should be used to ensure that only RTP port numbers used in the target network are forwarding down an IP tributary 24 with the RTP compression enabled.
[0072] The feature must be turned on at both ends of an IP tributary 24 for the compression to work. If it is enabled on only one end, then all traffic is sent uncompressed and there is no benefit gained—this should be avoided as the performance overhead of looking for the conversations is still there. If the feature is enabled on one end of an IP tributary, but the peer is using older software that does not support the feature, then all RTP traffic will be discarded by the peer unit.
[0073] Timestamp Stage 38 , Jitter Buffer Stage 54
[0074] Some SIP devices are not very tolerant of the large jitter seen in some IP networks, especially satellite networks. This jitter can be removed from an RTP stream that is forwarded through the embedded IP router 12 and across the network 14 . When enabled, any RTP packets that are forwarded from the IP router 12 to an IP tributary 24 are pre-pended with a timestamp (16 bits) in their data payload. This timestamp is sent across the network with each RTP packet, and the timestamp can be used at the peer unit to forward packet onto the ultimate destination at the same frequency that the packets arrived at the original multiplexer.
[0075] Note that this scheme relies on creating timestamps from the clocks on peer routers across the network and using these to control packet synchronization—if these clocks themselves are not synchronized then over long conversations the jitter buffer may overrun or underrun. This could cause glitches in the delivered voice—however if silence suppression is used, then this is unlikely to occur.
[0076] As discussed above, a separate timestamp is used in addition to the RTP timestamp. This avoids the requirement of having knowledge about the format of the standard RTP timestamp which may change according to the type of data being carried across the RTP stream.
[0077] Note that the additional 16 bit timestamp overhead is not included in the packet formats and calculations in the RTP compression section. This additional overhead is only present when the jitter buffering is enabled, however, there is still an overall bandwidth saving even with the timestamps in use.
[0078] The techniques as described above may be executed on any appropriate hardware or in a software implementation.
[0079] These techniques are primarily described in relation to VoIP RTP traffic used for conversation transmission but can readily be used with any form of RTP traffic, for example, any form of media traffic. In particular, the format of the additional time stamp may be tailored for the needs of the data being transmitted.
[0080] The term conversation is used to identify a simplex RTP stream, that is to say any RTP packets in the reverse direction will be provided with their own separate compression establishment mechanism.
[0081] These techniques may also be applied to any appropriate type of network and for any type of conversation or other data session. Specifically, these techniques may be implemented to jitter-buffer any IP application, not just RTP streams. SIP filtering may also be performed for any codec type, not just G.711.
|
A method of transmitting data traffic from a network node comprising the steps of identifying a plurality of data packets as being members of a data session adding a timestamp to the header or data payload of each packet within the session wherein the timestamp is an additional timestamp and transmitting the packets to their destination.
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FIELD OF THE INVENTION
[0001] The invention herein relates to the field of topical antimicrobial compositions applied to the user's skin. In particular, the invention pertains to a topical antimicrobial composition that, in addition to exhibiting desirable levels of antimicrobial efficacy, exhibits improved moisturization and feel.
BACKGROUND OF THE INVENTION
[0002] In certain fields, such as the medical and food preparation fields, it is desirable to lower the risks of microbial contact during the performance of various tasks. A variety of techniques or methods to maintain cleanliness are well known, for example, washing hands, donning gloves, and the like. Various topical antimicrobial compositions and antimicrobially effective ingredients are well known in the art. Some compositions are typically formulated as soaps or products that are intended to have short term residence on the skin before they are rinsed off.
[0003] Another method of reducing the presence of microbes on the skin, e.g., bacteria, viruses, fungus, etc., is through the use of topical antimicrobial compositions intended to remain on the user's skin. These products reduce the amount of infectious organisms on healthcare worker's hands, for example, thus reducing the likelihood of healthcare-acquired infection. Commonly referred to as “hand sanitizers”, such compositions are often used by healthcare workers to clean their hands throughout the day when washing with soap and water is not convenient. Examples of such hand sanitizer products include Purell® (available from Gojo Industries, Inc., Akron, Ohio) and Endure® 320 (available from Ecolab, Inc., St. Paul, Minn.).
[0004] Because such compositions are applied onto the skin surface and remain thereafter, the active antimicrobial ingredient(s) also come into extended contact with the skin surface. Certain ingredients, such as ethanol, chlorhexidine gluconate, and the like, have been known to produce irritation and moisture loss on the user's skin.
[0005] Because an applied composition in the form of a lotion, for example, has an extended topical residence, undesirable effects such as loss of skin moisture is even more likely. For those individuals that repeatedly or frequently use such compositions, whether out of necessity or hygiene preference, the impact on the condition of the user's skin can be more aggravated. Alcohol-based hand sanitizers are particularly problematic, since alcohol is a drying agent. It is known that frequent and repeated use of alcohol-based hand sanitizers can result in skin disorders, such as contact dermatitis.
[0006] Another problem associated with existing topical antimicrobial compositions is the balance of attaining a desirable threshold of broad spectrum antimicrobial efficacy (kills gram positive bacteria, gram negative bacteria, yeast) while reducing the adverse effects of the composition ingredients on the skin. Another problem associated with certain compositions is that while moisturizing agents can be added or incorporated alongside the active antimicrobial agent, the moisturizers can also interfere with the antimicrobial effect. Furthermore, many moisturizing agents can produce a greasy, sticky, or otherwise unpleasant sensation on the skin following their application to the skin surface. Extended dry times have been associated with such uncomfortable feel.
[0007] Thus, difficulty has been encountered in formulating an effective topical antimicrobial composition that also effectively moisturizes the user's skin intended for extended residence on the user's skin, as opposed to a soap or composition intended to be rinsed off the skin. Particular difficulty has been experienced in accomplishing this, and creating a formulation that still exhibits a relatively short dry time.
[0008] There exists a need in the field of topically applied broad spectrum antimicrobial compositions for compositions that achieve desired levels of antimicrobial efficacy while improving moisturization and feel, despite the necessary presence of certain harsh ingredients for antimicrobial effect. Even more preferred would be such a composition that exhibits a pleasant feel and avoids extended dry times.
SUMMARY OF THE INVENTION
[0009] The invention provides an extended resident topical antimicrobial composition comprising an active antimicrobial and moisturizing ingredients that meets antimicrobial efficacy requirements and improves the condition of the user's skin as well. It has been surprisingly discovered that such a composition can be developed which not only exhibits broad spectrum antimicrobial efficacy levels at a desired standard, but which also exhibits an improved skin moisturization property without significant chemical interference with the active antimicrobial ingredient and which counteracts the harsh effects of the ingredients. It has further been discovered that certain combinations of moisturizing agents actually improve moisturization beyond the moisturization effects associated with the moisturizing ingredients individually. It has further been discovered that the desired efficacy and therapeutic effects can be accomplished with a formulation that still exhibits a relatively short dry time to avoid unpleasant feel. The invention is particularly useful to healthcare workers, whose usage of hand sanitizers can be on a daily and frequent basis.
[0010] The invention provides an extended resident topical antimicrobial composition comprising: a) an antimicrobial agent; and b) a moisturization component comprising a combination of a saccharide isomerate and carbohydrate complex together with glycerin. In a preferred embodiment, the antimicrobial agent is a broad spectrum antimicrobial agent such as alcohol.
[0011] The invention further provides a method of topically sanitizing and moisturizing skin comprising applying to said skin an extended resident topical antimicrobial composition comprising: a) an antimicrobial agent; and b) a moisturization component comprising a combination of a saccharide isomerate and carbohydrate complex together with glycerin.
[0012] One advantage of the invention is that it achieves the balance of antimicrobial effectiveness, while at the same time improving the condition of the user's skin over long term use, and minimizing dry time to avoid unpleasant feel on the user's hands associated with prolonged skin surface “wetness”.
DETAILED DESCRIPTION OF THE INVENTION
[0013] As used herein, the term “resident” within the context of topical application is meant to refer to a formulation and context of use intended to remain on the user's skin for some period of time after its application, in the absence of subsequent rinsing, washing or other removal methods. The phrase “extended resident” is meant to refer to residency that occurs for relatively long periods of time, even indefinitely, once applied to the skin.
[0014] In general, the composition of the invention is an extended resident topical antimicrobial composition intended to remain on the skin for a relatively prolonged period of time while delivering antimicrobial effect to the skin surface. An important aspect of the invention is that despite the prolonged residence on the skin surface of an antimicrobial agent, the formulation also provides moisturizing effect to the skin which actually increases over time. The result is a “hand sanitizer” composition that at the same time is beneficial to the user's skin.
[0015] The extended resident topical antimicrobial composition comprises an antimicrobial agent and a moisturizing agent comprising a saccharide isomerate. The saccharide isomerate can be in the form of a complex formed by the combination of the saccharide isomerate and carbohydrates in aqueous solution. In one embodiment, the moisturizer comprises a saccharide isomerate of D-glucose in combination with an aqueous solution of carbohydrates. Preferably, the moisturizer further comprises glycerin in combination with the saccharide isomerate. The moisturizing agent can be present in an amount ranging from about 0.1% by weight to about 5% by weight of the composition, preferably from about 0.01% by weight to about 2%. In a preferred embodiment, saccharide isomerate is present in about 0.4% by weight and glycerin is present in about 0.4% by weight of the composition.
[0016] Aside from saccharide isomerate and glycerin, secondary moisturizers can be added to the composition of the invention as well. Suitable secondary moisturizers fur use in topical formulations include, but are not limited to, lanolin, pentylene glycol, and sodium pyrrolidone carboxylic acid.
[0017] A variety of antimicrobial agents can be used in accordance with the invention, preferably broad spectrum antimicrobial agents. Antimicrobial agents include, but are not limited to, chlorophenols, biguanides, iodophors, biologically active salts, and alcohols. Each of these antimicrobial classes exhibits differences in speed, persistence, and spectrum of activity. For example, chlorhexidine can be used to provide a formulation with increased persistence, and alcohol can be used to provide a formulation with “quick kill” properties.
[0018] In a preferred embodiment, alcohol is used as the antimicrobial agent. The alcohol can be ethanol, isopropanol, or mixtures thereof, such as a mixture of about 95% ethanol and about 5% isopropanol. The antimicrobial agent can be present in an amount ranging from about 40% by weight to about 90% by weight of the composition, preferably from about 50% to about 70%. In a preferred embodiment, alcohol (95% ethanol, 5% isopropanol) is present in about 59% by weight.
[0019] The composition of the invention can further comprise secondary ingredients provided that such secondary ingredients do not substantially interfere with the advantageous properties associated with the invention. Secondary ingredients that can be included in the composition are solvents, vitamins, additional moisturizers, surfactants, thickeners or conditioners, coloring agents, fragrances, and the like.
[0020] Solvents can be used to combine formulation ingredients in order to appropriately deliver the formulation to the user's skin. Solvents include, but are not limited to, alcohols, ethers, and ketones—each of which exhibit differences in solubility, odor, and drying potential. In a preferred embodiment, water is used as a solvent. Water as the solvent can be present in an amount ranging from about 10% by weight to about 55% by weight of the composition, preferably from about 30% to about 40%, most preferably in about 38% by weight of the composition.
[0021] The composition of the invention can further comprise vitamins as well. Vitamins can be used to impart numerous benefits, such as the promotion of healing and reduction of oxidation. Vitamins that can be used in topical formulations include vitamin A, C, D and E. While different vitamins and various combinations of vitamins can be used in accordance with the invention, preferred vitamins include vitamin E (DL-α-tocopherol) and vitamin B5 (d-panthenol). Vitamin E and vitamin B5 each can be present in an amount ranging from about 0.01% to about 5% by weight of the composition, preferably from about 0.01% to about 1%. In a preferred embodiment, vitamin E (DL-α-tocopherol is present in about 0.03% by weight and vitamin B5 (d-panthenol) is present in about 0.10% by weight.
[0022] Alpha hydroxy acids can be used in the composition of the invention as well. Alpha hydroxy acids are used in topical formulations to promote exfoliation and minimize skin flakiness. A variety of alpha hydroxy acids can be used in topical formulations, including glycolic acid, lactic acid, and hydroxycaprylic acid. A preferred alpha hydroxy acid for use in the invention is gluconolactone. Alpha hydroxy acids can be present in amount ranging from about 0.01% by weight to about 5% by weight of the composition, preferably from about 0.01% to about 0.5%. In a preferred embodiment, gluconolactone is present in an amount of about 0.05% by weight of the composition.
[0023] The composition of the invention can further comprise a surfactant. Surfactants can be used in topical formulations as wetting agents, to provide detergency and enhance foaminess. Suitable surfactants for topical formulations include, but are not limited to, glycerol monostearate, cocamidopropyl betaine, and lauramine oxide. Different surfactants and combinations of surfactants can be used in the invention. Preferred surfactants for use in the composition of the invention are nonionic surfactants. More preferred is stearamine oxide, which is both a nonionic surfactant and conditioning agent. Surfactants can be present in an amount ranging from about 0.01% by weight to about 5% by weight of the composition, preferably from about 0.01% to about 2%. In a preferred embodiment, stearamine oxide is present in an amount of about 1% by weight.
[0024] Thickeners and conditioners can be used in the composition to enhance viscosity and cosmetic attributes. Suitable topical thickeners or conditioners include carbomer, hydroxymethyl cellulose, and chitosan. Preferred for use in the invention as a thickener/conditioner is polyquaternium-10. The thickener/conditioner can be present in an amount ranging from about 0.1% by weight to about 3% by weight of the composition, preferably from about 0.5% to about 1.25% by weight. In a preferred embodiment, polyquaternium-10 is present in about 0.75% by weight of the composition.
[0025] Other additional ingredients that can be used include pigments, dyes, opacifiers, fragrances, and the like.
EXAMPLE 1
Preparation of the Resident Topical Anti-Microbial Composition
[0026] A composition in accordance with the invention was prepared as follows. In a stainless steel mixing vessel with both top and side-sweep agitators, ethanol and DL-α-tocopherol were initially mixed together under continuous agitation. After the DL-α-tocopherol was completely dissolved in solution, ambient water was added. Polyquaternium-10 was then added along with glycerin. The resulting solution was mixed until a clear smooth gel formed. Subsequently, saccharide isomerate and stearamine oxide were slowly added to the mixing vessel, and the resulting solution was mixed until the stearamine oxide was completely in solution. Finally, gluconolactone and d-panthenol were added and the solution was mixed until a clear homogenous solution was obtained.
[0027] The ethanol used to prepare the formula was SD alcohol, 200 proof (ATF 3C) (95% ethanol and about 5% isopropyl alcohol) (obtained from Equistar Chemicals, Houston, Tex.). Stearamine oxide used was Mackamine™ SO (obtained from McIntyre Group, University Park, Ill.). Polyquaternium-10 was Celquat™ SC-230M (obtained from National Starch, Bridgewater, N.J.). Saccharide isomerate/carbohydrate complex used in the formulation was Pentavitimm (available from Centerchem, Norwalk, Conn.).
[0028] The resulting composition contained the following Formula 1:
[0029] Formula 1 Anti-Microbial Composition of Invention Containing Combined
Amount Ingredient: Function: (wt %): Deionized water Solvent 38.27 Ethanol Antimicrobial agent 59.00 DL-α-tocopherol Vitamin E/skin 0.03 conditioning agent Gluconolactone Alpha hydroxy acid/skin 0.05 conditioning agent d-panthenol Vitamin B5/skin 0.10 conditioning agent Stearamine oxide Surfactant 1.00 Polyquaternium-10 Thickener/conditioner 0.75 Glycerin Moisturizer 0.40 Saccharide isomerate/ Moisturizer 0.40 carbohydrate complex Total: 100.00
EXAMPLE 2
Comparative In-Vitro Antimicrobial Efficacy Data
[0030] In a similar manner to the preparation of Formula 1, two additional topical antimicrobial formulas were prepared to compare different moisturizer components with the formulation of the invention. In all three formulas, ingredients remained identical and were present in identical weight % amounts, except for the presence and amounts of glycerin and saccharide isomerate as moisturizer components. In Formula 2, only glycerin was present as the moisturizer component. In Formula 3, only saccharide isomerate was present as the moisturizer component. In all three formulas, the total weight percent of moisturizer component present, irrespective of its ingredient(s), was 0.80. The formulas used in the experiment are set forth in the following table:
TABLE 1 Comparative Formulations Ingredient Formula 1 Formula 2 Formula 3 Deionized water 38.27 38.27 38.27 Alcohol 59.00 59.00 59.00 DL-α-tocopherol 0.03 0.03 0.03 Gluconolactone 0.05 0.05 0.05 d-panthenol 0.10 0.10 0.10 Stearamine oxide 1.00 1.00 1.00 Polyquaternium-10 0.75 0.75 0.75 Glycerin 0.40 0.80 0.00 Saccharide isomerate/ 0.40 0.00 0.80 carbohydrate complex Total Weight % 100.00 100.00 100.00
[0031] The antimicrobial efficacy for each of the formulas was evaluated in accordance with the In Vitro Time Kill Test procedures. Approximately 24 hours before initiating the study, the bacteria were propagated on soybean-casein digest agar (TSA=tryptic soy agar) plates and incubated at 35° C.±2° C. for bacteria, and at 25° C.±2° C. for 48 hours for yeast. Immediately prior to the testing procedure, well-isolated colonies were selected and transferred by sterile loop to 4-5 ml sterile physiological solution until a turbidity of 0.5 on McFarland Index Standard was reached. Accordingly, the suspensions contained approximately 1.0×10 8 CFU/ml.
[0032] The inoculum titer was then prepared. An initial population was determined for each suspension by mixing 0.2 ml of the suspension with 1.8 ml sterile saline. A series of ten-fold dilutions (10 −1 , 10 −2 , 10 −3 , 10 −4 and 10 −5 ) was made by adding 0.22 ml into 2.0 ml sterile neutralizing solution containing lecithin, Tween 80 and sodium thiosulfate and vortex mixing. 0.2 ml aliquots of the dilutions were inoculated in duplicate onto an agar surface of TSA. The plates were then incubated at appropriate temperature and time parameters in an incubator: for bacteria at 35° C.±2° C. for 24 hours; and for yeasts 25° C. 2° C. for 48 hours.
[0033] For the testing procedure, 0.2 ml aliquot of each challenge suspension containing approximately 1.0×10 8 CFU/ml was inoculated into a test tube containing 1.8 ml of test product (of Formulas 1, 2 and 3) and mixed thoroughly using a vortex mixer. The challenge microbial cells were exposed to each test product for 15 second and 1 minute exposure times.
[0034] After lapse of each exposure time, 0.22 ml was removed from the reaction tube into another test tube containing 2 ml sterile neutralizing solution. Ten-fold dilutions (10 −1 , 10 −2 and 10 −3 ) were made by placing 0.22 ml into 2 ml of sterile neutralizing solution.
[0035] Enumeration of microorganisms was done by standard plate count procedure. 1 ml aliquots of all 10 −1 dilutions were inoculated in duplicate, and 0.2 ml aliquots of the remaining dilutions were inoculated in duplicate onto the agar surface of TSA plates. The plates were then incubated for appropriate temperature and time parameters as described herein above for bacteria and yeasts. Following incubation, the growth colonies on the plates were then counted manually using hand tally counter. The raw CFU data was collected and converted to Log. Log reduction was calculated by subtracting the post treatment Log counts from the Log of the inoculum titer.
TABLE 2 Comparative Antimicrobial In-Vitro Efficacy Results Test Microorganism Formula Exposure Time Log Reduction Ps. aeruginosa Formula 1 15 sec >6.25 ATCC# 15442 1 min >6.25 Gram (−) bacteria Formula 2 15 sec >6.25 1 min >6.25 Formula 3 15 sec >6.25 1 min >6.25 E. coli Formula 1 15 sec >6.12 ATCC# 11229 1 min >6.12 Gram (−) bacteria Formula 2 15 sec >6.12 1 min >6.12 Formula 3 15 sec >6.12 1 min >6.12 Ent. faecalis Formula 1 15 sec >5.8 ATCC# 29212 1 min >5.8 Gram (+) bacteria Formula 2 15 sec >5.8 1 min >5.8 Formula 3 15 sec >5.8 1 min >5.8 St. aureus Formula 1 15 sec >6.02 ATCC# 6538 1 min >6.02 Gram (+) bacteria Formula 2 15 sec >6.02 1 min >6.02 Formula 3 15 sec >6.02 1 min >6.02 Candida albicans Formula 1 15 sec >5.09 ATCC# 10231 1 min >5.09 Yeast Formula 2 15 sec >5.09 1 min >5.09 Formula 3 15 sec >5.09 1 min >5.09
[0036] As can be seen from the data, the formulation prepared according to the invention exhibits comparable antimicrobial efficacy as compared to Formulas 2 and 3. Therefore, it can also be determined from the results that the moisturizer component used in the inventive composition, i.e., the combination of saccharide isomerate and glycerin in the formulation prepared according to the invention does not adversely affect in vitro antimicrobial efficacy.
EXAMPLE 3
Comparative Moisturization Study
[0037] A study was performed to compare the skin moisturization potential of various topical antimicrobial formulations on subjects with dry skin. The moisturization effects of the topical antimicrobial composition of the invention (Formula 1) was evaluated and compared to that of Formula 2 (glycerin only) and Formula 3 (saccharide isomerate only). In addition, commercialized compositions Purell® available from Gojo Industries, Inc., Akron, Ohio), Endure® 320 (available from Ecolab, Inc., St. Paul, Minn.) and a control formulation (no moisturizing agents present) were included in the study. The Purell® formulation contains 62% ethanol and glycerin, among other ingredients. The Endure® 320 formulation contains 62% ethanol and glycerin, among other ingredients. The control formulation contained 59% weight of 200 proof SD alcohol (95% ethanol, 5% isopropyl alcohol) and 41% weight of deionized water.
[0038] Twelve female subjects ranging from 31 to 59 years of age were selected following a six-day wash-out period, during which only non-moisturizing cleansing bars (Neutrogena™) were used on the lower legs of the subjects in the absence of any moisturization products. Further, the subjects were to refrain from shaving their legs within 72 hours of the test date. Subjects were selected based on pre-treatment phase NOVA reading of less than 110 on their lower legs. NOVA measurements were taken using NOVA DPM 9003® (NOVA Technology Corporation, Portsmouth, N.H.).
[0039] The subjects were equilibrated in a controlled environment of less than 50% relative humidity and 70°±3 F. for 30 minutes before undergoing any measurements. At baseline, each of the subjects had three test sites demarcated (using a skin marker) on the outer aspect of one lower leg measuring 4 cm×4 cm and four test sites demarcated on the outer aspect of the contra-lateral leg measuring 4 cm×4 cm. Six of the sites were treated with the test formulations, and the seventh site served as a control (untreated) site. Baseline measurements were taken using the NOVA meter of each test site. The site treatments were rotated from right to left and top to bottom among the subjects to remove positional bias.
[0040] Next, approximately 20 μl of each test formulation was applied to each of the respective test sites using a finger cot and spread evenly over the site. NOVA meter measurements taken immediately upon drying (at time 0). NOVA readings were taken at each test site in duplicate after 30 seconds following application. The test formulations were re-applied at approximately 1 hour later, followed by additional NOVA meter readings. The procedure was repeated at hours 2, 3 and 4 for a total of 5 applications at each test site of the designated test formulation. The subjects were required to remain in the test facility throughout the duration of the teasing without drinking excessive water, smoking or eating.
[0041] The NOVA data for each subject was compiled and statistical analysis was performed using ANOVA followed by Tukey-Kramer Multiple Comparisons Test utilizing the deltas from baseline to one hour, baseline to two hours, three and four hours respectively.
[0042] The group mean NOVA readings for each test formulation and the untreated control at each evaluation time are set forth in the following table:
TABLE 3 NOVA Group Means Treatment Baseline 0 hour 1 hour 2 hour 3 hour 4 hour Formula 1 95.67 102.42 107.17 118.50 114.92 126.17 Formula 2 95.75 102.17 108.17 110.83 119.17 126.00 Formula 3 95.92 98.17 110.25 112.08 108.17 119.92 Purell ® 96.33 96.08 102.08 100.00 96.75 98.42 Formula Endure ® 97.25 101.33 107.67 108.67 104.50 106.75 320 Formula Ethanol 96.00 95.67 94.83 97.08 97.50 98.25 Control Untreated 97.42 96.67 96.08 96.25 96.67 96.17 control
[0043] As can be seen from the above data, group mean scores for Formulas 1, 2 and 3 were comparatively higher than the Purell® and Endure® 320 formulations. Furthermore, Formulas 1, 2 and 3 exhibited an additive moisturization effect over time, whereas Purell® and Endure® exhibited decreasing moisture readings at two and three hour evaluation times, respectively. At the two hour and four hour evaluation times, Formula 1 of the invention exhibited the highest moisturization effects of the test formulations, even within the test formulation subgroup of Formulas 1, 2 and 3.
[0044] The NOVA data was calculated in terms of percent change from baseline as well. The percent change data for each of the test formulations is set forth in the following table.
TABLE 4 Percent Change in NOVA Readings Baseline Baseline Baseline Baseline Baseline to 0 to 1 to 2 to 3 to 4 hour % hour % hour % hour % hour % Treatment change change change change change Formula 1 7.1% 12.0% 23.9% 20.1% 31.9% Formula 2 6.7% 13.0% 15.7% 24.5% 31.6% Formula 3 2.3% 14.9% 16.8% 12.8% 25.0% Purell −0.3% 6.0% 3.8% 0.4% 2.2% Endure 320 4.2% 10.7% 11.7% 7.5% 9.8% Ethanol −0.3% −1.2% 1.1% 1.6% 2.3% control Untreated −0.8% −1.4% −1.2% −0.8% −1.3% control
[0045] As can be seen from the percent change data, Formula 1 of the invention produced the highest increase in skin moisturization over the entire study with a final group percent change in moisturization over baseline of 31.9%. Formula 2 produced a lower overall percent change of 31.6%, and Formula 3 produced a 25% increase in skin moisturization over baseline. Commercial formulas Purell® and Endure® produced percent changes over baseline of 2.2% and 9.8% respectively. Accordingly, Formula 1 of the invention produced the most significant long term skin moisturization effect as compared to the other formulations in the study.
INDUSTRIAL APPLICABILITY
[0046] The extended resident topical antimicrobial composition of the invention is useful as a hand sanitizer when washing with soap and water is inconvenient. The composition of the invention is formulated to reduce adverse effects on the skin from frequent use, and even improve the condition of the user's skin. The invention is particularly useful to healthcare workers to reduce and avoid healthcare-acquired infection while accommodating daily and frequent use of the composition.
[0047] The invention has been described herein above with reference to various and specific embodiments and techniques. In will be understood by one of ordinary skill in the art, however, that reasonable variations and modifications to such embodiments and techniques can be made without significantly departing from either the spirit or scope of the invention as defined by the following claims.
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The invention described herein provides an extended resident topical antimicrobial composition comprising an active antimicrobial and moisturizing ingredients that meets antimicrobial efficacy requirements and improves the condition of the user's skin as well. The composition of the invention achieves desired antimicrobial efficacy and therapeutic effect and still exhibits a relatively short dry time to avoid unpleasant feel. The composition of the invention comprises: a) an antimicrobial agent; and b) a moisturization component comprising a combination of a saccharide isomerate and carbohydrate complex together with glycerin. In a preferred embodiment, the antimicrobial agent is a broad spectrum antimicrobial agent such as alcohol. The invention is particularly useful to healthcare workers, whose usage of hand sanitizers can be on a daily and frequent basis.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to arthroscopic knee surgery, and specifically to a novel grasper-stitcher device which is intended to facilitate the surgical repair of torn anterior cruciate ligament tissue within the knee cavity. Also disclosed is a method for use of the device.
2. Brief Description of the Prior Art
With the advent of the arthroscope, surgeons have become able to view remotely located areas within the humand body, and therefore operate with fewer incisions, reduced surgical trauma and shorter recovery times.
Recent advantages in arthroscopic knee surgery have focused on the repair of torn meniscal cartilage within the knee cavity. For example, WHIPPLE et al., (U.S. Pat. No. 4,662,371), disclose a cutting-suctioning instrument for removing damaged meniscal cartilage during arthroscopic knee surgery. A pistol grip configuration linearly actuates an inner suction tube that has a distal end connected to a cutting jaw, at one end of an elongated tubular member. The tube serves as a suction passageway for the removal of the cut frgments of tissue. Hence, WHIPPLE et al., addresses rhe problem of remotely cutting damaged cartilage within a knee cavity, and removing fragments with a device that remains in situ for repeated cutting.
MULHOLLAN et al. (U.S. Pat. No. 4,621,640) demonstrate a mechanical needle carrier which can grasp and carry a small, curved surgical needle through a cannula, position the needle and set a stitch through torn meniscal cartilage, then release the needle and be withdrawn from the cannula. However, MULHOLLAN et al. do not address the problem of grasping the free end of acutely injured ligament, peripheral meniscus or even cartilage, to avoid neurovascular damage that might occur when needles are passed blindly, during athroscopic procedures.
STORZ (U.S. Pat. No. 4,607,620) illustrates a medical gripping instrument with an elongated tubular passage and a set of gripping arms, but an instrument configured to simply grasp tissue with the help of an endoscope.
None of these representative prior partents provide a suggestion that a grasper-stitcher as taught herein could be particularly valuable to perform a direct repair, arthrosscopically, by suturing a free end of torn anterior cruciate ligament (ACL) tissue within the knee cavity. Damage to the ACL is a common injury, especially among athletes such as skiers. A problem generally associated with prior art methods for arthroscopic repair of ACL tissue is the difficulty the surgeon encounters in attempting to simultaneously grasp and pass a surgical needle through the torn ACL tissue. A small surgical opening greatly limits his access to the location of the injury. As such, the surgeon is not free to insert one tool to hold and position the damaged tissue, and another to carry out the suturing of the ACL. It would therefore be extremely beneficial to have a surgical instrument which would allow a physician to simultaneously grasp and stitch damaged anterior crucitate ligament tissue within a remotely located knee cavity, under the limitations imposed by arthroscopic surgery.
The prevailing philosophy tody among knee surgeons is that primary repair alone of the anterior cruciate ligament is perhaps less than successful. Repair of a damaged mid substance ACL is still a major problem and has not been successful when done alone. The grasper-stitcher device of the present invention has its primary advantage in permitting a technique for repair of acutely injured ACL that will, it is believed, permit a repair that is sufficiently strong, and simulative of the original action of the ACL, so as to permit augmentation, as by the harvesting of a middle or lateral one-third of patella tendon.
There is definitely a place for arthroscopic repair of the ACL if this repair is backed up by a small extra-articular tenodesis of the iliotibial tract. The repair itself adds stability to the knee as a working unit. In those patients that are perhaps recreational athletes or manual laborers that need to minimize their rehabilitiation time, the present invention offers significant advantage. If the repair of the primary rupture of the ACL can be accomplished arthroscopically without painful arthrotomy incisions, stability is added to the extra-articular augmentation. In the population of 25 to 40 year old recreational athletes or sedentary individuals, an arthroscopic repair of ACL is definitely indicated.
In reviewing the literature there are basically two studies that report "successful" repair of the ACL. A series of articles by Marshall and Warren: Marshall, John L., D.V.M., M.D., F.A.C.S.; Warren, Russell, M.D., F.A.C.S., Wickiewicz, Thomas L., M.D.: Primary Surgical Treatment of Anterior Cruciate Ligament Lesions, The American Journal of Sports Medicine, Vol. 10, No. 2, 1982, 103-107; Warren, Russell F., M.D.: Primary Repair of the Anterior Cruciate Ligament, Clinical Orthopaedics and Related Research, No. 197, Jan-Feb, 1983, pp. 65-70) describe a multiple loop technique. An article by Odenstein, Suture of Fresh Ruptures of the Anterior Cruciate Ligament, ACTA OrthoP. Scand. 55, 270-276, 1984, describes how at least 7 nonabsorbable sutures can be utilized in a repair. Neither one of these techniques had the benefit of an extra-articular stabilizing procedure. The present procedure tends to minimize the stresses on the primary anterior cruciate repair, thus allowing healing to take place. Other studies in the literature, such as those by Feagin and Weaver, describe the use of only several stitches in the repair, but do not describe any type of extra-articular augmentation. According to applicant's procedure, a successful repair preferably comprises six to eight loops of nonabsorbable number 0 suture, and the device of the present invention greatly facilitates such repeated suture steps.
OBJECTS AND SUMMARY OF THE INVENTION
It is accordingly the principal object of this invention to provide a grasper-stitcher instrument for arthroscopic knee surgery, which permits a stump of torn ACL tissue to be simultaneously held and directly stitched.
The above objects are achieved in accordance with the present invention by providing an arthroscopic tool of the general type discussed above with a pair of atraumatic grasping jaws, as well as an elongated tubular member for the passage of long (10-15 inch) surgical needles through a stump of ACL tissue. The grasping jaws are located at one end of the tubular structure, and comprise a moveable first transverse jaw and a stationary, opposed second jaw. Each jaw further comprises a pair of parallel, transversely spaced arcuate finger elements that cooperate to define a longitudinal passage that accomodates passage of a surgical needle in various degrees of relative opening. The moveable first jaw is pivoted about a vertical fulcrum by being connected to the distal end of a hollow tube which is slidable within an elongated, outer tubular housing member. In a preferred embodiment of the invention, a pistol grip configuration is used to linearly actuate this hollow inner tube, and thus control the opening and closing of grasping jaws that are configured especially so as to be atraumatic. A leaf spring is used to urge the jaws into a normally open configuration. An a latch with at least one detent is used to position the jaws at a fixed position upon the grasped tissue, once the pistol grip is set at a desired level of compression.
A tubular cannula is used to receive each surgical needle as it is passed through the tissue, being sutured. One receiving cannula type is curved at a radius which matches the back of the knee, in order to be passed over the joint. A second type is straight with a beveled opening, so that it can be passed through a bony canal in the lateral femoral condyle and into a position where its distal end is proximate to the exit point of a needle exiting from its guided passage through ACL tissue or meniscus.
Further objects, features and advantages of the present invention will become more apparent froM consideration of the following detailed description of a preferred embodiment, wherein reference is made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a left side elevation perspective of a preferred grasper-stitcher device according to the present invention; and,
FIG. 2 is an enlarged detail of a left side elevation view of FIG. 1, showing a surgical needle being passed through the jaw assembly; and,
FIG. 3 is an enlarged detail top plan view, in partial section, for the jaw assembly of FIG. 2; and,
FIG. 4 is a rear elevation view of the device of FIG. 1; and,
FIG. 5 is schematic, perspective view showing use of the FIG. 1 device in a first step of a method according to the present invention, wherein a first suture is made in an ACL stump using a firsst needle; and,
FIG. 6 is a schematic perspective view showing a second step, wherein the other end of a first suture is passed through the ACL stump with a second needle to create a first loop; and,
FIG. 7 is a schematic, perspective view showing a third step, wherein the first end of a second suture is passed through a medially or laterally displaced point of the ACL stump with a third needle; and,
FIG. 8 is a schematic, perspective view showing completion of a second loop using the second suture and a fourth needle; and,
FIG. 9 is a schematic, perspective view showing the first and second loops completed, will all needles passed through the receiving cannula, and available for anchoring, or further augmentation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Structure of the Device:
A preferred embodiment for a grasper-stitcher made according to the present invention is shown by FIGS. 1-4. With reference to side elevation view FIG. 1, the device comprises a fixed handle, 2, and a movable handle, 4, which are arranged about a pivot, 6. The fixed handle is connected at an upper end to a proximate portion of an elongated, longitudinal outer tubular housing, 8. The movable handle, 4, is positioned to cause longitudinal movement of an elongated hollow inner tube, 10, within the housing, 8, by a connection to a proximate portion of the hollow inner tube, 10.
As shown in the detail, partial section side elevation view of FIG. 2, the elongated tubular housing, 8, has a distal end comprising a first movable jaw, 14. Laterally opposed to the first movable jaw, 14, is a second, stationary jaw, 12, shown most clearly by viewing FIGS. 2 and 3. The elongated inner tube, 10, has a flattened distal end extension, 20, that is pinned so as to pivot the movable jaw laterally upon a longitudinal motion within the elongated housing, 8. As shown in FIGS. 2 and 3, the distal end extension of the inner tube, 10, is pinned at 16 so as to cause lateral motion of the movable jaw, 14, about a fulcrum, 18. The extended section, 20, is hollow and connected to the pin, 16, so as not to impede axial or longitudinal insertion of a surgical needle, 32, for purposes which now will be described. The fulcrum, 18, may comprise a pair of pins in opposed side walls of housing, 8, so as not to interfere with an open central space within both the hollow tube, 10, and the jaw assembly region. FIGS. 2 and 3 show two positions as the distal end of the surgical needle, 32, passes through the jaw assembly, and particularly between the claw-like fingers which are spaced to be parallel to the longitudinal axial of the tubular housing, 8.
As shown at FIG. 2, the movable jaw, 14, has a first curved finger-like element, 26, and a second finger-like element, 28, which are longitudinally parallel and laterally spaced apart to facilitate passage of a surgical needle, 32. As further shown in the top, partial section view of FIG. 3, the stationary jaw, 12, has a complementary upper finger, 22. A lower stationary finger, 24 (not shown) is equivalent and opposed to the lower movable finger, 28. In FIG. 3, the jaws are in a relatively closed position, and there is still a clearance space, 30, between a directly opposed tip, (22, 26, and 24, 28) of the fixed and movable jaws. The lateral curvature of both fixed jaw, 12, and movable jaw, 14, cooperates with the clearance space, 30, to create atraumatic engagement of tissue. Tissue trapped between the jaws will tend to slide along the arcuate inner surfaces towards the larger central zone, if completely encircled. If a stump or mass of tissue is not completely encircled, then the non-closure of opposed tips, (22, 26, and 24, 28) as by space 30, helps to ensure that the surgeon will not unduly apply compression to the tissue, and cause trauma. FIG. 2 shows that lateral spacing between upper and lower arcuate fingers, 24, 26, of each jaw will facilitate clearance of axially disposed surgical needle, 32.
A preferred technique to axially translate the hollow inner tube, 10, with respect to the tubular housing, 8, is provided by a rear connector, 40, which is fixed to the hollow inner tube, 10, as shown in FIGS. 1 and 4. The fixed handle, 2, is welded or otherwise connected to a cannister-like rear support, 38, which in turn is welded or otherwise secured to the elongated hollow housing, 8. Upon closure of the movable handle, 4, towards the fixed handle, 2, movable jaw, 14, is urged into the closed position, of FIG. 3. This action is result of counterdockwise rotation of the handle, 4, and contact of pin, 36, in a vertical slot within the rear connector, 40. The rear connector, 40, as well as the rear support, 38, are hollow tubular members and, as shown in FIG. 4, there is a guided entraceway, 34, at the proximate end of the device that enables a surgical needle, 32, to be axially inserted, enter through the hollow supports, 38, 40, and then be guided along the longitudinal extent of the hollow inner tube, 10. In FIG. 2, the distal end of a needle, 32, is just proximate the distal end of the jaw assembly, and in FIG. 3, the distal end has passed through the jaw assembly, even through the movable jaw, 14, is in its relatively closed position. Clearance for the needle, 32, primarily is provided by the lateral spacing between each of the fingers, (26, 28, and 22, 24) which comprise the movable jaw and fixed jaws, respectively.
In order to control the compression force being exerted at the jaw assembly, a leaf spring element, 48, is pinned at a proximate end, 50, and a distal end is connected into a notch, 54, at the distal end of a spring support, 52, that in turn is attached to the movable handle, 4. In this fashion, the spring will tend to force the jaws into a normally open position, and the surgeon will have jaw closure pressure resisted by action of the spring. Further, a latch, 42, may have detent, and be pinned as at 44, so as to permit fixing of the instrument at a desired amount of relative compression, through tightening of a screw member, 46. A ratchet type of latch also may be employed. The latch allows the surgeon to fix the amount of compression exerted by the jaws with respect to grasped tissue, and thereafter concentrate on insertion of needles through the entrance, 34, along the hollow tubular member, 10, and outwardly through the jaw assembly, 14.
Use of the device of FIGS. 1-4, will become more apparent with reference to the schematic procedural steps shown in FIGS. 5-9, inclusive.
Method for Use of the Device:
Utilizing 10 inch double needles with number 0 nonabsorbable suture, applicant hereafter teaches a novel technique for repair of the ACL. If some ligament tissue can be gotten back to the isometric femoral drill hole then it is felt to be repairable, and the technique is attempted. Preferably, 6 to 8 sutures are distributed throughout the anterior cruciate stump, thus distributing the stresses throughout the already plastically deformed structure. The stitches at the base of the anterior cruciate stump on the tibia also snug the synovial sleeve up around the anterior cruciate stump, thereby enhancing blood supply to the region and healing. The ligament stump is brought into a drill hole in bone, thus allowing good fixation and enhancement of blood supply. By passing the sutures through the ligament in an oblique fashion, as will be described, more of the ligament stump is traverse with each pass. The sutures thereby tend to align with individual fibers comprising the ACL.
The preferred extra-articular procedure utilizes one free strip of iliotibial tract that goes beneath the fibular collateral ligament. This keeps the iliotibial tract behind the center of rotation of the knee, thus preventing the problem known as pivot shift phenomenon. A second layer of posterior iliotibial tract also may be secured with a screw to help prevent the pivot shift phenomenon. Free ends of the the strips can be passed under the fibular collateral ligament. It is preferred to use number 5, nonabsorbable suture in the extra-articular procedure, to create a double layer of "synthetic" extra-articular ligament. The position of the extra-articular procedure is optimized by putting the screw directly at Krackow's point with a cancellous screw and toothed washer. The isometricity of both the intra-articular repair and the extra-articular augumentation are checked on the operating table by taking the knee through a full range of motion. The screw fixation also allows immediate motion in a CPM machine and subsequent passive extension during the first week of postoperative treatment.
In the case of mid substance ACL tears, especially in young athletic individuals, a patella tendon intra-articular augmentation may be utilized. Preferrably, repairing the anterior cruciate stump around the patella tendon graft is accomplished with a double needle, multiple loop technique. This enhances blood supply from the ligament stump on the tibial end. In a situation where there is a young, athletic individual with associated pathology such as meniscus tears, the use of the patella tendon augmentaation is more aggressively applied. From a review of such patients, the "isolated" anterior cruciate tears do quite well with an intra-articular, double needle, multiple loop repair technique. Patients that require patella tendon augmentation tend to have more associated pathology and also are more competitive individuals.
In summary, the double needle multiple loop anterior cruciate ligament repair technique with extra-articular augmentation appears to be a viable alternative in the slightly older individuals, and those that are recreational athletes. In a test of this technique, several competitive athletes also did well. This technique allows easier and quicker rehabilitation without compromise of extensor mechanism. In those individuals that have associated pathology, are more competitive athletically and are of a younger age, the patella tendon augmentation has proved helpful. However, even in these patients the anterior cruciate stump preferrably should be repaired around the patella tendon, utilizing the double needle multiple loop technique. Although the results are preliminary, the following technique appears viable, easily accomplished and worthwhile when arthroscopic technique is called for.
SURGICAL TECHNIQUE EXAMPLES
1. ACL repair.
A thorough examination under anesthesia is first done on both knees in order to compare laxity in both knees an to define instability of the affected knee. The leg is then placed in a leg holder that includes a tourniquet, thereby allowing placement on the proximal thigh. This allows flexion past 90 degrees for proximal exposure. The knee and leg from the tourniquet to the toe are then prepped for 10 full minutes with Betadine and then double draped. A diagnostic anthroscopy is begun by inserting a large bore (7 mm.) inflow cannula into the superior medial portal. Meniscal repair or partial excision is performed, as necessary. Number 0 nonabsorbable suture is used to allow immediate postoperative passive motion.
Any debris including excess fat pad or hypertrophic synovium is removed from the intracondylar notch and the existing anterior cruciate stump is retracted medially. A large burr is then introduced into the anterior medial portal and a lateral notch plasty is accomplished. The notch is widened from anterior opening to the posterior intercondylar shelf, where the remaining anterior cruciate fibers can be identified.
As shown in FIG. 5, a small drill hole approximately 4.5 mm. is made through a puncture hole in the anterior medial tibial flare. The hole is made through the medial tibial condyle, 60, exiting just anterior to the ACL stump, 58. With the knee flexed 90-100 degrees a guide pin is driven from inside out, through the lateral femoral condyle. This pin is then over reamed with a 6 mm. reamer. A large bore cannula is then placed through the femoral drill hole and into the intracondylar notch behind the ACL stump.
As shown in FIGS. 5, 6, a small receiving cannula, 56, is passed through the tibial drill hole. The ACL stump, 58, is then grasped with the grasper-stitcher jaws 12, 14, as described hereinbefore, through the anterior medial portal and actually folded back over the cannula through the tibia. Using 10 inch double needles 61, 63, and at least a number 0 nonabsorbable suture, a loop is passed through the ACL stump, 58, from the tibial cannula through the stump and through the femoral cannula, and exits laterally. A first loop is shown being formed between entrance points 62, 64, by use of two needles, 61, 63, attached at opposite ends of a first suture, in FIG. 7.
As shown by FIGS. 7 and 8, the ACL stump, 58, further is manipulated by selective actions of the jaws of the grasper-stitcher, in order to obtain different positions for the second, and each following, suture loop. A second set of needles 65, 67, attached to opposite end of a second suture creates a second loop between points, 66, 68. At least six to eight loops of number 0 nonabsorbable suture preferrably are passed through the ACL stump and out the lateral side. As shown in FIG. 9, all such loops then can all be pulled tightly through grasping of the set of needles (61, 63, 65, 67) that were passed through the receiving cannula, 56, thereby allowing the tension to be dispersed throughout the ACL stump as the ACL is being pulled into the femoral drill hole. The free ends of the loops then are tied around a screw (not shown) that also may be utilized in the lateral augmentation procedure, discussed hereafter.
2. Lateral augmentation.
If a mid substance tear is identified in the ACL, a middle or lateral one-third of the patella may be utilized for intra-articular augmentation. The small puncture hole in the anterior medial tibial flare area is expanded to approximately a 1-2 inch incision. The middle or lateral one-third of the patella tendon is harvested with a 1/2 inch×1/4 inch plug of bone off the tibia. Three drill holes are placed in this plug of bone prior to removal.
The patella tendon is then dissected off the patella without harvesting a large petalla bone plug. A number 5 permanent stitch is woven through the holes in the tibial bone plug and through the proximal free end of the patella tendon. Two sutures are placed in each end. The hole in the tibial flare is then expanded to approximately an 8 mm. hole. A suture passer is then passed through the lateral femoral condyle, through the intracondylar notch and out the titial hole. A number 20 wire that has been twisted into a loop may be used for this step. The patella tendon is then pulled retrograde through the tibia hole, through the ACL stump and out the femoral hole. The bony plug from the tibia rests in the tibial hole. A small staple is then utilized to secure this bony plug in the oblique tibial hole. The sutures are tied around the staple. The sutures in the proximal end are tied around the same screw that the ACL stump sutures have been repaired around. Even though the ACL is mid-substance, a multi-loop repair is accomplished in the stump in addition to the intra-articular patella tendon augmentation.
3. Extra-articular procedure.
The posterior border of the iliotibial tract is identified, and an incision is made 1.5 cm. anterior to the posterior border. One centimeter anterior to that incision a second incision is made creating a free iliotibial tract slip. A number 5 suture permanent stitch is placed in both strips. The free iliotibial tract slip is then passed under the fibular collateral ligament from anterior to posterior. The septum is actually taken off the femur right at the point recommended by Krackow, et al. and using a 3.2 mm. drill bit a hole is made in this area for the screw. A depth guage is then used to determine the exact length of the screw and approximately 5 mm. is added to the measured length. A Polyethylene washer backed by a steel washer is then placed on the screw and it is passed through the posterior band. The number 5 suture is then tied around the screw. The free strip is then passed under and around the screw, and the screw is then secured. The sutures from the intra-articular procedure to repair the ACL tear are wrapped around the same screw. Hemovacs are then inserted into the intracondylar area and the lateral incision, and then closure is accomplished in a routine fashion.
Postop procedure is that the patient is placed in a hinged brace locked at 45 degrees. On the second day postop, constant passive motion is begun from 40-60 degrees, for slowly increasing the flexion. Daily the brace is removed and passive extension is obtained to at least 10 degrees.
In summary, and as illustrated schematically by the surgical steps of FIGS. 5-9, use of the grasper-stitcher has made the intra-articular aspect of the ACL repair much easier. By inserting the device through the anterior medial portal, the stump of an ACL can be securely grasped and manipulated without damage to the ligament tissue. Rather than having to separately secure the ACL stub while passing the 10 inch needles through a tibial drill hole, these long needles are passed directly through the instrument of the present invention. As each needle is passed through the ACL stump, the needle safely enters a separate receiving cannula, that is positioned against movement within the bored hole in the lateral femoral condyle.
While I have described a preferred embodiment of my invention, it is to be understood that the invention is to be limited solely by the scope of the appended claims.
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An elongated grasper-stitcher instrument particularly useful for arthroscopic knee surgery, permits the grasping and stitching of a stump of torn tissue, such as anterior cruciate ligament, or meniscus, during arthroscopic knee surgery. The grasper-stitcher permits multiple loops of suture to engage a stump of tissue at varying levels, and subsequent anchoring of the suture outside of a bore in the lateral pfemoral condyle. The arthroscopic tool defines a pair of atromatic grasping jaws, through parallel fingers of arcuate enclosure, which are spaced laterally so as to accommodate axial passage of a long surgical needle into the proximate end of the elongated tubular housing, through the hollow inner tube, and out through the jaw assembly, even for positions of relative closure between the movable jaw and the fixed jaw. The invention further comprises a method of comparing tissue by permitting several plurality of loops to be defined in the tissue by inserting a first needle with suture through the tissue, and using the opposite end of the suture with a second needle that also is inserted through the hollow tube and out through a receiving cannular, on the opposite side of the tissue through which the loop has been defined.
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BACKGROUND OF INVENTION
[0001] Circuit breakers typically provide protection against the very high currents produced by short circuits. This type of protection is provided in many circuit breakers by a magnetic trip unit, which trips the circuit breaker's operating mechanism to open the circuit breaker's main current-carrying contacts upon a short circuit condition.
[0002] Modern magnetic trip units include a magnet yoke (anvil) disposed about a current carrying strap, an armature (lever) pivotally disposed near the anvil, and a spring arranged to bias the armature away from the magnet yoke. Upon the occurrence of a short circuit condition, very high currents pass through the strap. The increased current causes an increase in the magnetic field about the magnet yoke. The magnetic field acts to rapidly draw the armature towards the magnet yoke, against the bias of the spring. As the armature moves towards the yoke, the end of the armature contacts a trip lever, which is mechanically linked to the circuit breaker operating mechanism. Movement of the trip lever trips the operating mechanism, causing the main current-carrying contacts to open and stop the flow of electrical current to a protected circuit.
[0003] Currently, circuit breakers having a magnetic trip unit described above allow for adjusting the air gap distance between the magnet yoke and the armature to obtain different trip set points. The trip set point range offered by adjusting the distance between the magnet yoke and the armature is limited because a large trip set point range requires a large air gap adjustment range. Because available space is often limited, a smaller than desired adjustment range results. Furthermore, overcurrent protection at a low current trip setting (e.g., three times the rated current of the circuit breaker) is inhibited because the magnetically induced force acting on the armature isn't significant enough to trip the latch system.
[0004] Those skilled in the art will appreciate that the electrical load of a motor is characterized by a starting (run-up) current and a running current. The starting current averages about six times the full load current of the motor, but the peak of the first half cycle, the so-called “inrush” current, can reach values of up to twenty times the full load current. The lower overcurrent range for motor protection is commonly 3× the full load current of the motor.
[0005] It is necessary for such magnetic trip units to be reliable at a low overcurrent setting without altering the magnetically induced force acting on the armature at high overcurrent settings. In addition, it is desired that magnetic trip units offer a broader spectrum of overcurrent ranges (e.g., for use in motor protection), so that the breaker can offer a broader range to trip at different levels of overcurrent. It is also desired that the magnetic trip units be compact.
SUMMARY OF INVENTION
[0006] The above discussed and other drawbacks and deficiencies are overcome or alleviated by a magnetic trip unit for actuating a latching mechanism to trip a circuit breaker upon an overcurrent condition, the magnetic trip unit including: a first electrically conductive strap configured to conduct an electrical current; a first magnet yoke disposed proximate to the first electrically conductive strap; and a first armature pivotally disposed proximate to the first magnetic yoke in operable communication with the latching mechanism; the first armature providing a magnetic path having a reluctance to magnetic flux; and the reluctance is adjusted to prevent saturation of the magnetic flux when the current through the strap is a first number times a rated current of the circuit breaker and the reluctance is adjusted to promote saturation of magnetic flux when the current through the strap is a second number times the rated current of the circuit breaker, wherein the first number is a number smaller than the second number.
[0007] In an alternative embodiment, a method of increasing an induced magnetic force from a magnet yoke on a pivotally mounted armature of a trip unit in a circuit breaker at a low current without substantially altering the induced magnetic force acting on the armature at a high current, the method comprising: configuring the armature to provide a magnetic path having a reluctance to a magnetic flux; and adjusting the reluctance of the magnetic path to prevent saturation of the magnetic flux when a current through the trip unit is a first number times a rated current of the circuit breaker, and the magnetic path is generally saturated when the current through the circuit breaker is a second number times the rated current, wherein the first number is a number smaller than the second number.
BRIEF DESCRIPTION OF DRAWINGS
[0008] Referring to the drawings wherein like elements are numbered alike in the several Figures:
[0009] [0009]FIG. 1 is an elevation view of a circuit breaker with a magnetic trip unit;
[0010] [0010]FIG. 2 is an elevation view of the magnetic trip unit from the circuit breaker of FIG. 1;
[0011] [0011]FIG. 3 is a perspective view of a multi-pole circuit breaker including the magnetic trip unit of FIG. 2;
[0012] [0012]FIG. 4 is a perspective view of an armature and yoke of the magnetic trip unit in FIG. 3;
[0013] [0013]FIG. 5 is a perspective view of an alternative embodiment of the yoke shown in FIG. 4; and
[0014] [0014]FIG. 6 is a graph illustrating the relationship between the induced force and gap distance of two different armature configurations shown in FIGS. 4 and 5.
DETAILED DESCRIPTION
[0015] A circuit breaker 1 equipped with an adjustable magnetic trip unit of the present disclosure is shown in FIG. 1. The circuit breaker 1 has a rotary contact arm 2 , which is mounted on an axis 3 of a rotor 4 such that it can rotate. The rotor 4 itself is mounted in a terminal housing or cassette (not shown) and has two diametrically opposed satellite axes 5 and 6 , which are also rotated about the axis 3 when the rotor 4 rotates. The axis 5 is the point of engagement for a linkage 7 , which is connected to a latch 8 . The latch 8 is mounted, such that it can pivot, on an axis 10 positioned on the circuit breaker housing 9 . In the event of an overcurrent or short circuit condition, the latch 8 is released by a latching mechanism 11 , moving the contact arm 2 to the open position shown in FIG. 1.
[0016] The latching mechanism 11 can be actuated by a trip lever 13 that pivots about an axis of rotation 12 . The other end of the trip lever 13 contacts a trip shaft 14 , which is mounted on an axis 15 supported by the circuit breaker housing 9 . Disposed on the trip shaft 14 is a cam 14 a, which can be pivoted clockwise in opposition to the force of a torsional spring 14 b wound about the axis 15 .
[0017] Mounted to the circuit breaker housing 9 in the bottom region of the circuit breaker is a rotational solenoid type magnetic assembly comprising a magnet yoke 16 and a biased armature 18 . Magnet yoke 16 encircles a current carrying strap 17 electrically connected to one of the contacts of the circuit breaker 1 . Arranged facing the magnet yoke is the armature 18 in the form of a metallic lever, which is hinge-mounted by means of hinge pin sections 19 to hinge knuckles (not shown) formed on the circuit breaker housing 9 . The armature 18 is also connected to strap 17 by a spring 20 , which biases the armature 18 in the clockwise direction, away from the magnet yoke 16 . In its upper region, armature 18 is equipped with a clip 21 rigidly mounted thereon, which can be brought into contact with the cam 14 a by pivoting of the armature in a counter-clockwise direction. Movement of cam 14 a by the armature 18 causes the trip shaft 14 to rotate about axis 15 and thereby actuate the latching mechanism 11 by means of the trip lever 13 . Once actuated, latching mechanism 11 releases latch 8 to initiate the tripping process in circuit breaker 1 . While the clip 21 is described herein as being mounted to armature 18 , the clip 21 can also be formed as one piece with the armature 18 , preferably of metal.
[0018] Referring now to FIG. 2 and FIG. 3, an adjusting bar 23 extends parallel to the axis 15 and is mounted on the axis 15 , by means of support arms 22 . The adjusting bar 23 has an adjusting arm 24 which is threadably engaged to an adjusting screw 25 for calibrating the trip unit. Adjusting bar 23 also includes a lever arm 26 which extends to a side of the adjusting bar 23 diametrically opposite adjusting arm 24 . A top end of the lever arm 26 is in contact with a cam pin 27 of a rotary knob 28 , which is mounted in a hole in the upper wall of the circuit breaker housing 9 (FIG. 1). The surface of the rotary knob 28 is equipped with a slot 29 to make it possible to adjust the rotary knob 28 with the aid of a suitable tool, such as a screwdriver.
[0019] In the unactuated state of the magnet yoke 16 , which is to say when the contact arm 2 (FIG. 1) is closed and an overcurrent is not present, the adjusting screw 25 is in constant contact with an angled surface of the clip 21 . Contact between adjusting screw 25 and the angled surface of the clip 21 is ensured by a tensile force exerted by the spring 20 on the armature 18 . The force of the angled surface of the clip 21 on adjusting screw 25 biases the adjusting bar 23 in a clockwise direction about axis 15 , thus forcing lever arm 26 away from yoke 16 and against pin 27 . In this state, it is possible to change the tilt setting of the armature 18 either by extending (or retracting) adjusting screw 25 downward from (upward to) adjusting arm 24 , or by rotating the adjusting bar 23 about axis 15 by adjusting the rotary knob 28 . Thus, the distance L shown in FIG. 2 between the armature 18 and the magnet yoke 16 is adjusted, thereby setting the current level at which the trip unit responds.
[0020] The circuit breaker with adjustable magnetic trip unit shown in FIGS. 1, 2, and 3 operates as follows. First, a person adjusting the circuit breaker 1 by turning rotary egg knob 28 sets the position of the adjusting bar 23 on the axis 15 and thus the distance between the armature 18 and the magnet yoke 16 , as shown in detail in FIG. 2. Because of the relatively greater length of the lever arm 26 as compared to the adjustable arm 24 , the adjustment made by rotary knob 28 is fine. It must be noted here that a coarser adjustment of the gap L between the magnet yoke 16 and the armature 18 can be accomplished by turning the adjusting screw 25 during installation of the trip unit in the circuit breaker housing 9 .
[0021] In the case of a short circuit, an overcurrent naturally occurs, which flows through the current carrying strap 17 . This activates the magnet yoke 16 to the extent that when a specific current is exceeded, the magnetic force generated by the magnet yoke is sufficient to attract the armature 18 in opposition to the tensile force exerted by the spring 20 . Armature 18 pivots towards yoke 16 , and the cam 14 a is pivoted clockwise in FIG. 1 (counter-clockwise in FIG. 2) by the clip 21 until the trip lever 13 is actuated. Actuation of the trip lever 13 then tilts the latching mechanism 11 such that it in turn can release the latch 8 for a pivoting motion, upward in FIG. 1, about the axis 10 . This motion is caused by a spring, which is not shown in detail in FIG. 1. The motion of the linkage 7 that is coupled with the pivoting motion of the latch 8 brings about a rotation of the rotor 4 by means of the axis 5 , and thus finally a disconnection of the contact arm 2 from the current carrying straps.
[0022] As shown in FIG. 3, the trip unit can be arranged for use in a circuit breaker 1 having a plurality of breaker cassettes 30 , with each cassette 30 having its own contact arm 2 and rotor 4 arrangements. While only one cassette 30 is shown, it will be understood that one cassette 30 is used for each phase in the electrical distribution circuit. Adjusting bar 23 extends along the row of circuit breaker cassettes 30 , parallel to the axis 15 of the trip shaft 14 . Extending from adjusting bar 23 are several adjusting arms 24 corresponding to the number of circuit breaker cassettes 30 . Also formed on the adjusting bar 23 is one lever arm 26 , which is sufficient to rotate the adjusting bar 23 about axis 15 and, thus, pivot the armatures 18 . The tripping sensitivity in each circuit breaker cassette 30 can be adjusted separately by means of the screws 25 carried by each adjusting arm 24 . As a result, individual calibration of each circuit breaker cassette 30 can be undertaken independently of the adjustment of rotary knob 28 .
[0023] Referring to FIG. 4, a perspective view of an exemplary embodiment of armature 18 and yoke 16 of a magnetic trip unit assembly is illustrated. The magnet yoke 16 is shaped from a ferrous steel plate to define a backwall 40 having side arms 42 , 44 extending generally perpendicularly from backwall 40 towards armature 18 . Each of side arms 42 , 44 includes a flange 46 , 48 extending generally perpendicularly therefrom to form a four-sided enclosure. Flanges 46 and 48 form an increased pole face area over that offered by side arms 42 , 44 . Flanges 46 , 48 further include a gap ‘z’ (pole face gap z) between edges 50 , 52 of the flanges 46 , 48 .
[0024] The armature 18 comprises of generally a flat metallic plate having a portion of material removed in the form of a rectangle 60 . Above rectangle 60 is a crossbeam component 62 of armature 18 that joins legs 64 , 66 . Crossbeam 62 includes an aperture 68 formed therein for attaching one end of spring 20 . Clip 21 is formed at a top edge 70 of armature 18 .
[0025] Electrical current passing through strap 17 (FIG. 2) induces magnetic flux in yoke 16 and armature 18 . Accordingly, a magnetic relationship exists between the length of the flanges 46 and 48 of the magnet yoke 16 and armature 18 that is dependent on gap L that separates the flanges 46 , 48 from the armature 18 and gap z that separate edges 50 , 52 . The magnetic flux generated within the flux concentrating magnet yoke 16 seeks the path of least magnetic reluctance. The path of least reluctance is the shorter of the gaps z or L. By maintaining the gap z greater than the gap L, the flux gathers between the flux concentrator magnet side arms 42 , 44 , thereby driving the flux concentration within arms 42 and 44 to a high value.
[0026] Because of the high flux concentration within arms 42 and 44 , larger magnetic forces are generated at lower current levels resulting in more force generated at clip 21 to trip the latch mechanism (i.e., cam 14 a ). The added force is beneficial at low current trip settings (e.g., three times the rated current) where the low current is otherwise not enough to induce sufficient magnetic force on armature 18 to trip the latch system. For higher trip settings, however, this added force is not needed and may cause damage to the trip latch system. Therefore, the armature 18 is pivoted away from yoke 16 , thereby increasing gap L until it is greater than gap z. With gap L greater than gap z, yoke 16 shunts the magnetic flux from yoke 16 onto itself because the flux seeks the path of least magnetic reluctance. Accordingly, the magnetic force of yoke 16 on armature 18 is reduced. However, a further reduction in magnetic force may be needed. To achieve this reduction, an amount of material is removed from armature 18 such that armature 18 does not saturate at low current settings (e.g., having a maximum flux density of approximately 1.9 T (B MAX ) before saturation flux density (B SAT ) of steel at 2.0 T) and saturates at high current settings. Because the armature does not saturate at low current settings, armature 18 does not affect the increase of the magnetically induced force due to the increased pole face area of flanges 46 , 48 acting on cross beam component 62 at low current settings.
[0027] More specifically, the reluctance of a magnetic circuit is analogous to the resistance of an electric circuit. Reluctance depends on the geometrical and material properties of the circuit that offer opposition to the presence of magnetic flux. Reluctance of a given part of a magnetic circuit is proportional to its length and inversely proportional to its cross-sectional area and a magnetic property of the given material called its permeability (μ). Iron, for example, has an extremely high permeability as compared to air so that it has a comparatively small reluctance, or it offers relatively little opposition to the presence of magnetic flux. Thus, it will be appreciated that opposition to an increase in magnetic flux and hence reaching saturation, is optionally controlled by selecting the length and cross-sectional area of the magnetic path or selecting a material with a permeability that is near saturation when the gap is small and approaches saturation as the gap increases. The magnetic path length is defined by the width of armature 18 and a cross section area 63 of cross beam 62 . Cross section area 63 of cross beam 62 is selected to obtain a reluctance that provides favorable magnetic properties at both small gaps L and large gaps L (i.e., first distances and second distances larger than first distances).
[0028] By setting the cross section area 63 based on low current requirements, armature 18 saturates at high current settings which results in a lower relative induced magnetic force. When an emanating magnetic field H permeates through a cross-section area of a medium (i.e., cross section area 63 ), it converts to magnetic flux density B according to the following formula: B magnetic flux density=μH magnetic field where μ is the permeability of the medium. Flux density (B) is simply the total flux (φ) divided by the cross sectional area (A e ) of the part through which it flows—B=φ/A e teslas
[0029] Initially, as current is increased the flux (φ) increases in proportion to it. At some point, however, further increases in current lead to progressively smaller increases in flux. Eventually, the armature 18 can make no further contribution to flux growth and any increase thereafter is limited to that provided by the permeability of free space (μ0)—perhaps three orders of magnitude smaller. It will be appreciated that the missing material to form aperture 68 must be accounted for in the minimum cross sectional area (A e ) calculation for the flux density (B) in armature 18 cross beam component 62 .
[0030] Turning to FIGS. 5 and 6, FIG. 5 illustrates a yoke 16 without an increase in pole face area provided by flanges 46 and 48 extending from side arms 42 and 44 . FIG. 6 illustrates the relationship between the induced force/torque and gap distance of the two different yoke configurations shown in FIGS. 4 and 5. In FIG. 6 of the drawings, the force/torque versus gap graph 72 shows the different electromagnetic force levels recorded at different magnetic force levels (F m ) (I×N ampere-turns) at different gap distances (L) utilizing two different yoke 16 configurations (FIGS. 4 and 5). Based on the characteristic curves, one can easily see that the magnetically induced force/torque is substantially increased at small gap distances with a yoke 16 configured having inwardly facing flanges 46 and 48 , while at larger gap distances the magnetically induced force is basically unchanged between the two configurations. More specifically, curves 72 , 76 , and 78 indicate a yoke with flanges 46 and 48 . Curves 84 , 86 , and 88 indicate a yoke without flanges 46 and 48 . Curves 74 and 84 illustrate the torque at 3× the rated current, curves 76 and 86 illustrate the torque at 4.5× the rated current, and curves 78 and 88 illustrate the torque characteristic at 7.5× the rated current. In each case tested, the torque at a specific gap was substantially larger, about 10 N mm more, using a yoke with flanges 46 , 48 (FIG. 4) than a yoke 16 without flanges 46 , 48 (FIG. 5) at a first distance such as a low gap setting, i.e., about 2 mm. However, as the gap L increased, the resultant torque is substantially the same between the two yoke configurations. The reduction in the magnetically induced force at the high current settings (large gaps) due to saturation and due to the flux shunt yoke effect described above, allows a magnetic force that remains unchanged at a second distance such as a high current setting (large gap).
[0031] Thus, the above described yoke-armature system having a yoke with inwardly facing flanges with a gap z therebetween provides the necessary torque to trip the latch mechanism at small gaps (low current setting), while providing a torque that remains virtually unchanged at larger gaps (high current setting).
[0032] It will be understood that a person skilled in the art may make modifications to the preferred embodiment shown herein within the scope and intent of the claims. While the present invention has been described as carried out in a specific embodiment thereof, it is not intended to be limited thereby but is intended to cover the invention broadly within the scope and spirit of the claims.
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A method and magnetic trip unit for actuating a latching mechanism to trip a circuit breaker upon an overcurrent condition, the magnetic trip unit including: a first electrically conductive strap configured to conduct an electrical current; a first magnet yoke disposed proximate to the first electrically conductive strap; and a first armature pivotally disposed proximate to the first magnetic yoke in operable communication with the latching mechanism; the first armature providing a magnetic path having a reluctance to magnetic flux; and the reluctance is adjusted to prevent saturation of the magnetic flux when the current through the strap is a first number times a rated current of the circuit breaker and the reluctance is adjusted to promote saturation of magnetic flux when the current through the strap is a second number times the rated current of the circuit breaker, wherein the first number is a number smaller than the second number.
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The invention herein described relates to novel heteroalkyl biphenyl oxadiazoles and thiadiazoles useful as pharmaceutical agents, to methods for their production, to pharmaceutical compositions which include these compounds and a pharmaceutically acceptable carrier, and to pharmaceutical methods of treatment as well as the use of these agents as diagnostic tools. More particularly, the novel compounds of the present invention are antagonists of angiotensin II (AII) useful in controlling hypertension, hyperaldosteronism, congestive heart failure, and glaucoma in mammals.
The enzyme renin acts on a blood plasma α 2 -globulin, angiotensinogen, to produce angiotensin I, which is then converted by angiotensin converting enzyme to AII. The latter substance is a powerful vasopressor agent which has been implicated as a causative agent for producing high blood pressure in various mammals, such as rats, dogs, and humans. The compounds of this invention inhibit the action of AII at its receptors on target cells and thus prevent the increase in blood pressure produced by this hormone receptor interaction. By administering a compound of the instant invention to a species of mammal with hypertension due to AII, the blood pressure is reduced. The compounds of the invention are also useful for the treatment of congestive heart failure, hyperaldosteronism, and glaucoma.
SUMMARY OF THE INVENTION
Accordingly, the invention is a compound of the formula ##STR1## wherein Ra is independently hydrogen, lower alkyl, lower alkoxy, or halo;
X is oxygen or sulfur;
Y is OH or SH, and
Ar is selected from the group consisting of ##STR2## wherein X' is oxygen or sulfur; R 1 and R 1 ' are each independently a lower alkyl group; R 2 is CH 2 OH, CHO, or CO 2 R 4 ; R 3 is hydrogen, halo, or a pyrrole group attached at the nitrogen atom and unsubstituted or substituted by lower alkyl, and R 4 is hydrogen or lower alkyl;
a tautomer thereof and a pharmaceutically acceptable salt thereof.
Angiotensin II mediates a variety of responses in various tissues, including contraction of vascular smooth muscle, excretions of salt and water from kidney, release of prolactin from pituitary, stimulation of aldosterone secretion from adrenal gland, and possible regulation of cell growth in both cardiac and vascular tissue. As antagonists of angiotensin II, the compounds of Formula I are useful in controlling hypertension, hyperaldosteronism, and congestive heart failure in mammals. Additionally, antihypertensive agents as a class have been shown to be useful in lowering intraocular pressure. Thus, the compounds of Formula Ia or Ib are also useful in controlling glaucoma.
A still further embodiment of the present invention is a pharmaceutical composition for administering an effective amount of a compound of Formula Ia or Ib in unit dosage form in the treatment methods mentioned above.
Finally, the present invention is directed to methods for production of a compound of Formula Ia or Ib.
DETAILED DESCRIPTION OF THE INVENTION
In the compounds of Formula I, the term "lower alkyl" means a straight or branched hydrocarbon radical having from one to six carbon atoms and includes, for example, methyl, ethyl, n propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, and the like.
"Lower alkoxy" is 0-alkyl of from one to six carbon atoms as defined above for "lower alkyl."
"Halogen" is fluorine, chlorine, bromine, or iodine.
The compounds of Formula I are capable of further forming both pharmaceutically acceptable acid addition and/or base salts. All of these form a are within the scope of the present invention.
Pharmaceutically acceptable acid addition salts of the compounds of Formula I include salts derived from nontoxic inorganic acids such as hydrochloric, nitric, phosphoric, sulfuric, hydrobromic, hydriodic, phosphorous, and the like, as well as the salts derived from nontoxic organic acids, such as aliphatic mono- and dicarboxylic acids, phenyl-substituted alkanoic acids, hydroxyalkanoic acids, alkanedioic acids, aromatic acids, aliphatic and aromatic sulfonic acids, etc. Such salts thus include hydrochloride, hydrobromide, hydroiodide, sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, nitrate, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, chloride, bromide, iodide, acetate, propionate, caprylate, isobutyrate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, mandelate, benzoate, chlorobenzoate, methylbenzoate, dinitrobenzoate, phthalate, benzenesulfonate, toluenesulfonate, phenylacetate, citrate, lactate, maleate, tartrate, methanesulfonate, and the like. Also contemplated are salts of amino acids such as arginate and the like and gluconate, galacturonate (see, for example, Berge, S. M., et al, "Pharmaceutical Salts," Journal of Pharmaceutical Science 66:1-19 (1977)).
The acid addition salts of said basic compounds are prepared by contacting the free base form with a sufficient amount of the desired acid to produce the salt in the conventional manner. The free base form may be regenerated by contacting the salt form with a base and isolating the free base in the conventional manner. The free base forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free base for purposes of the present invention.
Pharmaceutically acceptable base addition salts are formed with metals or amines, such as alkali and alkaline earth metals or organic amines. Examples of metals used as cations are sodium, potassium, magnesium, calcium, and the like. Examples of suitable amines are N,N, dibenzylethylenediamine, chloroprocaine, choline, diethanolamine, ethylenediamine, N methylglucamine, and procaine (see, for example, Berge, S. M., et al., "Pharmaceutical Salts," Journal of Pharmaceutical Science 66:1-19 (1977)).
The base addition salts of said acidic compounds are prepared by contacting the free acid form with a sufficient amount of the desired base to produce the salt in the conventional manner. The free acid form may be regenerated by contacting the salt form with an acid and isolating the free acid in the conventional manner. The free acid forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free acid for purposes of the present invention.
Certain of the compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms, including hydrated forms, are equivalent to unsolvated forms and are intended to be encompassed within the scope of the present invention.
The compounds of the present invention can exist in tautomeric forms and such forms are included within the scope of the present invention. For example, a compound of the Formula Ia and its tautomeric form are illustrated as follows and is formed by shifting of a hydrogen atom. ##STR3## Similarly, a compound of the Formula Ib and its tautomer are shown as follows: ##STR4##
A preferred embodiment of the present invention is a compound of the formula ##STR5## wherein X, Y, and Ar are as defined above.
A more preferred embodiment is a compound of the Formula IIa or IIb wherein X, X', Y, and Ar are as defined above i which R 1 and R 1 ' are lower alkyl; R 2 is CH 2 OH, CHO, CO 2 H, or CO 2 CH 3 ; R 3 is hydrogen, chloro, or a pyrrole group attached at the nitrogen atom, and R 4 is hydrogen or lower alkyl.
Most preferred is a compound of Formula IIa or IIb wherein X and Y are as defined above, and Ar is ##STR6## in which R 1 is lower alkyl; R 2 is CH 2 OH, CHO, CO 2 H, or CO 2 H 3 , and R 3 is hydrogen, chloro, or a pyrrole group attached at the nitrogen atom.
Particularly valuable are:
5-[4'-[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-one;
5-[4'-[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl[1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-thione;
5-[4'-[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-thiadiazol-2[3H]-one;
5-[4'-[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-thiadiazol-2[3H]-thione;
3-[4'-[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]-1,2,4-oxadiazol-5[4H]-one;
5-[4'-[2-Butyl-4-chloro-5-(hydroxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-thione; and
5-[4'-[2-Butyl-4-chloro-5-(hydroxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-one.
Most valuable are:
5-[4'-[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-one and
5-[4'-[5,7-Dimethyl-2--ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-thione.
The compounds of the present invention are prepared by the following series of described reactions and illustrated by the following synthetic schemes.
The preferred route is through an intermediate 2 illustrated in Scheme I and using this key intermediate in Schemes II and III to prepare the compounds of Formula Ia. The compounds of Formula Ib are preferably prepared through the cyano intermediate 4 using Schemes V and VI.
The key intermediates 2 and 4 are prepared as illustrated in Scheme I which involve the reaction of known bromomethyl biphenyl compounds 1 and 3 by reaction with the appropriate heterocycle ArH in the presence of base. Such bases are, for example, sodium hydride, sodium carbonate, cesium carbonate, and the like. The reaction can also be carried out in a suitable solvent such as, for example, tetrahydrofuran (THF), dioxane, or dimethylformamide (DMF) at temperatures of -20° C. to room temperature.
The heterocyclic ArH compounds are either known or can be prepared by known methods. These known heterocyclics have been described in the following references:
J. Med. Chem. 33:1312-1336 (1990),
Ep 253310,
EP 399731,
EP 400974,
J. Med Chem. 34:2919 2922 (1991),
EP 399732,
EP 400835,
EP 412848,
EP 456442,
EP 453210,
EP 323841,
EP 409332,
EP 411507,
EP 419048,
EP 412594,
EP 411766,
and references cited therein. ##STR7##
In certain cases it may be necessary to use known protecting groups on substituents of this heterocycle ArH which are then easily removable subsequent to the synthesis of the compounds 2 or 4. It also may be necessary in certain cases to separate regioisomeric alkylation products from intermediates 2 or 4 using standard separation techniques such as column chromatography.
The compounds of Formula Ia or Ib are then prepared using these key intermediates as illustrated in Schemes II to VI. ##STR8##
In Scheme II, the methyl ester of the heterocyclic biphenyl carboxylic acid is treated with hydrazine to form a hydrazide, which is then reacted with a carbon disulfide in the presence of base such as, for example, potassium hydroxide, to form a 2-mercapto-1,3,4-oxadiazole. Alternatively, the hydrazide can be treated with carbonyldiimidazole (CDI) to form a corresponding 2-hydroxy-1,3,4-oxadiazole.
In Scheme III, intermediate 2 is first treated with base such as sodium hydroxide to hydrolyze the ester followed by treatment with oxalylchloride and H 2 N-NH C(S)-SMe to form the methylthioester hydrazide compound which is cyclized in acid conditions, e.g., aryl sulfonic acids or methanesulfonic acid in a solvent such as toluene at temperatures of 0° C. to reflux, to form the 2-thiomethyl-1,3,4-thiadiazole, which is demethylated under standard conditions such as with sodium thiomethoxide at elevated temperatures to form the desired 2-mercapto-thiadiazole or, alternatively, is oxidized with a reagent such as hydrogen peroxide or metachloro perbenzoic acid, followed by base hydrolysis to form the 2-hydroxy-1,3,4-thiadiazole.
In Scheme IV, intermediate 4, the heterocyclic biphenyl nitrile is treated with hydrogen sulfide to form the thioamide followed by treatment with hydrazine to form the imide hydrazone. Treatment of that compound with carbon disulfide, forms a cyclized product, the desired 2-mercapto 1,3,4 thiadiazole, which can be subsequently converted to the 2-hydroxy compound in three steps by treating first with methyl iodide, followed by hydrogen peroxide or meta-chloroperbenzoic acid and base hydrolysis.
In Scheme V, intermediate 4 is treated with hydroxylamine followed by ethyl chloroformate at elevated temperatures to form the compound of Formula Ib, in tautomeric form, namely the 5 oxo-1,2,4-oxadiazole. Alternatively, the product obtained with hydroxylamine is treated with thiocarbonyldiimidazole to form the 5-thiono 1,2,4-oxadiazole. Alternatively, intermediate 4 is treated with ammonia and ammonium chloride to form the amidine which, on treatment with carbon disulfide, gives the 5-thiono-1,2,4 thiazole.
In Scheme VI, intermediate 4 is treated with sodium hydroxide to form the amide followed by chlorocarbonyl sulfenyl chloride to form a 2-oxo-1,3,4-oxathiazole which decomposes to an intermediate nitrile sulfide which reacts with tosyl cyanide to give the 5-tosyl 1,2,4-thiadiazole, which on treatment with aqueous base provides the 5 hydroxy-1,2,4-thiadiazole. Alternatively, treatment of the tosyl compound with thiourea or thioacetic acid followed by hydrolysis yields the 5-mercapto-1,2,4-thiadiazole.
The compounds of Formula Ia or Ib can alternatively be prepared by constructing the thiadiazole or oxadiazole ring first followed by reaction with the desired heterocyclic ArH, as shown in Schemes VII through IX. ##STR9##
In Schemes VII through IX the key intermediates are compounds similar to compounds of formulae 2 and 4 where instead of the bromomethyl biphenyl compound a hydroxymethyl biphenyl carboxylic acid methyl ester or cyano compound is used where the hydroxyl group is protected with a suitable protecting group such as, for example, tetrahydropyranyl ether.
In Scheme VII, the methyl ester of the biphenyl carboxylic acid is treated in a similar manner as previous schemes to form either the 2-mercapto or 2-hydroxy-1,3,4-oxadiazoles where the heterocyclic group is placed following the formation of a 2-methylmercapto-1,3,4-thiadiazole compound by removing the hydroxyl protecting group according to known methods, for example, by treatment of the hydroxyl group with phosphorous tribromide and displacing the bromide with the desired heterocyclic compound in the presence of base in a similar manner as in the preparation of the key intermediates in Scheme I.
Scheme VIII illustrates the same kind of preparation incorporating the heterocyclic followed by the preparation of the thiadiazole.
Scheme IX begins with a biphenyl nitrile compound having a protected hydroxyl. Treatment with sodium hydroxide forms a corresponding amide which is then treated with chlorocarbonyl sulfenyl chloride to form a 5-oxo 1,3,4-oxathiazole, which is treated with tosyl cyanide as shown previously in Scheme VI. At this stage, the hydroxyl group on the biphenyl is deprotected, brominated, and displaced with the desired heterocyclic moiety as described above. The tosyl intermediate with a heterocyclic moiety attached is then converted either to the 5-mercapto- 1,2,4-thiadiazole or the 5-hydroxy-1,2,4-thiadiazole, as described again previously in Scheme VI.
The effectiveness of the compounds of the instant invention is determined by a test (RBAT) entitled Receptor Binding of Angiotensin II. The test method is described by Dudley, D. T., et al, Molecular Pharmacology 38:370-377 (1990). In this in vitro test the inhibition of tritiated angiotensin II binding to rat liver membranes is measured. The data in the following table show the binding activity of representative compounds of the invention.
TABLE______________________________________Example RBAT (μM)______________________________________3 0.094 0.0069 0.610 6______________________________________
Based on the observations that ACE inhibitors are known to benefit patients with heart failure, the instant compound which also interrupts the renin angiotensin system (RAS), would show similar benefits.
For preparing pharmaceutical compositions from the compounds described by this invention, inert, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, dispersible granules, capsules, cachets, and suppositories. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, or tablet disintegrating agents. It can also be encapsulating material. In powders, the carrier is a finely divided solid which is in admixture with the finely divided active compound. In the tablet the active compound is mixed with a carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired. The powders and tablets preferably contain from 5 to 10 to about 70 percent of the active ingredient. Suitable solid carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, a low melting wax, cocoa butter, and the like. The term "preparation" is intended to include the formulation of the active compound with encapsulating material as carrier providing a capsule in which the active component (with or without other carriers) is surrounded by carrier, which is thus in association with it. Similarly, cachets are included. Tablets, powders, cachets, and capsules can be used as solid dosage forms suitable for oral administration.
The compounds of the present invention may be administered orally, buccally, parenterally, by inhalation spray, rectally, or topically in dosage unit formulations containing conventional nontoxic pharmaceutically acceptable carriers, adjuvants, and vehicles as desired. The term parenteral as used herein includes subcutaneous injections, intravenous, intramuscular, intrasternal injection, or infusion techniques.
For preparing suppositories, a low melting wax such as a mixture of fatty acid glycerides or cocoa butter is first melted, and the active ingredient is dispersed homogeneously therein by stirring. The molten homogeneous mixture is then poured into convenient sized molds, allowed to cool, and thereby solidify.
Liquified form preparations include solutions, suspensions, and emulsions. As an example may be mentioned water or water/propylene glycol solutions for parenteral injection. Liquid preparations can also be formulated in solution in aqueous polyethyleneglycol solution. Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, i.e., natural or synthetic gums, resins, methylcellulose, sodium carboxymethyl cellulose, and other well-known suspending agents.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for either oral or parenteral administration. Such liquid forms include solutions, suspensions, and emulsions. These particular solid form preparations are most conveniently provided in unit dose form and as such are used to provide a single liquid dosage unit. Alternately, sufficient solid may be provided so that after conversion to liquid form, multiple individual liquid doses may be obtained by measuring predetermined volumes of the liquid form preparation as with a syringe, teaspoon, or other volumetric container. When multiple liquid doses are so prepared, it is preferred to maintain the unused portion of said liquid doses at low temperature (i.e., under refrigeration) in order to retard possible decomposition. The solid form preparations intended to be converted to liquid form may contain, in addition to the active material, flavorants, colorants, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like. The liquid utilized for preparing the liquid form preparation may be water, isotonic water, ethanol, glycerin, propylene glycol, and the like, as well as mixtures thereof. Naturally, the liquid utilized will be chosen with regard to the route of administration, for example, liquid preparations containing large amounts of ethanol are not suitable for parenteral use.
Preferably, the pharmaceutical preparation is in unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, for example, packeted tablets, capsules, and powders in vials or ampules. The unit dosage form can also be a capsule, cachet, or tablet itself, or it can be the appropriate number of any of these in packaged form.
The quantity of active compound in a unit dose of preparation may be varied or adjusted from 1 mg to 500 mg, preferably 5 to 100 mg according to the particular application and the potency of the active ingredient. The compositions can, if desired, also contain other compatible therapeutic agents.
In therapeutic use as renin inhibitors, the mammalian dosage range for a 70 kg subject is from 0.1 to 1500 mg/kg of body weight per day or preferably 1 to 500 mg/kg of body weight per day optionally in divided portions. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day if desired.
The following examples are provided to enable one skilled in the art to practice the present invention. These examples are not intended in any way to limit the scope of the invention but are illustrative thereof.
EXAMPLE 1
4'-[[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid methyl ester
To a suspension of sodium hydride (345 mg, 60% in oil, 8.6 mmol) in dry DMF (10 mL) was added 5,7-dimethyl-2-ethylimidazo[4,5-b]pyridine (1.5 g, 8.6 mmol) under an atmosphere of dry nitrogen. The reaction mixture was stirred at room temperature until the evolution of gas subsided. The reaction mixture was cooled to 0° C. and a solution of methyl 4'-bromomethylbiphenyl-2-carboxylate (2.7 g, 8.84 mmol) in dry DMF (5 mL) was added dropwise. The resulting solution was stirred at room temperature overnight. The reaction mixture was poured into water (250 mL), the pH was adjusted to pH 6 by the addition of 1N HCl, and the product was extracted into ethyl acetate. Flash chromatography (silica, ethyl acetate) gave 4'-[[5,7-dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid methyl ester (2.05 g, 61%) as an amorphous solid.
EXAMPLE 2
4'-[[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl]1,1'-biphenyl-2-yl]carboxylic acid hydrazide
A solution of 4'-[[5,7-dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl[1,1'-biphenyl-2-yl]carboxylic acid methyl ester (1.3 g) and hydrazine hydrate (8 mL) in methanol (20 mL) was heated at reflux overnight under a nitrogen atmosphere. The reaction mixture was concentrated to 10 mL under reduced pressure and diluted with water. The resulting precipitate was collected by filtration, washed with water, and dried under vacuum overnight. Recrystallization from ethyl acetate gave pure 4'-[[5,7-dimethyl-2-ethyl-3H-imidazo[4,5 b]pyridin-3yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid hydrazide (1.2 g, 96%) as a monohydrate, mp 139°-142° C.
Analysis calculated for C 24 H 25 N 5 O.H 2 O: C, 69.04; H, 6.52; N, 16.82. Found: C, 69.20; H, 6.32; N, 16.67.
EXAMPLE 3
5-[4'-[[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-one
To a solution of 4'-[[5,7-dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid hydrazide (400 mg, 1 mmol) and triethylamine (130 mg, 1.3 mmol) in THF (20 mL) was added carbonyldiimidazole (275 mg, 1.7 mmcl) at 0° C. The reaction mixture was stirred at room temperature overnight and the solvent was evaporated. The residue was dissolved in water and the solution was adjusted to pH 3 by the addition of IN HCl. The resulting precipitate was collected by filtration and dried under vacuum to give 5- [4'-[[5,7-dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin 3-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4 oxadiazol-2[3H]-one (0.35 g, 81%) as a partial hydrate, mp 210°-212° C.
Analysis calculated for C 25 H 23 N 5 O 2 0.4H 2 O: C, 69.39; H, 5.54; N, 16.19. Found: C, 69.43; H, 5.54; N, 16.16.
EXAMPLE 4
5- [4'-[[5,7-Dimethyl-2-ethyl-3H-imidazo[4,5 b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-thione
A solution of 4'-[5,7-dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid hydrazide (400 mg, 1 mmol), and KOH (56 mg, 1 mmol), and carbon disulfide (0.18 mL) in methanol (20 mL) was heated at reflux overnight. The reaction mixture was cooled and evaporated. The residue was dissolved in water (20 mL) and the resulting solution was acidified to pH 3. The solid was collected by filtration, washed with water, and dried under vacuum to give 5-[4'-[[5,7-dimethyl-2-ethyl-3H-imidazo[4,5-b]pyridin-3-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-thione (0.33 g, 73%) as a partial hydrate, mp 260°-268° C. dec.
Analysis calculated for C 25 H 23 N 5 OS.1/2H 2 O: C, 66.64; H, 5.37; N, 15.54. Found: C, 66.84; H, 5.39; N, 15.40.
EXAMPLE 5
4'-[[2-Butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid methyl ester
A solution of methyl 4'-bromomethylbiphenyl-2-carboxylate (2.05 g) in dry THF (10 mL) was added dropwise to a solution of 2-butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazole (2.03 g) and NaN(TMS) 2 (1.48 g) in dry THF (20 mL) at 0° C. and the reaction mixture was stirred at room temperature overnight. It was diluted with brine and the organic layer was collected, dried over MgSO 4 , and evaporated under reduced pressure. The residue was purified by flash chromatography (EtOAc, silica) to separate the two regioisomeric alkylation products. The major isomer, 4'-[[2-butyl-4 chloro-5-(t-butyldimethylsilyloxymethyl) 1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid methyl ester (1.4 g) was used in the next step and the regiochemistry of this alkylation product was proven by NOE experiments at the stage of the hydrazide.
EXAMPLE 6
4'-[2-Butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid hydrazide
According to the procedure of Example 2, 4'-[[2-butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid methyl ester was treated with hydrazine to give 4'-[[2-butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid hydrazide (60%).
EXAMPLE 7
5-[4'-[[2-Butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H-one
According to the procedure of Example 3, 4'-[[2-butyl-4-chloro-5-(t butyldimethylsilyloxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid hydrazide was treated with triethylamine and carbonyldiimidazole to give 5-[4'-[[2-butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol-1yl]methyl][1,1 -biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]one (80%).
EXAMPLE 8
5-[4'-[[2-Butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-thione
According to the procedure of Example 4, 4'-[[2-butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]carboxylic acid hydrazide was treated with KOH and carbon disulfide to give 5-[4'-[[2-butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol 1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]thione (70%).
Analysis calculated for C 29 H 37 ClN 4 O 2 Si: C, 61.19; H, 6.55; N, 9.84. Found: C, 60.78; H, 6.33; N, 9.79.
EXAMPLE 9
5-[4'-[[2-Butyl-4-chloro-5-(hydroxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-thione
A solution of 5-[4'-[[2-butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-thione (100 mg) in 1:9 48% HF/acetonitrile (10 mL) was stirred at room temperature for 3 hours in a plastic flask. The reaction mixture was neutralized by the dropwise addition of saturated aqueous NaHCO 3 (to pH 5) and was diluted with water. The resulting precipitate was collected by filtration and washed with water. Recrystallization from ethyl acetate gave pure 5-[4'-[[2-butyl-4-chloro-5-(hydroxymethyl)1H imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-thione (40 mg, 50%), mp 193°-194° C. dec.
Analysis calculated for C 23 H 23 ClN 4 O 2 S: C, 60.72; H, 5.10; N, 12.31. Found: C, 60.66; H, 4.99; N, 12.24.
EXAMPLE 10
5-[4'-2-Butyl-4-chloro-5--(hydroxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]one
According to the procedure of Example 9, 5-[4'-[[2-butyl-4-chloro-5-(t-butyldimethylsilyloxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-one (170 mg) was treated with HF. Recrystallization from hexane/ethyl acetate gave pure 5-[4'- [[2-butyl-4-chloro-5-(hydroxymethyl)-1H-imidazol-1-yl]methyl][1,1'-biphenyl-2-yl]-1,3,4-oxadiazol-2[3H]-one (100 mg, 75%), mp 158°-159° C.
Analysis calculated for C 23 H 23 ClN 4 O 3 : C, 62.94; H, 5.28; N, 12.76. Found: C, 62.93; H, 5.28; N, 12.65.
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Heterocyclic methyl derivatives of biphenyl oxadiazoles and thiadiazoles are described, as well as methods for the preparation of said derivatives and pharmaceutical compositions of the same, which are useful as antagonists of the angiotensin II enzyme and thus useful in treating hypertension, hyperaldosteronism, congestive heart failure, and glaucoma.
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BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
[0001] 1. Field of the Invention
[0002] The present invention relates to a sewing machine with pattern stitching function and more particularly relates to pattern data which may be selectively used to form an optional stitch pattern including a plurality of pattern elements, the pattern data being optionally modified with respect to each of the pattern elements.
[0003] 2. Prior Art
[0004] It has been generally prevalent that the sewing machine is operated under control of a zigzag stitch producing mechanism and a work feeding amount adjusting mechanism to form a pattern of zigzag stitches. Namely, according to the conventional sewing machine with pattern stitching function, the pattern data are particularly provided to each of the different patterns to be selectively formed. Therefore, in case a pattern is modified or varied, it is required that the pattern data is modified or varied accordingly in its entirety.
[0005] However, actually it is often required to modify or vary a pattern, particularly as to the individual pattern elements which form the pattern, instead of modifying the entire pattern.
[0006] In this case, it may be considered that the pattern is divided into the elements to be individually modified or varied so that the modified or varied pattern elements may be reconstructed into a pattern. It is, however, very difficult to position the individual pattern elements so as to form a single pattern.
OBJECTS OF THE INVENTION
[0007] The invention has been provided to eliminate the defects and disadvantages of the prior art. It is, therefore, an object of the invention to provide a sewing machine with pattern stitching function which may be operated under control of pattern data to form a pattern of a plurality of different pattern elements, the pattern data being modified or varied with respect to each of the pattern elements.
SUMMARY OF THE INVENTION
[0008] For attaining the object of the invention, the sewing machine substantially comprises a needle mechanism including a vertically reciprocating needle and a work feeding mechanism including a feed dog for transporting a work relative to the needle so as to be stitched, the needle mechanism being swingable transversely of the direction in which the work is transported, the needle mechanism and the work feeding mechanism being operated under control of pattern data to form a pattern of stitches on the work, means for giving pattern data for producing a stitch pattern composed of a plurality of pattern elements, means for modifying the pattern data for each of said pattern elements.
[0009] With combination of the elements including the means for modifying the pattern data for each of said pattern elements, the variation of a stitch pattern may be increased. Further, since the pattern is formed by a set of pattern data, the stitching position may be easily changed.
[0010] According to a preferred embodiment, the pattern may be composed of a portion of dense zigzag stitches and a portion of one or more straight stitches. Therefore, in case the pattern data for modifying the straight stitch portion is optionally changed, the pattern may be modified in so many ways. It is needless to say that the zigzag stitch portion may be modified, instead of the straight stitch portion.
[0011] The pattern of dense zigzag stitches may be replaced by another pattern of other stitches than the zigzag stitches.
[0012] Preferably, the pattern data may includes the data for controlling the zigzag stitch width, the data for controlling the work feeding amount and the data for controlling the thread tension. The thread tension may be changed for the zigzag stitch portion and for the straight stitch portion to obtain an optimal stitch pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block diagram showing the functions of a sewing machine of the invention.
[0014] [0014]FIG. 2 is an explanatory view of a composite pattern, shown by way of example, to be formed by the sewing machine of the invention.
[0015] [0015]FIG. 3 is an enlarged view of the pattern as shown in FIG. 2.
[0016] [0016]FIG. 4 (A) through (D) are explanatory views of the pattern shown as modified in so many ways.
[0017] [0017]FIG. 5 is an explanatory view of the pattern shown in connection with variation of thread tension.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] The invention will be described in detail in reference to a preferred embodiment as shown in the attached drawings.
[0019] In FIG. 1, CPU 1 is provided to control the operation of a sewing machine in accordance with programs stored in a program memory 10 . The CPU 1 is responsive to an instruction from a rotation speed instructing device 27 including a speed controller to control a machine motor drive circuit 20 , thereby to control the rotation speed of a machine motor 21 . Thus the machine motor 21 will operate a needle mechanism 23 and a work feeding mechanism 25 at a speed as instructed by the rotation speed instructing device 27 .
[0020] The number of rotations of the machine motor 21 is detected by a rotation detector 22 and is feedbacked to the CPU 1 for controlling the rotation speed of the machine motor 21 .
[0021] The needle mechanism 23 is so formed as to be moved by a stitch amplitude producing mechanism 24 in a direction transversely of the direction in which the work is transported by the work deeding mechanism 25 , thereby to form zigzag stitches of optional amplitude (zigzag stitch width). The CPU 1 is responsive to pattern data from the program memory 10 to control the stitch amplitude and the work feeding amount (stitch length) through the stitch amplitude adjusting mechanism 24 and the work deeding mechanism 25 respectively, thereby to form various patterns of stitches.
[0022] Further, the CPU 1 is responsive to pattern data from the program memory 10 to control the operation of a thread tension adjusting device 26 .
[0023] A pattern data memory 2 has pattern data stored therein which may be optionally selected by operation of a pattern selecting device 3 and may be modified by operation of a pattern data modifying device 4 with respect to the predetermined elements which form a single pattern.
[0024] [0024]FIGS. 2 and 3 show a composite pattern, that is, the pattern of French knots by way of example formed by the pattern data stored in the pattern memory 2 .
[0025] Here the French knot pattern is composed of a series of patterns including two painted out elements 30 , 30 and the two straight line elements 31 , 31 located between the two painted out elements 30 , 30 . The pattern data may be modified by the pattern data modifying device 4 for each of the painted out elements 30 , 30 and straight line elements 31 , 31 . The pattern data stored in the pattern data memory 2 include the data for controlling the operation of thread tension adjusting device 26 in addition to the data for controlling the operation of the work feeding mechanism 25 and of the stitch amplitude adjusting mechanism 24 . The pattern data may be modified regarding a plurality of predetermined elements to be stitched in a composite stitch pattern.
[0026] [0026]FIG. 4 shows the examples of patterns formed by the pattern data as modified. In FIG. 4, (A) shows a stitch pattern formed by use of the data before the same is modified. (B) shows the same stitch pattern, but having the straight stitch lines 31 ′, 31 ′ elongated as compared with the straight stitch lines 31 , 31 of (A). (D) shows the same stitch pattern, but having further elongated straight stitch lines 31 ″, 31 ″ as compared with the straight stitch lines 31 ′, 31 ′ of (B).
[0027] Further, (D) shows the stitch pattern modified to have the straight stitch lines 31 increased up to four.
[0028] [0028]FIG. 5 shows the thread tension set to each of the pattern elements of the composite pattern. As to the zigzag stitch portions, that is, the painted out portions 30 in FIG. 2, the thread tension adjusting device 26 is adjusted to give the upper thread 41 a high tension such that the lower thread 42 may be exposed at the upper side of the work 40 , thereby to give the painted out portions 30 a voluminous appearance. On the other hand, as to the straight lines 30 , the thread tension adjusting device 26 is adjusted to give the lower thread 41 a normal tension such that the lower thread 42 may not be exposed at the upper side of the work 40 .
[0029] [0029]FIG. 3 shows generally circular patterns 30 of zigzag stitches corresponding to the painted out portion 30 in FIG. 2, the amplitude of the zigzag stitches being varied per stitch. Such variation of stitch amplitude will prevent the work or cloth from being shrunk which may otherwise be caused.
[0030] The circular pattern 30 includes a reverse stitch portion 35 formed as the work transported in the reverse direction so as to prevent a skipped stitch at the time of formation of the next straight stitch 31 .
[0031] According to the embodiment of the invention, the circular pattern portion, that is, the painted out portion 30 and the straight stitch portions 31 , 31 form one composite pattern with variation of the pattern data with respect to each of the pattern elements. As the result, the composite pattern may be modified in many ways as shown in FIG. 4 (A) through (D) with the thread tension being adjusted accordingly with respect to each of pattern elements as shown in FIG. 5.
[0032] Further, since the painted out portion 30 and straight portions 31 , 31 form a single composite pattern, the pattern may be displaced in its entirety in the width direction thereof.
[0033] As is described above, according to the invention, the pattern data for forming a stitch pattern of a plurality of pattern elements may be modified with respect to each of the pattern elements. It is, therefore, apparent that the formation of a variety of patterns may be realized.
[0034] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications are intended to be included within the scope of the following claims.
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A sewing machine with pattern stitching function is disclosed, wherein pattern data may be optionally selected to control the swinging movement of the vertically reciprocating needle and the work feeding amount of the work feeding mechanism, thereby to form a pattern composed of a plurality of pattern elements, the selected pattern data being modified with respect to each of the pattern elements.
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This application is a continuation in part of Ser. No. 293,946 filed Jan. 5, 1989, now issued as U.S. Pat. No. 4,924,761.
This invention relates to roof vents.
BACKGROUND AND SUMMARY OF THE INVENTION
It has heretofore been known that it is desirable to provide means for ventilating a roof. Typical patents that have been heretofore suggested are, for example, 2,799,214, 3,236,170, 3,949,657, 4,280,399, 4,325,290, 4,554,862, 4,642,958, 4,643,080 and 4,817,506.
Among the objectives of the present invention are to provide an improved roof vent which will effectively vent the interior of a building; which will preclude entry of water and blowing snow and insects by the action of wind from entering the building; which will prevent insects and the like from entering the building; which can be readily adapted to roofs of varying slopes and inclinations; which will prevent ice build-up thereon; which is pleasing in appearance; which is low cost; and which can be readily handled in the field; and which can be utilized for arrangement of roofs which are unsymmetrical.
In accordance with the invention, a roof vent comprising a one piece plastic body including a base wall having transversely spaced rows of integral vanes extending from one surface thereof. The vanes of adjacent rows are positioned such that the vanes define a sinuous path. Preferably, one of each of said rows having the wings extending at an acute angle to the axis of the wall and the other row of each set of rows has the wings extending at an oppositely directed acute axis to the longitudinal axis of the wall toward the wings of the one row. Thus air is vented through sinuous paths outwardly when the vent is positioned with the wings engaging the roof and the base wall spaced from the roof. Water and snow are prevented by the wings from entry beneath the vent into the building.
In another form, the plastic body is constructed and arranged to accommodate roofs with different slopes while at the same time providing and aesthetic appearance.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is fragmentary part sectional view of a building utilizing the roof vent embodying the invention.
FIG. 2 is a transverse section through a roof of a building utilizing the roof vent embodying the invention.
FIG. 3 is a sectional view taken along the line 3--3 in FIG. 5.
FIG. 4 is a fragmentary view showing the overlapping of adjacent roof vents along a roof.
FIG. 5 is a bottom plan of the roof vent embodying the invention before it is bent to conform to the roof.
FIG. 6 is fragmentary bottom plan view on a reduce scale of the roof vent shown in FIGS. 3 and 5.
FIG. 7 is a sectional view through a portion of the roof vent as fastened to a roof.
FIG. 8 is fragmentary sectional perspective view showing the adaptation of the roof vent to a different roof.
FIG. 9 is fragmentary sectional perspective view showing the adaptation of the roof vent to another roof.
FIG. 10 is a fragmentary plan view of a modified roof vent.
FIG. 11 is a fragmentary sectional view taken along the line 11 in FIG. 10.
FIG. 12 is a fragmentary sectional view on an enlarged scale of a portion of the roof vent shown in FIG. 11.
FIG. 13 is an end view of a further modified form of roof vent.
FIG. 14 is a partly diagrammatic view of the roof vent shown in FIG. 13 on a roof having a predetermined slope.
FIG. 15 is a view similar to FIG. 14 showing the roof vent applied to a roof having a greater slope.
FIG. 16 is a fragmentary plan view of a modified form of roof vent.
DESCRIPTION
Referring to FIGS. 1 and 2 the roof vent 10 embodying the invention is adapted to be mounted on the ridge of a roof by nails 11 extending into the roof in order that the interior of the building may be vented. In accordance with well known construction, portions of the roof walls 12 are cut away as at 13 adjacent the ridge board 14 and the vent 10 is positioned over the shingles on the roof walls 12 and over the opening 13. Subsequently, sections of roofing or shingle material 15 are provided over the vent in overlapping relation, if desired over the roof vent.
In accordance with the invention, the roof vent 10 comprises a one piece plastic body which is molded preferably by injection molding and includes a base wall 16 from which a plurality of rows of wings 17, 18 extend in generally perpendicular fashion from the wall 16. In addition the roof vent includes end walls 19, 20, 21, 22 that are molded integrally with the base wall 16 and extend outwardly in relatively longitudinally spaced relation for purposes presently described. Each set of the wings 17, 18 is provided in two rows along the longitudinal edges of the base wall 16 (FIG. 5), the wings 17, 18 being identical except that the row of wings 17 in the outermost row are in longitudinally spaced parallel relation and the wings 18 in the innermost row are in longitudinally spaced relation such that the plane of the wings 17 intersects the plane of the wings 18. In addition, each of the wings 17 is provided with a curved end 23 as are the wings 18 provided with a curved end 24. The curved ends 23, 24 function to entrap water and snow that may be blown inwardly by wind.
Further, a layer 25 of foraminous material such as open cell foam plastic is interposed between the adjacent ends 23 and 26 of the wings 17, 18 and functions to prevent insects from entering the building while permitting air to exit from under the roof. Preferably, the layers 25 are held in position by integral pins 25a that extend from inner surface of the base wall 16.
Similarly, a layer 30 of nonporous plastic material is provided adjacent each end of the walls 19-22 and is held in position by projections 31 that extend from the surface of the wall to prevent the entry of insects as well as air and moisture through the end walls.
The base wall 16 is formed with portions 32, 33 that extend longitudinally and have a thinner cross section so that the user can bend the wall to the desired angle for conforming the roof vent to the angle of the roof members 12. After such a conformation, the nails 11 can be driven through openings 34 to mount the vent in position on the roof. As shown in FIG. 7, a membrane M of thinner cross section closes the elongated openings 34 such that only a portion of the elongated opening will be pierced by the nail 11 thus minimizing any chance of moisture or rain from entering through the openings that are formed by the piercing. Walls 50 are provided against each opening 34 opposite each wing 18. When a nail 11 is driven, the wing 18 and adjacent wall 50 cooperate to absorb the force of the hammer on the base wall 16 preventing deformation of the back wall 16 as might occur if the portion were not supported. Thus, the pleasing appearance of the roof vent is facilitated.
It can be seen that the periphery of the vent adjacent the shingles is designed such that moisture, snow and rain cannot collect to cause ice build-up.
The edges 35 of the wall are a slight angle to the plan of the wall such that they form an overhang as that shown in FIG. 1. When the base wall 16 is bent along the lines 32, 33, the end walls 20, 21 are caused to overlap one another as viewed in FIG. 1, as shown in the broken lines to close and form a continuous wall.
A guide line in the form of an integral ridge 36 is provided along the inner surface of the wall 16 to serve as a visual indicator to the roofer so that the nails 11 for fastening the roofing 15 are provided inwardly of the rows of wings 17, 18. Preferably as shown in FIG. 6, indicia I in the form of lettering is provided in the areas so that a workmen will not nail through these areas.
As adjacent lengths of roof vent are applied to a roof, the ends of the base wall 16 are molded such that opposite ends overlap as at 37, 38 (FIG. 4). In order to provide sufficient space for normal longitudinal expansion and contraction due to temperature changes, aligning ridge 38a is provided on base wall 16 and the portion 37 is formed with a bevelled surface 37a. The workman utilizes the aligning ridge 38a for initial positioning of the adjacent roof vents and the bevel will permit longitudinal movement of the roof vents relative to one another as may occur during expansion and contraction due to temperature variations. In addition, the end walls 19, 22 are provided with spaced longitudinally extending walls portions 39, 40 that cooperate with a portion 41 on the wall 19 to telescope within portions 39, 40 and interfit the ends of one roof vent with respect to the other.
In order to hold the material 25 in position, the wings 17, 18 may also be provided with projections 42 that tend to engage and hold the material in position.
As shown in FIG. 3, the height of the layers 25, 30 is greater than the height of the wings 17, 18 and end walls 192 22 such that when the vent is nailed into position, the layers 25, 30 become compressed to seal against the shingles and fill any underlying slots in the shingles.
Although the roof vent embodying the invention is partially intended for use in connection with roofs that have inclined roof walls 12 as shown in FIGS. 1 and 2, it can readily adapted to other roof arrangements by severing a portion of the roof vent along a line 33 by a hand knife. Thus as shown in FIG. 8 such a partial roof vent can be adapted to a roof having an inclined wall 50 that extends from a vertical wall 51 that has siding 52 thereon. In such an arrangement, the roof vent from which part of the base wall and two rows of the wings have been severed is positioned with the remaining rows of the roof vent and base wall overlying the opening 53 which is to be vented with base wall 16 folded about the remaining bend line 33 to extend in overlapping relation to the uppermost siding 52. The roof vent is nailed in the same fashion over the shingles S of the wall 50, and if desired shingle sections 15 can be provided over the roof vent.
The partial roof vent can also be utilized in an arrangement such as shown in FIG. 9 wherein the roof 55 is inclined and intersects a wall 56 that extends vertically above the roof and has siding 57 thereon. As in the form shown in FIG. 8 the remaining rows of wings contact the shingles S and wall 16 is bent along the line 33 to extend along the vertical wall 56 of the building.
In the modified form of roof vent shown in FIGS. 10-12, the wings 18 are longer than arrays 17 and are provided with generally axially extending straight portions 60 which are tangent to the curved portions 24 and extend longitudinally of the roof vent to provide deflection of moisture and the like and inhibit passage thereof through the roof vent to the interior.
The portions 60 preferably extend at an acute angle to the longitudinal axis of the roof vent which is less than the acute angle between the portions 60 and a transverse axis at a right angle to the longitudinal axis.
The distance between the free end of each portion 60 and the adjacent curved portion 24 is substantially equal to the distance between each vane 18 and the return straight portion 24a of each curved portion 24 in order that there is minimal pressure drop in the flow of air through the roof vent. In addition, tubular projections 61 are provided on the inner ends of the vane 17 and have there lower ends closed by a membrane 62. The projection 61 provide guides for the nails 11 and further provide support so when the nails are driven into the roof 12, the extent of a passage of the nails is limited by the height of the tubular portions 61, which is the same as that of the walls 19.
In the form shown in FIGS. 13-15, the lower edges of the walls 19a, 22a are tapered so that the height of the walls 19a, 22a increases progressively toward the interior. The walls 20a, 21a have there lower edges tapered so that the height progressively decreases toward the center of the roof vent. In addition, each of the walls 20a, 21a is provided with scribe lines 65, 66, 67 along which a portion of the lower edge can be broken or cut away so that the roof vent can be used of roofs of different slopes as shown in FIGS. 14 and 15 respectively.
By this construction, a more flat appearance is provided so that the viewer views more of the top wall and less of the vanes, especially when the roof has a steep slope.
In the form of the invention shown is FIG. 16, the roof vent 10 includes indicia in the form of a plurality of transverse ribs 70 which facilitate the workman in positioning the roofing material so that its edges are at a right angle to the axis of the roof vent. The ribs 70 are interrupted at the nailing areas.
It can thus be seen that there has been provided a roof vent which will effectively vent the interior of a building; which will preclude entry of water and blowing snow and insects, by the action of wind from entering the building; which will prevent ice build-up thereon; which can be readily adapted to roofs of varying slopes and inclinations; which is pleasing in appearance; which is low cost; and which can be readily handled in the field; and which can be utilized for arrangement of roofs which are unsymmetrical.
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A roof vent comprising a one piece plastic body including a base wall having transversely spaced rows of integral vanes extending from one surface thereof. The vanes of adjacent rows are positioned such that the vanes define a sinuous path. Preferably, one of each of the rows has the wings extending at an acute angle to the axis of the wall and the other row of each set of rows has the wings extending at an oppositely directed acute axis to the longitudinal axis of the wall toward the wings of the one row. Thus air is vented through sinuous paths outwardly when the vent is positioned with the wings engaging the roof and the base wall spaced from the roof. Water and snow are prevented by the wings from entry beneath the vent into the building.
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This is a continuation of application Ser. No. 394,139, filed Aug. 15, 1989 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a seat cushion and more particularly to a seat cushion having improved compression properties and also relates to a method for producing the same.
2. Prior Art:
Conventionally, there has been used a seat cushion in which an upper layer to be in contact with a seat occupant has a impact resilience of higher than 30% which is inferior in load dispersing properties, and as a result uncomfortable seating was experienced when rolling an the seat conditions. Such a seat cushion impresses a person, especially an overweight person, cramped at both sides and tends to give a local high pressure, and consequently fatigable seating conditions were induced.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a seat cushion which exerts superior load dispersing properties and comfortable seating even under rolling seating conditions.
In order to accomplish the above object, the present invention develops such a novel construction that an upper foamed layer to be in contact with a seat occupant is composed of a foamed body having low impact resilience in order to exert damping capacity due to hysteresis loss while investigations and developments were conventionally directed to the control of density and rigidity of a foamed body.
Namely a seat cushion in accordance with the present invention comprises an upper foamed layer of low impact resilience whose ratio is not higher than 25% which exhibits high hysteresis loss and a lower foamed layer, for supporting the upper foamed layer, of high impact resilience whose ratio is not lower than 55% which exhibits high rebound.
In accordance with the present invention, an intermediate foamed layer of moderate impact resilience whose ratio is 40-50% may be interposed between the upper foamed layer and the lower foamed layer. In this case, the upper layer is supported by both the intermediate layer and the lower layer.
A method for producing such a seat cushion comprises pouring and expanding foramable liquid compounds in a mold cavity successively in turn from an upper layer to a lower layer for forming integrally laminated foamed layers. Namely, for producing a two-layer seat cushion comprising an upper foamed layer of low impact resilience having a ratio of not higher than 25% and a lower foamed layer of high impact resislience having a ratio of not lower than 55%, a foamable liquid compound for said upper foamed layer is first poured and expanded in a mold cavity and then a foamable liquid compound for said lower foamed layer is successively poured in said mold cavity and expanded, whereby integrally laminated foamed structure of two layers are formed.
A three-layer seat cushion comprising an upper foamed layer of low impact resilience having a ratio of not higher than 25%, an intermediate foamed layer of moderate impact resilience having a ratio of 40-50% and a lower foamed layer of high impact resilience having a ratio of not lower than 55% is also produced in the same manner. Namely, a method for producing said three-layer seat cushion comprises pouring and expanding foamable liquid compounds in a mold cavity successively in turn from an upper layer to a lower layer for forming integrally laminated foamed layers. More precisely, a foamable liquid compound for said upper foamed layer is first poured and expanded in a mold cavity and then a foamable liquid compound for said intermediate foamed layer is successively poured in said mold cavity and expanded and finally a foamable liquid compound for said lower foamed layer is successively poured in said mold cavity and expanded, whereby integrally laminated foamed structure of three layers are formed.
It is preferable to use a plurality of upper molds to construct successively in turn a mold cavity for each of foamable liquid compounds and to use soft type polyurethane foamable liquid compounds.
The seat cushion provided in accordance with the present invention thus comprises an upper foamed layer of low impact resilience having a ratio of not higher than 25% which exhibits high hysteresis loss and a foamed layer supporting said upper layer of higher impact resilience, whereby said seat cushion fits any physiques and any postures of seat occupants without giving an impression of excessive pressure. Comfortable soft seating conditions are then attained even under rolling seating conditions. The lower foamed layer for supporting the upper foamed layer being composed of a foamed layer of higher impact resilience, good supporting and rebounding properties are attained. Synergistic actions derived from the laminated structure of the foamed layers having low impact resilience and higher impact resilience afford comfortable seating for a long period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a perspective view showing one embodiment of a seat cushion in accordance with the present invention,
FIG. 2 represents a sectional view taken along II--II line in FIG. 1,
FIG. 3 represents a partial sectional view taken along III--III line in FIG. 1, and
FIG. 4 represents a partial sectional view taken along IV--IV line in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
In the drawings, reference sign SF indicates a seat portion and BR indicates a back rest portion of a seat cushion. Reference numeral 1 indicates a skin; 2 indicates an upper foamed layer of low impact resilience having a ratio of not higher than 25%; and 3 indicates a lower foamed layer of high impact resislience having a ratio of not lower than 15%.
The seat portion SF and the back rest portion BR are manufactured respectively using a respective mold in such a manner that a foamable liquid compound for the upper foamed layer 2 of low impact resilience is first poured and expanded in a mold cavity and then a foamable liquid compound for the lower foamed layer 3 of high impact resilience is successively poured onto said first foamed upper layer and expanded so as to form an integrally laminated foamed structure of the upper and lower foamed layers.
Shown in the following Table 1 are the embodiments A, B, C and D of foamable liquid compounds for and the physical properties of the upper foamed layer.
TABLE 1______________________________________ A B C D______________________________________Ingredients (p.b.w.)POLYOL X 90 90 90 90HARDMASTER 17 10 10 10 10Water 2 2 2 2DABCO 33LV 0.7 0.7 0.7 0.7silicone 2.5 2.5 2.5 2.5TDI-80/20 36.6 41.2 45.8 50.3TDI-INDEX 80 90 100 110Physical propertiesapparent density (kg/m.sup.3)total density 62 58 56 55core density 58 54 50 50impact resilience (%)skin-covered 6 8 11 15core 8 10 12 1525% rigidity (kg/200 mmφ) 8 13 22 34hysteresis loss (%) 39 53 62 70tear strength (kg/cm) 0.40 0.58 0.80 0.95tensile strength (kg/cm.sup.2) 2.02 1.59 1.15 0.61elongation (%) 65 79 98 98______________________________________ (NOTE) POLYOL X: polyester polyolhel No. H9021 of Daiichi Kogyo Seiyaku Co., Ltd HARDMASTER 17: crosslinker of Daiichi Kogyo Seiyaku Co., Ltd. DABCO 33LV: amine catalyst of Sankyo Air product Co., Ltd. TDI80/20: tolylene diisocyanate2,4-/2,6- = 80/20
By variation of the quanity of HARDMASTER 17 or water, the rigidity can be modified, for example, in the range of 6 kg/200 mmφ to 60 kg/200 mmφ.
The physical properties such as apparent density, impact resilience and rigidity as described were determined in conformity with JIS K6401-1980. The total density in the apparent density(kg/m 3 ) was determined by using skin-covered test pieces of 350 mm×350 mm×100 mm and the core density was determined by using test pieces of 100 mm×100 mm×50 mm which were obtained by cutting the test pieces of 350 mm×350 mm×100 mm. The same is the cases when measurements of the impact resiliences of skin-covered test pieces and test pieces of cores were made.
Shown in the following Table 2 is an embodiment of the foamable liquid compounds for and the physical properties of the lower foamed layer.
TABLE 2______________________________________Ingredients (p.b.w.)EP-3033 60POP-31-28 40silicone surfactant 1.0Water 2.5DABCO 33LV 0.5diethanolamine 1.5TDI (80/20)-INDEX 115Physical propertiesapparent density 50-65(kg/cm.sup.3) (total density)impact resilience (%) 55-6025% rigidity (kg/200 mmφ) 16-25hysteresis loss (%) 25______________________________________ (NOTE) EP3033: polypropylene glycol (ppg) of MITSUITOATSU POP31-28: 20% acrylonitrile graft PPG of MITSUITOATSU
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A seat cushion comprising an upper foamed layer of low impact resilience having a ratio of not higher than 25% which exhibits high hysteresis loss and at least one foamed layer supporting said upper layer of higher impact resilience as well as a method for producing the same.
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BACKGROUND OF THE INVENTION
This invention relates to a method and an apparatus for removing fiber tufts from fiber bales of different origins and for mixing the detached fiber tufts, such as cotton, chemical fiber or the like. For the detaching operation the fiber bales are assembled into at least one transportable group (row).
According to a known method a plurality of bale groups are provided, each composed of a plurality of fiber bales. The fiber material is removed (detached) from the bales of the individual groups and is subsequently blended in a downstream-arranged mixing apparatus. The fiber bales are arranged in groups; within each group the fiber material is of the same origin. Stated differently, all the fiber bales within any individual group contain fiber of identical properties. The fibers of different groups are, as individual components, conveyed pneumatically to the mixing apparatus through transporting ducts and are intermingled for the first time in such mixer. The several bale series or bale groups each form a mixing component. The composition of the blend in the mixer is varied by changing the proportion of the fiber components from the individual groups as the blend is prepared.
It is a disadvantage of the above-outlined process that for each group a separate fiber bale opening device has to be provided, that is, the number of the fiber bale openers corresponds to the number of the different fiber origins. It is a further disadvantage of the conventional method that the various detaching processes have to be controlled differently, as a result of which the opening devices of the bale opener are periodically idle which is inefficient and uneconomical and may lead to operational disturbances in case of breakdown.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved method and apparatus of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, makes possible in a simple manner the detaching and blending of fiber tufts and a variation of the blend.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber bales are, for performing the detaching operation thereon, arranged into at least one fiber bale group (row) which has different but predetermined fiber properties and further, to each such group new fiber bales having predetermined fiber properties may be added in a controlled, variable manner.
By virtue of the fact that according to the invention the fiber bale group which is about to undergo a detaching (fiber tuft removing) operation, is composed of fiber bales having different fiber properties, there is obtained a blending of different fibers by the detaching operation itself. Thus, each such bale group is opened by a single fiber tuft detaching device which, in addition to the detaching operation, is performing a mixing operation as well. In order to vary the blend, at least one fiber bale having different fiber properties is added to the bale group from the bale storage in a simple manner. In this manner, the mixing of the fiber tufts is realized as early as the fiber detaching operation and the alteration of the mixing may be effected with simple means.
The method according to the invention has the following additional advantageous features:
The row of the fiber bales worked on by the bale opener is assembled as a function of predetermined and/or sensed actual property data of a subsequently made intermediate product such as a sliver and/or a subsequently made final product such as a yarn, and in case of deviations from a desired value, an immediate and automatic correction is performed.
The fiber bales are assembled in a fiber bale storage area into groups wherein each group has fiber bales of identical, predetermined properties and from which at least one fiber bale is periodically added to the bale row worked on by the bale opener.
The fiber bales are assembled in a fiber bale storage area in preselected groups according to predetermined properties.
The fiber bales are placed in an automatic bale storing apparatus, such as a vertical bale stand and are identifiable by means of bar codes.
The properties of the intermediate product or end product are automatically determined by on-line testing.
The properties of the intermediate product or the end product are determined semi-automatically.
The properties of the intermediate product or the end product are determined by random testing.
The determined property is the fineness of fiber.
The determined property is the color of the fiber.
The determined property is the content of impurities.
The determined properties are the content of neps, seed coats, and/or trash particles.
The determined property is the uniformity of the silver or yarn.
The determined properties are yarn defects.
The determined properties are imperfections in the yarn.
The determined property is the yarn strength.
The determined property is the fiber length.
For each value characterizing a property a limit interval is determined and a fiber bale of different properties is added to the bale row in case the sensed property of the finished product or the intermediate product is outside the predetermined limit.
The predetermined properties of the individual fiber bales are determined by random testing.
The predetermined properties of each fiber bale are determined by random testing.
The properties of the individual bales are determined based on test certificates.
The predetermined properties of the fiber bales are stored in a data memory.
The apparatus according to the invention has the following additional advantageous features:
The bale opener has an opening (detaching) device which is oriented obliquely in such a manner that the fiber tufts are detached from the top surfaces of the fiber bales at an inclined angle to the horizontal.
The bale transporting device for advancing fiber bales to the bale row worked on by the bale opener comprises conveyor belts.
The bale transporting device for the bales to be advanced to the bale row worked on by the bale opener has at least one bale transport carriage.
More than one fiber tuft detaching devices are provided with which there are associated a bale transporting and distributing apparatus.
The apparatus for determining the properties of the intermediate product or the end product, the conveyor device for accommodating the row of fiber bales to be worked on by the bale opener, and the bale transporting device for the bales in the bale storage area are connected to a common electronic control and regulating device.
The control and regulating device is connected to a memory containing data on predetermined properties of the fiber bales.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1a is a schematic side elevational view of an apparatus for performing the method according to the invention.
FIG. 1b is a schematic top plan view of the apparatus of FIG. 1a, illustrated with a block diagram of a control device.
FIG. 2 is a block diagram illustrating the method according to the invention performed on a spinning line and including measuring components for quality measurements, control device and bale selecting and forwarding apparatus.
FIG. 3 is a schematic top plan view of a device for supporting a fiber bale group undergoing a fiber-detaching operation and a pre-positioned bale-selecting and bale-transporting device as well as bale storage.
FIG. 4 is a schematic top plan view of details of a bale selecting device different from that shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 1a, there is illustrated therein a conveyor belt 1 which receives a group 2a formed of a plurality of fiber bales 2 from which fiber tufts are detached by a fiber tuft detaching device (bale opener) 3. The fiber bales 2 have different fiber properties (origins) A, B and C. Thus, the fiber bales 2 are assembled to form the fiber bale group 2a having different, yet predetermined fiber properties within the group. The upper and lower flights of the belt 1 travel in the direction indicated by the arrows I and II. The fiber bale opener 3 travels on rails (not shown) parallel to the fiber bale group 2a.
The fiber bale opener 3 may be, for example, a BLENDOMAT BDT 020, manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. The fiber bale opener 3 has an opening (detaching) device 4 accommodated in a housing 5 cantilevered to a bale opener tower 6. The housing 5, together with the detaching device 4, is movable relative to the tower 6 in a vertical direction as indicated by the arrows III and IV. The bale opener 3 travels on non-illustrated rails along the fiber bale series 2a as indicated by the arrows V and VI. The cantilever housing 5, together with the opening (detaching) device 4 may be set into an oblique position by pivoting it about a horizontal axis arranged perpendicularly to the travelling direction V, VI so that the bale opener removes fiber tufts along an oblique top bale face which is arranged at an angle α to the horizontal. The removed fiber tufts are conveyed away from the bale opening apparatus 3 by non-illustrated suction devices and are admitted to an after-connected mixer which may be, for example, an MPM MULTIMIXER model, manufactured by Trutzschler GmbH & Co. KG and in which an additional blending of the fiber tufts takes place. The mixer 7 may be followed by a cleaner 8 and a carding machine 9 which may be, respectively RST and EXACTACRD models, manufactured by Trutzschler GmbH & Co. KG.
According to FIG. 2, downstream of the bale opener 3, the cleaning machines 7 and 8 and the card 9 there are arranged drafting frames 10 and spinning machines 11.
Turning to FIG. 3, in a bale storage zone 12 in the vicinity of the bale opener 3 parallel-spaced storage conveyors 13, 14 and 15 are provided, respectively supporting fiber bale groups 2b, 2c and 2d. The group 2b has only bales with fiber origin A, the group 2c has only bales with fiber origin B and the group 2d has only bales with fiber origin C. Between the conveyor belt 1 and the storage zone 12 (occupied by conveyors 13, 14 and 15) there is provided a bale selecting and conveying device generally designated at 16 formed of at least one conveyor belt assembly 17, 18. The apparatus 16 includes a selecting assembly 27 (such as shown in FIG. 4) for the fiber bales 2 which are advanced by the selecting assembly 27 selectively from the bale groups 2b, 2c or 2d to the conveyor belt 1. Between the conveyor belts 14 and 18 there is situated a non-illustrated device for automatically removing wrappers, straps or the like from the fiber bales 2. The fiber bales 2 are advanced on the conveyor belts 13, 14 and 15 in the direction of the arrow VII and are moved by the intermediate collecting conveyor belt 17 in the direction of the arrow VIII and on the conveyor belt 18 in the direction of the arrow IX.
Reverting to FIG. 1b, at the output of the carding machine 9 there are provided a sensor 20 for measuring the fineness of fiber and a color sensor 21 for testing the sliver outputted by the carding machine. With the mixer 7, the cleaner 8, the carding machine 9 and with other intermediate devices and machines which may be present in the processing line, there are associated additional sensors 22, 23 and 24 for determining various properties of the intermediate products, for example, fiber tufts. In a similar manner, non-illustrated sensors are provided for testing the quality and/or properties of the intermediate or end products of the drafting frames 10 or the spinning machines 11.
The sensors 21-24, a motor 1a for driving the conveyor belt 1, a motor 17a for driving the conveyor belt 17 as well as motors 13a, 14a and 15a for driving the respective belts 13, 14 and 15 are connected to a common microprocessor constituting a control and regulating device 25. A memory 26 is connected to the control and regulating device 25 for storing and inputting data on predetermined properties of the fiber bales 2. Further, the non-illustrated motors for propelling the bale opener 3 in the travelling direction V, VI and a lifting motor for raising the fiber detaching device 3 in the direction as indicated by the arrows III and IV are also connected to the regulating device 25.
Turning once again to FIG. 4, the bale selecting assembly 27 includes a conveyor 30 which at one end is pivotal about a vertical axis in the direction of arrows X and XI by a motor 29. As a result, the pivotal or discharge end of the conveyor 30 is at all times associated with the input end of the conveyor 17, whereas the input end of the conveyor 17 may be selectively aligned with the discharge end of the conveyor 13, 14 or 15. Motor 28 is provided to circulate the conveyor belt 30. Both motors 28 and 29 are likewise connected to the control and regulating device 25.
Thus, with the above-described systems, a predetermined mixing of the fiber bales of fiber property A, B and C can be achieved on the conveyor 1 by an appropriate selection, by the control device 25, of the fiber bales 2 from respective storage conveyors 13 (supporting fiber bales with properties A), 14 (supporting fiber bales with fiber properties B) and 15 (supporting fiber bales with properties C). By inputting manually or automatically the desired sequence of selection, a desired mixing of the bale sequence on the conveyor 1 may be achieved. Thus, for example, to obtain the sequence A, B, C on the conveyor belt 1 as shown in FIG. 1b, a simultaneous actuation of the conveyors 13, 14 and 15 will result in a simultaneous deposition of bales A, B and C on the momentarily stationary conveyor 17 on which thus a leading bale A, a mid bale B and a trailing bale C will be positioned. This sequence is maintained as the conveyor 17 is intermittently moved to align a respective fiber bale with and to transfer such bale to the conveyor 1 for replenishing the fiber bale series 2a worked on by the bale opener 3. A similar selection may be achieved with the selecting assembly 27 shown in FIG. 4, by sequentially aligning the swinging end of the conveyor belt 30 with conveyors 13, 14 or 15.
The desired sequence of the fiber bale types on the conveyor 1 is determined by a regulating circuit as a function of the quality of the end product of the processing line such as a yarn or as a function of selected qualities of intermediate products, such as slivers or fiber tufts.
The quality signals may be obtained automatically on-line, for example, by a nep sensor, semiautomatically or based on random sampling in a laboratory environment. The quality signals may represent the fineness of fiber, color, dirt content, neps, seed coats, trash particles, uniformity, yarn defects or imperfections, yarn strength and/or fiber length. For each quality-representing signal a limit interval may be determined and if the actual values deviate from such a limit interval, the bale sequencing (bale supply) will automatically change.
For all fiber types (origin of fiber) which are to be used in the blend, the following fiber data that are relevant for the end product are determined:
(a) by random sample analysis of individual bales under laboratory conditions; or
(b) by random sample analysis of each bale under laboratory conditions; or
(c) based on test certificates relating to the individual bales (for example, HVI test results).
The above bale data are stored, for example, as a data bank. Dependent upon the intensity of the testing as noted under (a), (b) and (c) above, bale groups down to the individual bales may be unequivocally defined.
The control device 25 combines the quality signals obtained from the process with pre-stored bale data for making the appropriate selection (sequencing) of the bales 2 to provide the subsequent bale to be added to the bale group supported on the conveyor belt 1 and submitted to a fiber tuft detaching operation by the bale opener 3.
The selection of the fiber bales based on the actual and desired quality data may be effected according to different principles and takes into consideration the relatively long delay prior to the actual engagement by the bale opener 3 until the generation of the signal representing the quality which dependent on the location of determination may vary. For example, according to a simple regulating principle for the use of the quality signals, their magnitude is smaller than the desired value. In such a case, the bale sequence is to be varied such that bales A should occur in the mixture by x% more frequently than previously. According to another type of regulation, a special expert-system may be used for the weighted evaluation of the deviating quality characteristics or, as the case may be, for affecting the same by the bale magnitudes.
The bale storage zone 12 may consist of a conventional bale storage system (that is, bale groups are being held at different locations), a preselected bale storage corresponding to the determined fiber data or an automatic bale storage system with corresponding selecting apparatus (for example, the bales are selected by quality by means of bar codes).
Apart from the embodiments described, the selecting apparatus for the fiber bales 2 and the transport for the bale opening device may be realized by a conveying or transport system, for example, a transverse band system with deflectors or a roller system with deflectors, an automatic transport system (for example, inductively guided) or a semiautomatic system with fork lift which delivers the fiber bales 2 in a sequence according to instruction lists.
In an apparatus where the fiber bales 2 are continuously (automatically) worked on by the detaching apparatus (for example, the opening device 4) along an oblique fiber bale surface, the bale supply and transport device 16 arranged upstream of the conveyor belt 1 advantageously includes a device 31 for removing bale ties such as wires, bands, straps and/or packaging from the fiber bales 2. The bale tie removing apparatus 31 is situated between the group of storage conveyors 13, 14, 15 and the conveyor belt 1.
According to an expedient embodiment, the bale supply and transport device comprises a driven pusher element for the fiber bales 2 which may be positioned on a roller track or on a stationary base such as a sheet metal track. The bale supply and transporting apparatus delivers the fiber bales continuously to the conveyor belt 1. Between the bale supply and transport apparatus and the conveyor belt 1 there is provided a bale displacement element 32, for example, a roller track, a transport belt, a driven pusher or the like which displaces the fiber bales 2 onto the conveyor belt 1 in a direction that is transverse to the conveying direction of the bale supply and transporting apparatus. In this manner the bales 2, pass through the device 31 for removing the bale ties and/or bale package in a continuous flow and are placed by the bale displacement element 32 onto the conveyor belt 1 where they join the trailing end face of the bale group 2a to become a part thereof.
An apparatus where fiber tufts are continuously detached from fiber bales along an inclined top bale surface is described, for example, in U.S. patent application Ser. No. 07/806,250 filed Dec. 31, 1991. An apparatus for removing bale ties such as wires, bands or straps and/or bale packaging is described in U.S. patent applications Ser. Nos. 07/745,201 and 07/745,211, both filed Aug. 15, 1991. These three US-applications are hereby incorporated by reference.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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An apparatus for mixing fiber tufts includes a first conveyor for accommodating thereon a row of fiber bales; a bale opener for travelling along the row of fiber bales and removing fiber tufts sequentially from the fiber bales; a storage system for storing a plurality of fiber bales each containing fiber of predetermined properties; a selecting device for selecting fiber bales of desired properties from the fiber bales accommodated in the storage system; and a second conveyor for sequentially advancing the selected fiber bales from the storage system to the first conveyor for complementing the row of fiber bales accommodated on the first conveyor for obtaining a series of fiber bales thereon having preselected, determined properties.
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FIELD OF THE INVENTION
The present invention concerns a DFT (Discrete Fourier Transform) processor adapted in particular, but not exclusively, for integration in a receiver for a Global Navigation Satellite Systems (GNSS). Embodiments of the present invention relate to a power and area optimized architecture based on selectively activation of single DFT lines.
RELATED ART
The Fourier Transform (FT) is a function that converts a signal from the time domain into the frequency domain. In the case of discrete signals of finite duration {x 0 , . . . , x N-1 } the Fourier Transform is often referred to as Discrete Fourier Transform (DFT).
Fourier Transforms are applied, among many other applications, in demodulation and processing of GPS, Galileo, GLONASS, and other GNSS signals. In these applications, the Fourier Transform applied to the received data allows to process several carrier frequencies in a parallel fashion, with an important reduction of hardware complexity. Modern GNSS receiver or processors include in most cases a “DFT engine”, that is a section that is especially dedicated to the calculation of DFTs.
The theory and details of FT-based GNSS signal processing are known in the art, and will not be discussed at length in the present specification. Exhaustive information can be found in the available literature, for example in the book edited by E. D: Kaplan and C. Hegarty “Understanding GPS and its applications”, 2 nd edition, Published by Artech House, London (December 2005), which is hereby incorporated by reference.
The definition of a DFT point X k for the mentioned finite sampled signal {x N } is:
X k = ∑ n = 0 N - 1 x n · ⅇ - j 2 π N kn k = 0 , 1 , … , N - 1 ( 1 ) X k = ∑ n = 0 N - 1 x n · W n kn ( 2 )
where W N kn are the N th order complex roots of the unit, also called “twiddle factors” or, writing explicitly the real and imaginary parts of the sum terms in (1):
x
n
=
I
+
j
Q
W
N
kn
=
cos
(
2
π
N
kn
)
+
j
·
sin
(
2
π
N
kn
)
:=
C
I
+
j
·
C
Q
(
3
)
x
n
·
W
N
kn
=
(
I
·
C
I
-
Q
·
C
Q
)
+
j
(
I
·
C
Q
+
Q
·
C
I
)
(
4
)
Equation (1) can thus be expressed as a sum of DFT terms x n ·W N kn . The number of DFT terms needed to compute all the X k points is N 2 but each will require 4 multiplications and 2 additions.
An efficient algorithm to calculate the DFT is the well known Fast Fourier Transform (FFT) that is based on a split and conquers approach. If the N (power of 2) samples data stream is halved and processed in parallel, the computation order is reduced to N 2 /2 complex additions and (N 2 /2+N) complex multiplications. As the number of possible splits is equal to log 2 (N) then it follows that the computation order is given by N·log 2 (N) complex additions and N·log 2 (N)/2 complex multiplications.
The use of the FFT algorithm is generally considered the most efficient way of calculating N DFT points from N samples. However, there are certain DFT configurations where the FFT algorithm is not optimal. For instance in those applications where only a reduced set of M DFT lines is required (with M≦N), as it is often the case in signal processing and in particular in GNSS processors, the computation order of the FFT architecture is not optimized.
Moreover, the FFT algorithm takes its simplest and most efficient form only if N is a power of two. Variant FFT algorithm for an arbitrary N exist, but they are in general less efficient.
In a GNSS signal processor, the DFT computation reflects directly on cost, silicon area and power consumption of the receiver. There is therefore a need to provide a DFT algorithm having the lowest possible computation load.
The Fourier transform can be regarded as a spectral factorization of a function in the time domain over an orthonormal base of sine and cosine functions. Many other discrete integral transforms are relevant in signal processing techniques, corresponding to different orthonormal bases. These transforms include, for example, the Cosine transform (DCT) and its various modifications (MDCT), the discrete Hartley transform (DHT) and many others. The foregoing specification refers, for simplicity's sake, to the DFT transform only. It must be understood, however, that the present invention is not limited to this particular case, but include all the discrete integral transforms to which it applies.
It is an aim of the present invention to provide a more efficient algorithm to compute a set of DFT lines in a signal processor for processing GNSS signals. The present invention aims moreover to provide a low-power GNSS receiver.
BRIEF SUMMARY OF THE INVENTION
The goals of the present invention are achieved by the object of the appended independent claims, the variants of the dependent claims incorporating important, but not strictly essential features. The invention will be better understood referring to the detailed description of some embodiments, which is provided by way of example only, and to the drawings that illustrate schematically:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : a known implementation of a DFT computing.
FIG. 2 : a pipelined variant of the known device of FIG. 1 .
FIG. 3 : the structure of a DFT engine according to an aspect of the present invention.
FIG. 4 : a half butterfly architecture used in the structure of FIG. 3 .
FIG. 5 : a detail of the even coefficient bank, with (K+1)/2 multiplier-by-constant modules.
FIG. 6 : a detail of the odd coefficient bank, with (K+1)/2 multiplier-by-constant modules.
FIG. 7 : a representation of the search space in GNSS satellite acquisition.
FIG. 8 : a GNSS receiver architecture.
FIG. 9 : the position, in a particular case, of the twiddle factors of the DFT in the complex plane.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is based on the observation that GNSS processing requires the calculation, in general of a limited number of DFT lines. Twiddle factors used in GNSS DFT engine are a finite set and, moreover, have special symmetry properties in their real and imaginary parts. The invention thus proposes an optimised DFT algorithm that is able to calculate a reduced set M of DFT lines from N samples (with M≦N) being N not necessarily a power of 2, which takes advantage from these symmetries.
For these purposes data format considerations, dynamical disabling of non-used DFT lines and routing-effective design partitioning have to be taken into account.
A direct DFT implementation, as illustrated on FIG. 1 , is based on 4 multipliers and 2 adders needed to calculate the real and imaginary part of equation (4). This is normally referred as a full butterfly circuit or algorithm. The coefficient C I , C Q can be fetched from a pre-calculated table, not shown in the figure, for example.
FIG. 2 illustrates a variant of the full butterfly circuit, or Half Butterfly, which adopts a pipeline approach. The multiplexer 201 and the de-multiplexer 206 are used to compute separately the real part 207 I·C I −Q·C Q and the imaginary part 208 I·C Q +Q·C I in the arithmetic block 205 that has only two multipliers 202 , 203 and one adder 204 . The results are stored in complex register 209 .
Conventional DFT implementations that make use of real general purpose multipliers are sub-optimal because they do not take into considerations the fact that the possible twiddle factors W N kn and the C I , C Q coefficients can not take any value, but are necessarily included in a predefined finite set. The twiddle factors W N kn are the N th order complex roots of the unit and, therefore, their real and imaginary are parts have certain symmetries that are not exploited in conventional DFT implementations.
Preferably, the circuit of the present invention uses a set of multiplier-by-constant modules whose number is equal to the number K of different possible coefficients, disregarding their signs, plus 1 (the extra module is needed to take into account roots of the unity of the form±√{square root over (2)}/2±j·√{square root over (2)}/2, that have the same coefficient, in absolute value, for the real and imaginary part).
A simple formula for an approximate computation of the frequency span of each DFT is given by:
Δ f = 1 T s ( M N + 1 N eff ) ( 6 )
where T S is the sample period, N is the length of the input signal for the DFT (expressed in number of points), M is the number of calculated DFT lines (with M≦N), and N eff is the effective DFT length (how many points are effectively integrated).
The number K of different coefficients depends on the number N of the DFT points. Supposing that N is an integer multiple of 8 and exploiting the symmetry of the N th order complex roots of the unit, the number K of different coefficients is equal to N/4+1. This formula gives for N=8, 16, 24, 32, 40, 48 the following values of K=3, 5, 7, 9, 11, 15. It is straightforward to extend this to a DFT engine supporting other values of N, or any finite choice of values of K. If for instance N is intended to be configurable in the range of values {8, 16, 24, 32}, the number of needed coefficients K is (K(24)+K(32)−K C ), being K C the number of common coefficients between N=24 and N=32 (those having complex argument 0° or 45°.
An embodiment of the invention will now be described with reference to FIG. 3 . The Half butterfly arithmetic block 205 , is functionally equivalent to the block designated under the same number in FIG. 2 . Its structure is however different, as it will be explained in the following.
A control logic unit 303 drives the operation of the DFT engine. It makes use of incoming configuration parameters 301 to select the data to be processed 201 from an input buffer 302 . Configuration parameters 301 and input data in buffer 302 can have various sources. In the case of a GNSS receiver, for example, configuration may be provided by a non represented CPU, and that the input data could be generated by a correlation unit. Other configuration are however possible. The control logic unit 303 also controls the selection of the current coefficients pair 304 and determines if the partial terms should be added or subtracted in the half butterfly unit 205 , depending whether the real or imaginary part of equation (4) is being processed.
The Half Butterfly 205 calculates first the real part 207 (I·C I −Q·C Q ) and the demultiplexer 206 drives the result to the I part of the complex result register 209 . Afterwards, the Half Butterfly calculates the imaginary part 208 (I·C Q +Q·C I ) and stores the result in the Q part of the complex result register 209 .
The complex result 209 is optionally multiplied by a constant factor by scaling unit 305 and accumulated, together with previous DFT terms in the accumulator comprising the adder 306 and memory 308 , for example a RAM.
The DFT of the invention includes preferably a saturation stage 307 , to detect overflow in the accumulation RAM 308 . If saturation occurs a flag 310 is activated. The DFT control logic 303 or an external control unit implement an algorithm to calculate a proper scaling factor to avoid saturation.
The DFT processing unit of the present invention is preferably arranged to disable dynamically any unused DFT line as indicated by configuration parameters 301 . The input data selector 201 can be stuck to ‘0’, reducing the toggling of the Half Butterfly 205 and scaler 305 for the discarded DFT line. Additionally, the control logic 303 can be used to update the address of the RAM 308 , but avoid the unnecessary and power consuming memory read/write accesses.
According to a preferred variant of the invention, the DFT processor includes a Half Butterfly 205 having the structure illustrated in FIG. 4 , which calculates equation (4) in 2 steps. First the real part (I·C I −Q·C Q ) is calculated then the imaginary one (I·C Q +Q·C I ).
The structure of FIG. 4 takes advantage of the fact that, with the sole exception of the diagonal coefficient C 45 , having a complex argument multiple of 45° it is always C i ≠C q ; the set of coefficients can be split into two separate groups of even constant coefficients {C 0 , C 2 , . . . , C k-1 } and odd constant coefficients {C 1 , C 3 , . . . , C k-2 }. The subdivision is done in a way that it never happens that two coefficient for the same group are needed to calculate the Half Butterfly terms. Block 403 contains a plurality of multipliers specifically arranged to multiply by one of the constant even coefficients {C 0 , C 2 , . . . , C k-1 }, whereas block 406 contains a plurality of multipliers specifically arranged to multiply by one of the constant odd coefficients {C 1 , C 3 , . . . , C k-2 }. Both blocks contain a multiplier by the C 45 coefficient.
This feature of the invention is exemplified by FIG. 9 that illustrates the position of the twiddle factors W 32 kn appearing in equation (4) for the special case N=32. The W 32 kn are distributed along the unity circle in the complex plane, and are symmetrically placed about the 45° dashed line. Neglecting the sign, that can be computed trivially, the coefficient C Q and C I must necessarily take one of the values C 0 ,-C 8 shown. With the sole exception of the 45° twiddle factor, all the terms of equation (4) involve one coefficient from the finite set of constant numbers {C 0 , C 2 , C 4 , C 6 , C 8 } and another coefficient from the finite set of constant numbers {C 1 , C 3 , C 5 , C 7 , C 8 }. The structure of the Half Butterfly unit 205 is designed to take advantage of this symmetry.
Reverting now to FIG. 4 , input samples I, Q and the K coefficients are preferably coded as sign-magnitude. Eventually additional conversion logic can be added in front of the I, Q data with a small overhead in terms of area if the incoming data are not in sign-magnitude format. Magnitudes of the data and of the selected coefficients are multiplied to obtain the magnitude of the product in blocks 403 and 406 . Due to the fact that the multipliers have to deal with absolute magnitudes, internal toggling and dynamic power consumption are much reduced with respect to traditional multipliers arranged to tread numbers in two's complement format.
The multiplier by constant values contained in banks 403 and 406 are preferably implemented in integer arithmetic and are highly optimized. Trivial coefficients having 0° or 90° complex argument are implemented as shift and truncation operation to further minimize area and power. If appropriate, some coefficients may deviate slightly from the theoretical value, in order to simplify the structure and reduce the power consumption of the multiplier.
In the presented example the output of the Half Butterfly is in two's complement format. Since the products calculated in 403 and 406 are encoded in sign-magnitude format, conversion blocks 409 carry out the necessary conversion, before the data are combined by adder 410 . The configuration port 407 selects if the Half Butterfly is calculating the real (I·C I −Q·C Q ) or imaginary part (I·C Q +Q·C I ) of the complex DFT result 209 . It is also necessary to know the sign of the data and the sign of the coefficients before converting the data to two's complement format. It is also possible to bypass the conversion block 409 to have a sign-magnitude coding of the outputs. The output of the adder 410 is the real or the imaginary part of one of the DFT of equation (4). According to a variant, the values I, Q are represented as unsigned integers, and the multipliers in banks 403 and 406 operate in unsigned mode. The sign of the result, computed separately, is set by acting on the two's complement units 408 and 409 .
Each of the multiplier-by-constant modules contained in banks 403 and 406 is dynamically activated by the configuration bus 402 and 405 from the control unit 303 . Thereby only the part of the circuitry really needed for the current DFT line calculation is active at any given moment, and the multipliers in banks 403 and 406 are in an inactive quiescent state for most of the time. Preferably the order of sum of terms in equation (4) can be rearranged (scrambling).
FIG. 5 shows a possible structure for the even coefficient bank 403 . The input signal 501 is the result of selecting between I and Q performed by multiplexer 401 ( FIG. 4 ). This signal 501 is common to all the (K+1)/2 multiplier-by-constant modules 503 . The possibility of activating only the part of the circuitry really needed for the current DFT line calculation is performed using the control signals from 402 and listed as (Sel_I_ 0 , Sel_Q_ 0 , . . . , Sel_I_K−1, Sel_Q_K−1).
A similar approach is shown in FIG. 6 for the odd coefficient bank. The input signal 601 is the result of selecting between I and Q performed by multiplexer 404 . This signal 601 is common to all the (K+1)/2 multiplier-by-constant modules within 406 . The possibility of activating only the part of the circuitry really needed for the current DFT line calculation is performed using the control signals from 405 and listed as (Sel_I_ 1 , Sel_Q_ 1 , . . . , Sel_I_K−2, Sel_Q_K−2, Sel_I — 45°, Sel_Q — 45°. A multiplication unit 605 with the coefficient for 45° is also available in 403 , but has to be duplicated in 406 . What coefficient from 403 is also marked as 605 within 406 depends on the coding of coefficients adopted.
Only 2 coefficients are needed hence only 2 multiply-by-constant units are activated simultaneously (one from each coefficient bank 403 and 406 ). The other multiplier-by-constant blocks have their inputs tied to 0 (no consumption due to combinatorial logic toggling).
This approach reduces the toggling activity of about 30% if compared to a standard multiplier approach. Moreover the architecture is totally combinatorial and no pipeline stages are present inside it. Typically a pipeline in digital circuitry is implemented using simple flip-flop based registers that are not optimized in term of area and power consumption. Avoiding them area and power are minimized.
The order of the DFT lines being calculated is managed inside the control logic blocks 303 and 304 . The DFT lines can be calculated with a programmable order so that the post-processing computation load for a CPU is reduced.
With reference to FIGS. 5 and 6 and supposing that C I =C 0 and C Q =C 1 the calculation of equation (4) can be performed in 2 steps described below.
Step 1: calculation of real part of equation (4): Sel_I_ 0 =1, Sel_Q_ 1 =1, Sel_I_x=0 if x≠0, Sel_Q_x=0 if x≠1, Sel_I=1, Sel_Q=1, DFT_Re=1. Then A=I·C 0 , B=−Q·C 1 Step 2: calculation of imaginary part of equation (4): Sel_I_ 1 =1, Sel_Q_ 0 =1, Sel_I_x=0 if x≠1, Sel_Q_x=0 if x≠0, Sel_I=0, Sel_Q=0, DFT_Re=0. Then D=Q·C 0 , C=I·C 1
GNSS Receiver Embodiment
DFT algorithms are generally known in the art and described in the technical literature. In the following only the aspects specific to GNSS implementation will be discussed with reference to FIGS. 7 and 8 .
With reference to FIG. 7 , the acquisition and tracking of a GPS space vehicle (SV) requires the determination of the frequency/code bin 705 . For this purpose specific resources are needed to determine the code phase offset bin 703 and the Doppler bin 704 . In the case that there is no estimation of one of more of the above cited parameters, a full search over the entire frequency/code search space should be performed.
A serial search approach, where a frequencies sweep over all possible Doppler of the incoming GPS signal and a code phases sweep over 1023 possible values for a GPS PRN (Pseudo Random Noise) code, is a widely used method for the acquisition step in a GNSS system.
A parallel frequency approach may be used to speed up the acquisition process. The receiver architecture illustrated in FIG. 8 carries out a parallel search in the frequency domain calculating the DFT 806 of the signal generated from the correlation 805 between the processed GNSS signals 802 and a locally generated replica 804 of the PRN for a given SV.
The line-of-sight velocity of the satellite referred to the receiver cause a Doppler effect in the order of +/−10 KHz. A step frequency step of 150 Hz is the minimum required for a low level GNSS signal scenario.
The gain of the correlated signal 805 has the format sinc(x):=sin(x)·x −1 where x=πfT. Applying this sinc envelope to the DFT transfer function it becomes evident that all the DFT lines will be affected by an amplitude loss with the exception of the centre frequency line f (that correspond to the Doppler frequency) under the condition that the PRN code is perfectly aligned. Otherwise no peak is present.
The aforementioned properties justify the use of a reduced number M of DFT lines from N data samples out of the correlator 805 .
The present invention further concerns a DFT processor for a reduced number of spectrum lines to reduce hardware complexity and power consumption.
By careful application of appropriate design constraints specific to the SV navigation and analysis of the DFT algorithm an optimised hardware architecture can be realised for embedding frequency-domain analysis efficiently into a GNSS chipset.
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A device to perform DFT calculations, for example in a GNSS receiver, including two banks of multipliers by constant integer value, the values representing real and imaginary part of twiddle factors in the DFT. A control unit selectively routes the data through the appropriate multipliers to obtain the desired DFT terms. Unused multipliers are tied to constant input values, in order to minimize dynamic power.
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BACKGROUND
Oil field operators drill boreholes into subsurface reservoirs to recover oil and other hydrocarbons. If the reservoir has been partially drained or if the oil is particularly viscous, the oil field operators will often inject water or other fluids into the reservoir via secondary wells to encourage the oil to move to the primary (“production”) wells and thence to the surface.
This flooding process can be tailored with varying fluid mixtures, flow rates/pressures, and injection sites, but may nevertheless be difficult to control due to inhomogeneity in the structure of the subsurface formations. The interface between the reservoir fluid and the injected fluid, often termed the “flood front”, develops protrusions and irregularities that may reach the production well before the bulk of the residual oil has been flushed from the reservoir. This “breakthrough” of the flood fluid is undesirable, as it typically necessitates increased fluid handling due to the injected fluid's dilution of the oil and may further reduce the drive pressure on the oil. Continued operation of the well often becomes commercially infeasible.
BRIEF DESCRIPTION OF THE DRAWINGS
Accordingly, there are disclosed herein various fiberoptic systems and methods for formation monitoring. In the drawings:
FIG. 1 shows an illustrative environment for permanent monitoring.
FIGS. 2A-2E show various illustrative injected-current system configurations.
FIGS. 3A-3E show various illustrative sensing array configurations.
FIG. 4 shows yet another illustrative sensing array configuration.
FIGS. 5A-5B show illustrative combined source-sensor cable configurations.
FIG. 6 is a function block diagram of an illustrative formation monitoring system.
FIGS. 7A-7C show illustrative multiplexing architectures for distributed electromagnetic (“EM”) field sensing.
FIGS. 8A-8C show various illustrative EM field sensor configurations.
FIG. 9 is a signal flow diagram for an illustrative formation monitoring method.
It should be understood, however, that the specific embodiments given in the drawings and detailed description below do not limit the disclosure. On the contrary, they provide the foundation for one of ordinary skill to discern the alternative forms, equivalents, and other modifications that are encompassed in the scope of the appended claims.
DETAILED DESCRIPTION
The following disclosure presents a fiberoptic-based technology suitable for use in permanent downhole monitoring environment to track an approaching fluid front and enable actions to optimize hydrocarbon recovery from a reservoir. One illustrative formation monitoring system has an array of electromagnetic field sensors positioned in an annular space around a well casing, the sensors being coupled to a surface interface via a fiberoptic cable. Each electromagnetic field sensor is a device that produces signals that are a function of external electric or magnetic fields. Illustrative sensors provide signals that are directly or inversely proportional to electric or magnetic field strength, the temporal or spatial derivative of the electric or magnetic fields, or the temporal or spatial integral of the fields. Other illustrative sensors have reception characteristics that measure both electric and magnetic fields. The sensor measurements in response to an injected current or another electromagnetic field source can be used to determine a resistivity distribution around the well, which in turn enables tracking of the flood front. (Although the term “flood front” is generally used herein to refer to the interface between reservoir fluid and injected fluid zones, the teachings of the present disclosure will apply to the interface between any two fluids having different bulk resistivities.)
Turning now to the drawings, FIG. 1 shows an illustrative permanent downhole monitoring environment. A borehole 102 contains a casing string 104 with a fiber optic cable 106 secured to it by bands 108 . Casing 104 is a tubular pipe, usually made of steel, that preserves the integrity of the borehole wall and borehole. Where the cable 106 passes over a casing joint 110 , it may be protected from damage by a cable protector 112 . Electromagnetic (EM) field sensors 114 are integrated into the cable 106 to obtain EM field measurements and communicate those measurements to a surface interface 116 via fiberoptic cable 106 .
The remaining annular space may be filled with cement 118 to secure the casing 104 in place and prevent fluid flows in the annular space. Fluid enters the uncemented portion of the well (or alternatively, fluid may enter through perforated portions of the well casing) and reaches the surface through the interior of the casing. Note that this well configuration is merely illustrative and not limiting on the scope of the disclosure. Many production wells are provided with multiple production zones that can be individually controlled. Similarly, many injection wells are provided with multiple injection zones that can be individually controlled.
Surface interface 116 includes an optical port for coupling the optical fiber(s) in cable 106 to a light source and a detector. The light source transmits pulses of light along the fiber optic cable, including any sensors 114 . The sensors 114 modify the light pulses to provide measurements of field strength, field gradient, or time derivative for electrical fields and/or magnetic fields. The modifications may affect amplitude, phase, or frequency content of the light pulses, enabling the detector to responsively produce an electrical output signal indicative of the sensor measurements. Some systems may employ multiple fibers, in which case an additional light source and detector can be employed for each fiber, or the existing source and detector may be switched periodically between the fibers. Some system embodiments may alternatively employ continuous wave (CW) light rather than light pulses.
FIG. 1 further shows a power source 120 coupled between the casing 104 and a remote earth electrode 122 . Because the casing 104 is an electrically conductive material (e.g., steel), it acts as a source electrode for current flow into the formations surrounding the borehole 102 . The magnitude and distribution of the current flow will vary in accordance with the source voltage and the formation's resistivity profile. The EM field measurements by sensors 114 will thus be representative of the resistivity profile. This resistivity profile in turn is indicative of the fluids in the formation pores, enabling the flood front to be located and tracked over time.
The surface interface 116 may be coupled to a computer that acts as a data acquisition system and possibly as a data processing system that analyzes the measurements to derive subsurface parameters and track the location of a fluid front. In some contemplated system embodiments, the computer may further control production parameters to reduce risk of breakthrough or to otherwise optimize production based on the information derived from the measurements. Production parameters may include the flow rate/pressure permitted from selected production zones, flow rate/pressure in selected injection zones, and the composition of the injection fluid, each of which can be controlled via computer controlled valves and pumps.
Generally, any such computer would be equipped with a user interface that enables a user to interact with the software via input devices such as keyboards, pointer devices, and touchscreens, and via output devices such as printers, monitors, and touchscreens. The software can reside in computer memory and on nontransient information storage media. The computer may be implemented in different forms including, e.g., an embedded computer permanently installed as part of the surface interface 116 , a portable computer that is plugged into the surface interface 116 as desired to collect data, a remote desktop computer coupled to the surface interface 116 via a wireless link and/or a wired computer network, a mobile phone/PDA, or indeed any electronic device having a programmable processor and an interface for I/O.
FIG. 2A is a schematic representation of the system configuration in FIG. 1 . It shows a borehole 102 having a casing 104 and a fiberoptic cable 106 (with an integrated sensor array) in the annular space. An injected current 202 flows along casing 104 and disperses into the surrounding formations as indicated by the arrows. Two formations are shown, labeled with their respective resistivities R1 and R2. The heavier arrows in the lower formation represent a larger current flow, indicating that resistivity R2 is lower than resistivity R1. Due to divergence pattern of the currents away from the casing, depth of investigation is typically around 5-15 feet.
FIG. 2B shows an alternative system configuration, in which the fiberoptic cable 106 is replaced by an alternative fiberoptic cable 206 having a conductor or a conductive layer to transport an injected current 212 along the cable. The conductor may be a protective metal tube within which the fiberoptic cable is placed. Alternatively, the conductor may be a wire (e.g., a strength member) embedded in the fiberoptic cable. As another alternative, a metal coating may be manufactured on the cable to serve as the current carrier. Parts of the cable may be covered with an insulator 205 to focus the current dispersal in areas of interest. The optical fiber in cable 212 may act as a distributed sensor or, as in previous embodiments, localized sensors may be integrated into the cable. Because conductive layers can significantly attenuate certain types of electromagnetic fields, the sensors are designed to be operable despite the presence of the conductive layer, e.g., magnetic field sensors, and/or apertures are formed in the conductive layer to permit the EM fields to reach the sensors.
FIG. 2C shows another alternative system configuration. A conductor or conductive layer of fiberoptic cable 206 is electrically coupled to casing 104 to share the same electrical potential and contribute to the dispersal of current into the formation. Parts of the cable 206 and/or casing 104 may be covered with an insulator 205 to focus the current dispersal in areas of interest.
FIG. 2D shows yet another alternative system configuration. Rather than providing an injected current 202 from the surface as in FIG. 2A , the configuration of FIG. 2D provides an injected current 222 from an intermediate point along the casing 104 . Such a current may be generated with an insulated electrical cable passing through the interior of casing 104 from a power source 120 ( FIG. 1 ) to a tool that makes electrical contact at the intermediate point, e.g., via extendible arms. (An alternative approach employs a toroid around casing 104 at the intermediate point to induce current flow along the casing. The toroid provides an electric dipole radiation pattern rather than the illustrated monopole radiation pattern.)
FIG. 2E shows still another alternative system configuration having a first borehole 102 and second borehole 102 ′. Casing 104 in the first borehole 102 carries an injected current from the surface or an intermediate point and disperses it into the surrounding formations. The second borehole 102 ′ has a casing 104 ′ for producing hydrocarbons and further includes a fiberoptic cable 106 ′ with an integrated EM sensor array in the annular space around casing 104 ′. The EM sensors provide measurements of the fields resulting from the currents dispersed in the formations.
The sensor array may employ multiple fiberoptic cables 106 as indicated in FIG. 3A . With cables 106 positioned in parallel or at least in an overlapping axial range, the azimuthal arrangement of sensors 114 enables a multi-dimensional mapping of the electromagnetic fields. In some embodiments, the sensors are mounted to the casing 104 or suspended on fins or spacers to space them away from the body of casing 104 . If actual contact with the formation is desired, the sensors 114 may be mounted on swellable packers 302 as indicated in FIG. 3B . Such packers 302 expand when exposed to downhole conditions, pressing the sensors 114 into contact with the borehole wall. FIG. 3C shows the use of bow-spring centralizers 304 which also operate to press the sensors 114 into contact with the borehole walls. To minimize insertion difficulties, a restraining mechanism may hold the spring arms 304 against the casing 104 until the casing has been inserted in the borehole. Thereafter, exposure to downhole conditions or a circulated fluid (e.g., an acid) degrades the restraining mechanism and enables the spring arms to extend the sensors against the borehole wall. If made of conductive material, the spring arms may further serve as current injection electrodes, concentrating the measurable fields in the vicinity of the sensors. To further concentrate the fields, the spring arms outside the zone of interest may be insulated.
Other extension mechanisms are known in the oilfield and may be suitable for placing the sensors 114 in contact with the borehole wall or into some other desired arrangements such as those illustrated in FIGS. 3D and 3E . In FIG. 3D , the sensors are positioned near the radial midpoint of the annular region. In FIG. 3E , the sensors are placed in a spatial distribution having axial, azimuthal, and radial variation. Balloons, hydraulic arms, and projectiles are other contemplated mechanisms for positioning the sensors.
FIG. 4 shows an illustrative fixed positioning mechanism for sensors 114 . The cage 402 includes two clamps 403 A, 403 B joined by six ribs 404 . The fiberoptic cable(s) 106 can be run along the ribs or, as shown in FIG. 4 , they can be wound helically around the cage. In either case, the ribs provide each fiberoptic cable 106 some radial spacing from the casing 104 . Cable ties 406 can be used to hold the cable in place until cementing has been completed. The ribs can be made of insulating material to avoid distortion of the electromagnetic fields around the sensors.
In addition to providing support and communications for sensors 114 , the fiberoptic cable 106 may support electrodes or antennas for generating electromagnetic fields in the absence of current injection via casing 104 . FIG. 5A shows two electrodes 502 on cable 106 . A voltage is generated between the two electrodes 502 to create an electric dipole radiation pattern. The response of the electromagnetic sensors 114 can then be used to derive formation parameters.
Similarly, FIG. 5B shows a solenoid antenna 504 on cable 106 . A current is supplied to the solenoid coil to create a magnetic dipole radiation pattern. The response of the electromagnetic sensors 114 can then be used to derive formation parameters. In both cases the sensors are shown to one side of the source, but this is not a requirement. The source may be positioned between sensors 114 and/or one or more of the sensors may be positioned between multiple sources. The sensors 114 may even be positioned between the electrodes of a electric dipole source. Moreover, it is possible to tilt the sources and/or the sensors to provide improved directional sensitivity.
FIG. 6 provides a function block representation of an illustrative fiberoptic-based permanent monitoring system. The sensors 114 include electrodes, antennas, or other transducers 602 that convert a property of the surrounding electromagnetic field into a signal that can be sensed via an optical fiber. (Specific examples are provided further below.) An energy source 606 may be provided in the form of a pair of conductors conveying power from the surface or in the form of a powerful downhole battery that contains enough energy to make the device operate for the full life span. It is possible to use an energy saving scheme to turn on or off the device periodically. It is also possible to adjust the power level based on inputs from the fiber optic cable, or based on the sensor inputs.
A controller 604 provides power to the transducers 602 and controls the data acquisition and communication operations and may contain a microprocessor and a random access memory. Transmission and reception can be time activated, or may be based on a signal provided through the optic cable or casing. A single sensor module may contain multiple antennas/electrodes that can be activated sequentially or in parallel. After the controller 604 obtains the signal data, it communicates the signal to the fiberoptic interface 608 . The interface 608 is an element that produces new optical signals in fiberoptic cable 610 or modifies existing optical signals in the cable 610 . For example, optical signal generation can be achieved by the use of LEDs or any other type of optical source. As another example, optical signals that are generated at the surface can be modified by thermal or strain effects on the optical fiber in cable 610 . Thermal effects can be produced by a heat source or sink, whereas strain effects can be achieved by a piezoelectric device or a downhole electrical motor.
Modification can occur via extrinsic effects (i.e., outside the fiber) or intrinsic effects (i.e., inside the fiber). An example of the former technique is a Fabry Pérot sensor, while an example of the latter technique is a Fiber Bragg Grating. For optimum communication performance, the signal in the optical transmission phase may be modulated, converted to digital form, or digitally encoded. The cable is coupled to a receiver or transceiver 612 that converts the received light signals into digital data. Stacking of sequential measurements may be used to improve signal to noise ratio. The system can be based on either narrowband (frequency type) sensing or ultra wideband (transient pulse) sensing. Narrowband sensing often enables the use of reduced-complexity receivers, whereas wideband sensing may provide more information due to the presence of a wider frequency band.
Optionally, a power source 614 transmits power via an electrical conductor 616 to a downhole source controller 618 . The source controller 618 operates an EM field source 620 such as an electric or magnetic dipole. Multiple such sources may be provided and operated in sequence or in parallel at such times and frequencies as may be determined by controller 618 .
Multiple sensors 114 may be positioned along a given optical fiber. Time and/or frequency multiplexing is used to separate the measurements associated with each sensor. In FIG. 7A , a light source 702 emits light in a continuous beam. A circulator 704 directs the light along fiberoptic cable 106 . The light travels along the cable 106 , interacting with a series of sensors 114 , before reflecting off the end of the cable and returning to circulator 704 via sensors 114 . The circulator directs the reflected light to a light detector 708 . The light detector 708 includes electronics that separate the measurements associated with different sensors 114 via frequency multiplexing. That is, each sensor 114 affects only a narrow frequency band of the light beam, and each sensor is designed to affect a different frequency band.
In FIG. 7B , light source 702 emits light in short pulses. Each sensor 114 is coupled to the main optical fiber via a splitter 706 . The splitters direct a small fraction of the light from the optical fiber to the sensor, e.g., 1% to 4%. The sensor 114 interacts with the light and reflects it back to the detector 708 via the splitter, the main fiber, and the circulator. Due to the different travel distances, each pulse of light from source 702 results in a sequence of return pulses, with the first pulse arriving from the nearest sensor 114 , the second pulse arriving from the second nearest sensor, etc. This arrangement enables the detector to separate the sensor measurements on a time multiplexed basis.
The arrangements of FIGS. 7A and 7B are both reflective arrangements in which the light reflects from a fiber termination point. They can each be converted to a transmissive arrangement in which the termination point is replaced by a return fiber that communicates the light back to the surface. FIG. 7C shows an example of such an arrangement for the configuration of FIG. 7B . A return fiber is coupled to each of the sensors via a splitter to collect the light from the sensors 114 and direct it to a light detector 708 .
Other arrangement variations also exist. For example, multiple sensors may be coupled in series on each branch of the FIG. 7B , 7 C arrangements. A combination of time division, wavelength-division and/or frequency division multiplexing could be used to separate the individual sensor measurements.
Thus each production well may be equipped with a permanent array of sensors distributed along axial, azimuthal and radial directions outside the casing. The sensors may be positioned inside the cement or at the boundary between cement and the formation. Each sensor is either on or in the vicinity of a fiber optic cable that serves as the communication link with the surface. Sensor transducers can directly interact with the fiber optic cables or, in some contemplated embodiments, may produce electrical signals that in turn induce thermal, mechanical (strain), acoustic or electromagnetic effects on the fiber. Each fiber optic cable may be associated with multiple EM sensors, while each sensor may produce a signal in multiple fiber optic or fiber optic cables. Even though the figures show uniformly-spaced arrays, the sensor positioning can be optimized based on geology or made randomly. In any configuration, the sensor positions can often be precisely located by monitoring the light signal travel times in the fiber.
Cement composition may be designed to enhance the sensing capability of the system. For example, configurations employing the casing as a current source electrode can employ a cement having a resistivity equal to or smaller than the formation resistivity.
The sensors 114 referenced above preferably employ fully optical means to measure EM fields and EM field gradients and transfer the measurement information through optical fibers to the surface for processing to extract the measurement information. The sensors will preferably operate passively, though in many cases sensors with minimal power requirements can be powered from small batteries. The minimization of electronics or downhole power sources provides a big reliability advantage. Because multiple sensors can share a single fiber, the use of multiple wires with associated connectors and/or multiplexers can also be avoided, further enhancing reliability while also reducing costs.
Several illustrative fiberoptic sensor configurations are shown in FIGS. 8A-8C . FIG. 8A shows an atomic magnetometer configuration in which light from an input fiber 802 passes through a depolarizer 804 (to remove any polarization biases imposed by the fiber) and a polarizing filter 806 to produce polarized light. A gradient index (GRIN) lens 808 collimates the polarized light before it passes through an alkali vapor cell 812 . A quarter-wave plate 810 enhances optical coupling into the cell. A second GRIN lens 814 directs light exiting the cell into an output fiber 816 . The light passing through the cell consists of a pump pulse to polarize the alkali atoms, followed by a probe pulse to measure the spin relaxation rate. The attenuation of the probe pulse is directly related to the magnetic field strength.
FIG. 8B shows a sensor having a support structure 820 separating two electrodes 822 , 824 . A center electrode 826 is supported on a flexible arm 828 . The center electrode 826 is provided with a set charge that experiences a force in the presence of an electrical field between electrodes 822 , 824 . The force causes displacement of the center electrode 826 until a restoring force of the compliant arm 828 balances the force from the electrical field. Electrodes 824 and 826 are at least partially transparent, creating a resonant cavity 830 in the space between. The wavelengths of light that are transmitted and suppressed by the cavity 830 will vary based on displacement of center electrode 826 . Thus the resonant cavity shapes the spectrum of light from input electrode 802 , which effect can be seen in the light exiting from output fiber 816 . The electrodes 822 , 824 may be electrically coupled to a pair of spaced-apart electrodes (for electric field sensing) or to the terminals of a magnetic dipole antenna (for magnetic field sensing).
FIG. 8C shows a sensor having a support structure 840 with a flexible arm 842 that supports a mirror 846 above a window 844 to define a cavity 848 . The arm further includes a magnet 850 or other magnetically responsive material that experiences a displacing force in response to a magnetic field from a coil 852 . The coil's terminals 854 are coupled to spaced-apart electrodes (for electric field sensing) or another coil (for magnetic field sensing). Light entering the cavity 848 from fiber 840 reflects from mirror 846 and returns along fiber 840 to the surface. Displacement of the arm 842 alters the travel time and phase of the light passing along fiber 840 .
The foregoing sensors are merely illustrative examples and not limiting on the sensors that can be employed in the disclosed systems and methods. An interrogation light pulse is sent from the surface through the fiber and, when the pulse reaches a sensor, it passes through the sensor and the light is modified by the sensor in accordance with the measured electromagnetic field characteristic. The measurement information is encoded in the output light and travels through the fiber to a processing unit located at the surface. In the processing unit the measurement information is extracted.
FIG. 9 provides an overview of illustrative formation monitoring methods. A controlled electromagnetic field source generates a subsurface electromagnetic field. While it is possible for this field to be a fixed (DC) field, it is expected that better measurements will be achievable with an alternating current (AC) field having a frequency in the range of 1-1000 Hz. (In applications where shallow detection is desired, higher frequencies such as 1 kHz to 1 GHz can be used.) In block 902 , each of the sensors convert the selected characteristic of the electromagnetic field into a sensed voltage V i , where i is the sensor number. For energy efficiency, sensors can be activated and measurements can be taken periodically. This enables long-term monitoring applications (such as water-flood movements), as well as applications where only small number of measurements are required (fracturing). For further efficiency, different sets of sensors may be activated in different periods.
In block 904 , the voltage (or electric field or magnetic field or electric/magnetic field gradient) is applied to modify some characteristic of light passing through an optical fiber, e.g., travel time, frequency, phase, amplitude. In block 906 , the surface receiver extracts the represented voltage measurements and associates them with a sensor position d i . The measurements are repeated and collected as a function of time in block 908 . In addition, measurements at different times can be subtracted from each other to obtain time-lapse measurements. Multiple time-lapse measurements with different lapse durations can be made to achieve different time resolutions for time-lapse measurements. In block 910 , a data processing system filters and processes the measurements to calibrate them and improve signal to noise ratio. Suitable operations include filtering in time to reduce noise; averaging multiple sensor data to reduce noise; taking the difference or the ratio of multiple voltages to remove unwanted effects such as a common voltage drift due to temperature; other temperature correction schemes such as a temperature correction table; calibration to known/expected resistivity values from an existing well log; and array processing (software focusing) of the data to achieve different depth of detection or vertical resolution.
In block 912 , the processed signals are stored for use as inputs to a numerical inversion process in block 914 . Other inputs to the inversion process are existing logs (block 916 ) such as formation resistivity logs, porosity logs, etc., and a library of calculated signals 918 or a forward model 920 of the system that generates predicted signals in response to model parameters, e.g., a two- or three-dimensional distribution of resistivity. All resistivity, electric permittivity (dielectric constant) or magnetic permeability properties of the formation can be measured and modeled as a function of time and frequency. The parameterized model can involve isotropic or anisotropic electrical (resistivity, dielectric, permeability) properties. They can also include layered formation models where each layer is homogeneous in resistivity. Resistivity variations in one or more dimensions can be included. More complex models can be employed so long as sufficient numbers of sensor types, positions, orientations, and frequencies are employed. The inversion process searches a model parameter space to find the best match between measured signals 912 and generated signals. In block 922 the parameters are stored and used as a starting point for iterations at subsequent times.
Effects due to presence of tubing, casing, mud and cement can be corrected by using a-priori information on these parameters, or by solving for some or all of them during the inversion process. Since all of these effects are mainly additive and they remain the same in time, a time-lapse measurement can remove them. Multiplicative (scaling) portion of the effects can be removed in the process of calibration to an existing log. All additive, multiplicative and any other non-linear effect can be solved for by including them in the inversion process as a parameter.
The fluid front position can be derived from the parameters and it is used as the basis for modifying the flood and/or production profile in block 924 . Production from a well is a dynamic process and each production zone's characteristics may change over time. For example, in the case of water flood injection from a second well, water front may reach some of the perforations and replace the existing oil production. Since flow of water in formations is not very predictable, stopping the flow before such a breakthrough event requires frequent monitoring of the formations.
Profile parameters such as flow rate/pressure in selected production zones, flow rate/pressure in selected injection zones, and the composition of the injection fluid, can each be varied. For example, injection from a secondary well can be stopped or slowed down when an approaching water flood is detected near the production well. In the production well, production from a set of perforations that produce water or that are predicted to produce water in relatively short time can be stopped or slowed down.
We note here that the time lapse signal derived from the receiver signals is expected to be proportional to the contrast between formation parameters. Hence, it is possible to enhance the signal created by an approaching flood front by enhancing the electromagnetic contrast of the flood fluid relative to the connate fluid. For example, a high magnetic permeability, or electrical permittivity or conductivity fluid can be used in the injection process in the place of or in conjunction with water. It is also possible to achieve a similar effect by injecting a contrast fluid from the wellbore in which monitoring is taking place, but this time changing the initial condition of the formation.
The disclosed systems and methods may offer a number of advantages. They may enable continuous time-lapse monitoring of formations including a water flood volume. They may further enable optimization of hydrocarbon production by enabling the operator to track flows associated with each perforation and selectively block water influxes. Precise localization of the sensors is not required during placement since that information can be derived afterwards via the fiber optic cable. Casing source embodiments do not require separate downhole EM sources, significantly decreasing the system cost and increasing reliability.
Numerous other variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. For example, this sensing system can be used for cross well tomography with EM transmitters are placed in one well and EM fields being measured in surrounding wells which can be drilled at an optimized distance with respect to each other and cover the volume of the reservoir from multiple sides for optimal imaging. It is intended that the following claims be interpreted to embrace all such variations and modifications where applicable.
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A formation monitoring system includes a casing. An array of electromagnetic field sensors is positioned in the annular space and configured to communicate with the surface via a fiberoptic cable. A computer coupled to the fiberoptic cable receives measurements from the array and responsively derives the location of any fluid fronts in the vicinity such as an approaching flood front to enable corrective action before breakthrough. A formation monitoring method includes: injecting a first fluid into a reservoir formation; producing a second fluid from the reservoir formation via a casing in a borehole; collecting electromagnetic field measurements with an array of fiberoptic sensors in an annular space, the array communicating measurements to a surface interface via one or more fiberoptic cables; and operating on the measurements to locate a front between the first and second fluids.
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TECHNICAL FIELD
[0001] The present application relates generally to systems and methods for project collaboration in a cloud computing environment.
BACKGROUND
[0002] Contract research organizations (CROs) play a growing role in the medical diagnostic fields, life science research, and for those that are developing new pharmaceuticals or medical devices. Rather than attempting to internally support the often complex services provided by such groups, users can rely on the expertise of the CRO. This saves time and expense and often results in better study results.
[0003] Examples of the types of studies run by CROs include, but are not limited to, high-resolution quantitative imaging, drug dosing studies in small animals, cell analysis, and other general laboratory services. During the performance of these services, a CRO communicates frequently with their client. This communication usually takes the form of email, in-person interviews, web meetings, phone conferences, and paper-based correspondence. In advance of the project, the CRO uses email and phone meetings to understand the client's project goals and to define the CRO's role in the study. During the course of a study, the CRO will have phone and web-meetings with the client to present intermediate results and to provide an opportunity for the client to refine how their analyses and deliverables are tailored.
[0004] At the conclusion of a study, imaging data sets and other study data that are generated during the performance of the services provided to the client by the CRO are transferred to the client via, for example hard drives that are shipped to the client, or via a secure link to the CRO's server that is provided to the client. Upon receipt, the client will review both the written and raw data, perform additional analysis, store the data in file cabinets, desks, or internal servers, and, at some date in the future, attempt to find the data in order to compare it to other data for additional information.
[0005] Beyond accessing and viewing data sets, there is a need for clients to enter annotations, comments, indicators, questions, or other such non verbal communications to be linked to a client's data set and incorporated into a client's project. It is not uncommon for a project to have several collaborators located not only in different laboratories, but in different areas of the world. The methods by which a client can share the data amongst themselves have drawbacks. For instance, consider the case in which two researchers, working for the client that are not in the same building, or are at different worksites altogether, desire to review data that has been received from the CRO. In such instances, the researchers must go through a cumbersome and time-consuming exercise of agreeing on where the data is to be stored, and how they will review the data in a collaborative way. The above-identified process is repeated for each study in which not only the CRO participates, but with services from other third-party providers as well. Therefore, there is a need for a centralized location for users to access remotely from different locations to view and comment on data sets in a particular project. A CRO frequently fields questions and comments from clients about their data and the status of projects in progress. A large part of these communications center around questions, comments, and discussions in regard to the data generated from the client's specimens or samples.
[0006] Another drawback with conventional systems and methods of reporting project data based on CRO work is that there is not currently a system in place at most CRO sites that allows for a client to independently track the progress of their study or the sample processing that is being performed by the CRO. Normally, a client does not have access to or the ability to view individual samples as they are finished processing by the CRO, but rather the collection of samples are viewed at the conclusion of a project. This has the drawback of preventing the client to ascertain how well a project is going until at points in time determined by the client's needs. For example, the client may need to report to an investor or upper management on the progress of an ongoing project. Without real time access to the data as it is being processed, the client is unable to effectively meet these reporting demands.
[0007] Given the above background, improved interfaces for reviewing data provided by a testing laboratory to remote clients is needed.
SUMMARY
[0008] The present disclosure addresses the shortcomings found in the prior art. In the present disclosure a server computer system is provided that comprises one or more processing units, and a memory, coupled to at least one of the one or more processing units, the memory storing a virtual machine. A runtime system runs within the virtual machine. The runtime system is executed by at least one of the processing units. The runtime system comprising instructions for providing any combination of the following features: (i) providing a home page that provides details of a plurality of projects associated with a first user, (ii) providing an overview panel for a project, selected from the plurality of projects by the first user, the overview panel detailing a plurality of samples associated with the project, (iii), providing a data analysis panel for the selected project, the data analysis panel comprising a plurality of measurements for each sample in the plurality of samples associated with the project, (iv) providing a visual analysis panel for the selected project, the visual analysis panel including a plurality of objects associated with the selected project, (v) providing a discussion/notes panel for the selected project, the discussion/notes panel including notes associated with objects in the plurality of objects, (vi) providing a gallery panel for the selected project, for reviewing content that is associated with the selected project, and (vii) providing a live meeting panel for a selected project, where the live meeting panel comprises a whiteboard that is configured to be viewed by any user associated with the selected project, where any user associated with the project that is viewing the whiteboard can drag objects associated with the selected project onto the whiteboard and can annotate the whiteboard.
[0009] In some implementations, a method for user collaboration includes: at a computer system, hosting a collaboration software application and a plurality of data sets associated with the collaboration software application; establishing a first remote user session between the computer system and a first client device running on a first operating system; wherein the first client device is associated with a first user; establishing a second remote user session between the computer system and a second client device running on a second operation system, distinct from the first operating system; wherein the second client device is associated with a second user distinct from the first user; merging the first remote user session and the second remote user session into a single remote user session; and enabling, using the single remote user session, the first user and the second user to concurrently control the collaboration software application and the plurality of data sets.
[0010] In some implementations, the collaboration software application comprises a whiteboard application, and the plurality of data sets includes one of: audio files, video files, image files, 3D images, charts, tables, or data grids.
[0011] In some implementations, the plurality of data sets comprises histology data sets.
[0012] In some implementations, the method also includes preparing for concurrent display from a plurality of angles, a three-dimensional object represented in a three-dimensional image.
[0013] In some implementations, the method also includes adjusting a display of the three dimensional object from a first angle in the plurality of angles, without user intervention, in accordance with a change to a display of the three dimensional object from a second angle in the plurality of angles.
[0014] In some implementations, the method also includes preparing for display, in the collaboration application, status indicators for the first and second users.
[0015] In some implementations, the method also includes enabling the first and second users to concurrently access a plurality of projects using the collaboration software application.
[0016] In some implementations, the method also includes preparing for display a representation of a count of users having access to a project in the plurality of projects.
[0017] In some implementations, the method also includes preparing for concurrent display a data set in the plurality of data sets in a first visual representation, and a second visual representation distinct from the first visual representation.
[0018] In some implementations, the first visual representation is a grid view, and the second visual representation is a chart view.
[0019] In some implementations, the method also includes recording access history for a respective user in the first or second user.
[0020] In some implementations, the method also includes obtaining an update to the plurality of data sets, and in response to the update, preparing for display, to the first and second users, a second plurality of data sets in accordance with the first plurality of data sets and the update.
[0021] In some implementations, a computer system comprising: one or more processing units; one or more programs including instructions, configured to be executed by the one or more processing units, for: hosting a collaboration software application and a plurality of data sets associated with the collaboration software application; establishing a first remote user session between the computer system and a first client device running on a first operating system; wherein the first client device is associated with a first user; establishing a second remote user session between the computer system and a second client device running on a second operation system, distinct from the first operating system; wherein the second client device is associated with a second user distinct from the first user; merging the first remote user session and the second remote user session into a single remote user session; and enabling, using the single remote user session, the first user and the second user to simultaneously control the collaboration software application and the plurality of data sets.
[0022] In some implementations, the collaboration software application comprises a whiteboard application, and the plurality of data sets includes one of: audio files, video files, image files, 3D images, charts, tables, or data grids.
[0023] In some implementations, the plurality of data sets comprises histology data sets.
[0024] In some implementations, the one or more programs further comprise instructions for preparing for concurrent display from a plurality of angles, a three-dimensional object represented in a three-dimensional image.
[0025] In some implementations, the one or more programs further comprise instructions for automatically adjusting a display of the three dimensional object from a first angle in the plurality of angles, without user intervention, in accordance with a change to a display of the 3D object from a second angle in the plurality of angles.
[0026] In some implementations, the one or more programs further comprise instructions for preparing for display, in the collaboration application, status indicators for the first and second users.
[0027] In some implementations, the one or more programs further comprise instructions for enabling the first and second users to concurrently access a plurality of projects using the collaboration application.
[0028] In some implementations, the one or more programs further comprise instructions for preparing for display a representation of a count of users having access to a project in the plurality of projects.
[0029] In some implementations, the one or more programs further comprise instructions for preparing for concurrent display a data set in the plurality of data sets in a first visual representation, and a second visual representation distinct from the first visual representation.
[0030] In some implementations, the first visual representation is a grid view, and the second visual representation is a chart view.
[0031] In some implementations, the one or more programs further comprise instructions for recording access history for a respective user in the first or second user.
[0032] In some implementations, the one or more programs further comprise instructions for obtaining an update to the plurality of data sets, and in response to the update, preparing for display, to the first and second users, a second plurality of data sets in accordance with the first plurality of data sets and the update.
[0033] In some implementations, a non-transitory computer readable storage medium storing one or more programs, the one or more programs comprising instructions, configured to be executed by a computer system with one or more processors, for: hosting a collaboration software application and a plurality of data sets associated with the collaboration application; establishing a first remote user session between the computer system and a first client device running on a first operating system; wherein the first client device is associated with a first user; establishing a second remote user session between the computer system and a second client device running on a second operation system, distinct from the first operating system; wherein the second client device is associated with a second user distinct from the first user; merging the first remote user session and the second remote user session into a single remote user session; and enabling, using the single remote user session, the first user and the second user to concurrently control the collaboration software application and the plurality of data sets.
[0034] In some implementations, the collaboration software application comprises a whiteboard application, and the plurality of data sets includes one of: audio files, video files, image files, 3D images, charts, tables, or data grids.
[0035] In some implementations, the plurality of data sets comprises histology data sets.
[0036] In some implementations, the one or more programs further comprise instructions for preparing for concurrent display from a plurality of angles, a three-dimensional object represented in a three-dimensional image.
[0037] In some implementations, the one or more programs further comprise instructions for automatically adjusting a display of the three dimensional object from a first angle in the plurality of angles, without user intervention, in accordance with a change to a display of the 3D object from a second angle in the plurality of angles.
[0038] In some implementations, the one or more programs further comprise instructions for preparing for display, in the collaboration application, status indicators for the first and second users.
[0039] In some implementations, the one or more programs further comprise instructions for enabling the first and second users to concurrently access a plurality of projects using the collaboration application.
[0040] In some implementations, the one or more programs further comprise instructions for preparing for display a representation of a count of users having access to a project in the plurality of projects.
[0041] In some implementations, the one or more programs further comprise instructions for preparing for concurrent display a data set in the plurality of data sets in a first visual representation, and a second visual representation distinct from the first visual representation.
[0042] In some implementations, the first visual representation is a grid view, and the second visual representation is a chart view.
[0043] In some implementations, the one or more programs further comprise instructions for recording access history for a respective user in the first or second user.
[0044] In some implementations, the one or more programs further comprise instructions for obtaining an update to the plurality of data sets, and in response to the update, preparing for display, to the first and second users, a second plurality of data sets in accordance with the first plurality of data sets and the update.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] FIG. 1 illustrates a view of a system in accordance with some embodiments of the present disclosure.
[0046] FIG. 2 illustrates another view of the system in accordance with some embodiments of the present disclosure.
[0047] FIG. 3 illustrates a log in screen for a runtime system in accordance with some embodiments of the present disclosure.
[0048] FIG. 4 illustrates a home page for a project detailing a list of projects, and for each respective project in the list, (i) brief summary information, including direct links to most important documents, and (ii) an overview of recent project activity (e.g. project updates, questions/discussions) available to registered users through push notifications, e-mails, etc. in accordance with some embodiments of the present disclosure.
[0049] FIG. 5 illustrates a visual analysis panel for a plurality of objects, where the visual analysis panel supports various document types and process types for the objects (e.g., image types, movie types, applications) and includes badges that indicate where there are notes associated with data and further includes recent project activity (project updates, questions/discussions) that is available as push notifications, emails, etc., in accordance with some embodiments of the present disclosure.
[0050] FIG. 6 illustrates a visual analysis panel in which the selection of a first object type causes objects of the first object type that are associated with the project to drop into a lower frame of the visual analysis panel in accordance with some embodiments of the present disclosure.
[0051] FIG. 7 illustrates the selection of an object of the first object type from the visual analysis panel of FIG. 6 , resulting in the opening of a first light-box for the object, a movie, in accordance with some embodiments of the present disclosure.
[0052] FIG. 8 illustrates the visual analysis panel in which the selection of a second object type causes objects of the second object type that are associated with the project to drop into a lower frame of the visual analysis panel in accordance with some embodiments of the present disclosure.
[0053] FIG. 9 illustrates the selection of an object of the second object type from the visual analysis panel of FIG. 8 , resulting in the opening of a second light-box for the object, a histological image, in accordance with some embodiments of the present disclosure.
[0054] FIG. 10 provides an illustration of how an object can be annotated in a dataset associated with a project, where such annotations are linked to the discussion/notes page associated with a project and such annotations can be pushed to subscribers in accordance with some embodiments of the present disclosure.
[0055] FIG. 11 illustrates the selection of an object of an third object type from the visual analysis panel and the running an application to render the selected object on a remote server, in which display features can be toggled on and off in accordance with some embodiments of the present disclosure.
[0056] FIG. 12 illustrates the statistical treatment of data associated with a project using tools available in the runtime system thereby generating plot in accordance with some embodiments of the present disclosure.
[0057] FIG. 13 illustrates how statistical plots may be viewed directly from the runtime system in accordance with some embodiments of the present disclosure.
[0058] FIG. 14 illustrates how a comparative analysis of various selected datasets associated with a project may be done in accordance with some embodiments of the present disclosure.
[0059] FIG. 15 illustrates how the comparative analysis depicted in FIG. 14 may be opened using a comparison tab of the runtime system in accordance with some embodiments of the present disclosure.
[0060] FIG. 16 illustrates a discussion/notes board associated with a project in accordance with some embodiments of the present disclosure.
[0061] FIG. 17 illustrates a gallery associated with a project in accordance with some embodiments of the present disclosure.
[0062] FIG. 18 illustrates a live meeting in which project members can (i) drag objects associated with a project onto and off of a common white board viewable by all project members and (ii) annotate the objects and/or the white board in accordance with some embodiments of the present disclosure.
[0063] FIG. 19 illustrates a project dashboard, which shows a synopsis of various projects hosted by the runtime system in accordance with some embodiments of the present disclosure.
[0064] FIG. 20 illustrates a reference library, which shows information regarding procedure used to generate data for various projects hosted by the runtime system and other information relevant to such projects in accordance with some embodiments of the present disclosure.
[0065] FIG. 21 illustrates an upload interface for uploading data associated with a project hosted by the runtime system in accordance with some embodiments of the present disclosure.
[0066] Like reference numerals refer to corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0067] The present disclosure addresses the drawbacks identified in the background section. Disclosed is a cloud-based runtime system having remote access. As such, a user need not run the applications or software needed to review data produced by a testing laboratory on their own local computer system. As used herein, the term “cloud”, means both public clouds (e.g. AMAZON and MICROSOFT clouds), as well as private clouds, which typically reside in a company's own data center (e.g. some biotech, pharmaceutical, medical device and/or diagnostic companies have their own private cloud in their local data center, which employees of the respective companies access from their desktops). Cloud application services, also known as software as a service (SaaS), provide access to software applications running remotely over the Internet, eliminating the need for the user to install and run the application on their local computer. Cloud platform services, also known as platform as a service (PaaS), deliver a computing platform and/or solution stack as a service, which requires consuming cloud infrastructure and sustaining cloud applications.
[0068] A feature of the runtime systems of the present disclosure is that all computing and data storage occurs remotely in the cloud, and the user interacts with their data through their local desktop computer, iPad, or other mobile device. This eliminates the need for users to download, install, or learn all the complexities of the software implemented by the CRO. This concept—using a cloud framework to dramatically simplify the process of running and linking existing applications—is an advantageous feature of the disclosed runtime system.
[0069] Organization and varied views. Once logged in, the user can navigate to various views, features, tabs, and modules of the runtime system. In some embodiments, the runtime system includes a dashboard, a project overview, specimen details or information, relational views or spatial correspondence, statistical analysis, side-by-side comparisons, discussion/notes, a reference library, an electronic lab notebook, a virtual whiteboard, project management overview, a gallery, document management, profile management, auditing (provenance tracking, access controls, etc.), or a subset or a superset of these features.
[0070] In some embodiments, the runtime system supports a freeform investigation mode. In this mode, the user freely moves through various analytic tools, probing, dissecting, and aggregating the data as they explore. As they move through the different steps and tools, the runtime system tracks their history and parameters, and an interface is provided both for reviewing that history, as well as for going back and making modifications to specified parameters or tool selections.
[0071] Data organization. Another feature of the runtime system of the present disclosure is the ability to organize and manage large collections of data files. The runtime system provides the underlying infrastructure and user-interface components for tagging, grouping, and hierarchically organizing data. The runtime system allows for complex metadata tags, which encode information about how a dataset was created (e.g., equipment, operator, protocol, date, etc.), as well as project data (e.g., project number, specimen number, grouping information, etc.), with the history defining how a dataset has been processed (e.g., scripts, parameters, associated input and output datasets, operator, date, etc.). In some embodiments, the runtime system also supports annotations to datasets; examples of annotations include, but are not limited to text and drawing primitives (e.g., boxes, circles, arrows, curves, etc.). The runtime system stores the annotations as metadata as well as who created the annotations, when they created the annotations, and what data objects they were seeing when they created the annotations. In some embodiments, the runtime system support cross-links, which are metadata pointers that explicitly associate objects in one dataset with objects in other datasets, or that associate objects within the same dataset. The runtime system provides user interface views and widgets to support the creation, viewing and, where appropriate, editing of all of these metadata tags. Similarly, the runtime system provides user-interface elements for organizing and grouping datasets.
[0072] Integration with other applications. In some embodiments, the runtime system uses software developed by the CRO. In such instances, a user of the runtime system gains access to such software. In some embodiments, in addition to the software developed by the CRO, the runtime system makes use of software developed by vendors other than the CRO. Advantageously, in order to fully make use of the tools needed to review data, a user buys a subscription to the runtime system and thus gets access to the full array of software tools, including those provided by the CRO and third party vendors. In this way, the user does not have to purchase the servers, software, data-center space or network equipment, needed to run the full array of tools needed to analyze the data hosted by the runtime system. This obviates the need for users to download, install, operate, and manage the numerous applications the runtime system employs to view and analyze the user data sets. By integrating and leveraging this suite of applications within the runtime system, the runtime system of the present disclosure allows for users to easily retrieve, view, manipulate, analyze and process their data.
[0073] Whiteboard.
[0074] To address the communication drawbacks of the prior art methods and systems, the runtime system incorporates a virtual whiteboard to allow users to drop data onto the white board, and enter comments, calculations, graphs, etc. The whiteboard sessions are saved and archived by the runtime system and, moreover, users of the runtime system can email these saved sessions to each other. For example, a user can obtain an image of a specimen from within a project hosted by the runtime system, and drop the image onto the whiteboard, along with charts, statistical analysis, and specimen information, and then add annotations or pose questions on the whiteboard. The whiteboard session is then saved, and other users can then view the save session and also add annotations or comments.
[0075] Real-Time Tracking.
[0076] To the CRO laboratory and its users, the runtime system allows users to track the progress of their project. Using the runtime system, the user is able to access and view data sets as each sample is completed and uploaded to the runtime system.
[0077] Controlled Access and Credentials.
[0078] In some embodiments, a user can log into the platform via an internet website and thereby have access to restricted and unrestricted applications and data sets based upon the user's credentials. Individuals can subscribe to various projects, and thereby receive push notifications when information is added to the runtime system, whether they are data, comments, annotations, etc.
[0079] Data Analysis and Archiving.
[0080] In some embodiments, a user is able to complete computations and analysis tasks in the cloud, not on the user's local computer system. This allows for faster processing of the requisite computations. For example, a user could view the images of several specimens under a comparison feature, decide to analyze the cortical roughness of the samples, and then set a batch of samples to be processed, all within the cloud. As such, the runtime system provides a centralized source for all information, data, processing, progress, communications, and analysis for a user's projects.
[0081] The disclosed runtime system is suitable for the needs of any contract research organization in the biotechnology field, and is able to combine the databases of several contract research organizations into a single project hosted by the runtime system. More generally, the disclosed runtime system is useful in fields outside of life sciences. In one embodiment, the runtime system provides a cloud-based tool, coupled with thin client applications, that integrates management, processing, analysis, tracking, and communication about project data. Such a runtime system finds applicability in a broad spectrum of fields.
[0082] Now that an overview of the features of the runtime system have been disclosed, a detailed description of a system topology 10 in accordance with the present disclosure is described in conjunction with FIGS. 1 and 2 . In the topology, there is one or more server computers 100 hosting virtual machines ( FIG. 1 ), one or local client systems 200 ( FIG. 2 ) and, optionally, one or more back-end servers 300 ( FIG. 2 ). Of course, other topologies are possible, for instance, there may be any number of server computers like that of the server computer 100 collectively functioning in the same manner as the server computer 100 . Moreover, more typically, there are tens, hundreds, or even thousands of local client systems 200 or more. Also, optionally, there can be any number of backend servers 300 . The exemplary topology shown in FIGS. 1 and 2 merely serves to describe the features of an embodiment of the present disclosure in a manner that will be readily understood to one of skill in the art.
[0083] The server computer 100 will typically have one or more processing units (CPU's) 2 , a network or other communications interface 10 , a memory 14 , one or more communication busses 12 for interconnecting the aforementioned components, and a power supply 24 for powering the aforementioned components. The communication busses 12 may include circuitry (sometimes called a chipset) that interconnects and controls communications between system components. Memory 14 includes high-speed random access memory, such as DRAM, SRAM, DDR RAM or other random access solid state memory devices; and typically includes non-volatile memory, such as one or more magnetic disk storage devices, optical disk storage devices, flash memory devices, or other non-volatile solid state storage devices. Memory 14 optionally includes one or more storage devices remotely located from the CPU(s) 2 . Memory 14 , or alternately the non-volatile memory device(s) within memory 14 , comprises a non-transitory computer readable storage medium. Memory 14 can include mass storage that is remotely located with respect to the central processing unit(s) 2 . In other words, some data stored in memory 14 may in fact be hosted on computers that are external to the server computer 100 but that can be electronically accessed by the server computer 100 over an Internet, intranet, or other form of network or electronic cable (illustrated as element 26 in FIG. 1 ) using network interface 10 .
[0084] In some embodiments, Memory 14 stores a hypervisor 40 for initiating hardware virtual machines 42 and one or more hardware virtual machines 42 . There may be any number of hardware virtual machines 42 running on the server computer 100 . In some instances, there is only one hardware virtual machine 42 running on the server computer 100 . In some instances, there are two or more, three or more, five or more, or ten or more hardware virtual machines 42 running on the server computer 100 . In some instances, a single virtual machine 42 is running on multiple server computers 100 . Each respective hardware virtual machine 42 preferably comprises: an operating system 44 that includes procedures for handling various basic system services and a runtime system 46 .
[0085] In some embodiments, each runtime system 46 comprises:
a home page module 50 which provides a home page panel, an example of which is the home page panel 402 illustrated in FIG. 4 ; an overview module 52 which provides an overview panel for a selected project 410 , an example of which is the overview panel 1402 illustrated in FIG. 14 ; a data analysis module 54 which provides a data analysis panel for a selected project, and example of which is the data analysis panel 1202 illustrated in FIG. 12 ; a visual analysis module 56 which provides a visual analysis panel for a selected project, an example of which is the visual analysis panel 502 illustrated in FIGS. 5-6 ; a discussion/notes module 58 which provides a discussion/notes panel for a selected project, an example of which is the discussion/notes panel 1602 illustrated in FIG. 16 ; a gallery module 60 which provides a gallery panel for a selected project, an example of which is the gallery panel 1702 illustrated in FIG. 17 ; a live meeting module 62 which provides a live meeting panel for a selected project, an example of which is the live meeting panel 1802 illustrated in FIG. 18 ; and a user information module 64 which provides information about each user (client) 66 of the runtime system 46 including, for each user 66 , a user profile 68 that includes the user's access credentials; and a project module 70 which tracks the projects hosted by the runtime system 46 and, for each such project, stores project information 72 including the location of databases associated with the project and the project category; a plurality of applications 74 , each application either being run within the virtual machine 42 or on a backend server 300 ;
[0096] As will be understood by one of skill in the art, there is individual nontransitory memory (e.g. of type 14 ) associated 1:1 with each virtual machine 42 residing on server 100 . Such storage is where the virtual machine 42 operating systems and files are stored and accessed.
[0097] In practice, the hypervisor 40 initiates a virtual machine 42 on the server computer 100 and an operating system 44 is initiated within the initiated virtual machine 42 . The hypervisor 40 , also called a virtual machine manager (VMM), is any one of many hardware virtualization techniques that allow multiple operating systems 44 to run concurrently on the server computer 100 . The hypervisor 40 presents to each of the guest operating systems 44 a virtual operating platform and manages the execution of such operating systems. Multiple instances of a variety of operating systems 44 may share the virtualized hardware resources. Commercial embodiments of the hypervisor 40 include, but are not limited to, OPENSTACK, EUCALYPTUS, VMWARE ESXI, CITRIX XENSERVER, MICROSOFT HYPER-V HYPERVISOR, SUN'S LOGICAL DOMAINS HYPERVISOR, and HP's INTEGRITY VIRTUAL MACHINES. Examples of operating systems 44 include, but are not limited to, UNIX, OPEN VMS, LINUX, and MICROSOFT WINDOWS. The runtime system 46 runs under the operating system 44 in a virtual machine 42 .
[0098] Turning to FIG. 2 , a local client system 200 will typically have one or more processing units (CPU's) 102 , a network or other communications interface 104 , a memory 114 , a user interface 106 including a display 108 and keyboard 110 , one or more communication busses 112 for interconnecting the aforementioned components, and a power supply 124 for powering the aforementioned components. The communication busses 112 may include circuitry (sometimes called a chipset) that interconnects and controls communications between system components. Memory 114 includes high-speed random access memory, such as DRAM, SRAM, DDR RAM or other random access solid state memory devices; and typically includes non-volatile memory, such as one or more magnetic disk storage devices, optical disk storage devices, flash memory devices, or other non-volatile solid state storage devices. Memory 114 optionally includes one or more storage devices remotely located from the CPU(s) 2 . Memory 114 , or alternately the non-volatile memory device(s) within memory 114 , comprises a non-transitory computer readable storage medium. Memory 114 can include mass storage that is remotely located with respect to the central processing unit(s) 102 . In other words, some data stored in memory 114 may in fact be hosted on computers that are external to the local client system 200 but that can be electronically accessed by the client local system 200 over an Internet, intranet, or other form of network or electronic cable (illustrated as element 26 in FIG. 2 ) using network interface 104 .
[0099] In some embodiments, Memory 114 stores an operating system 140 that includes procedures for handling various basic system services, a browser 142 for communicating with the runtime system 46 , and user data 144 for uploading to the runtime system 46 .
[0100] FIG. 2 further discloses one or more optional back-end servers 300 . A back-end server 300 will typically have one or more processing units (CPU's) 202 , a network or other communications interface 204 , a memory 214 , one or more communication busses 212 for interconnecting the aforementioned components, and a power supply 224 for powering the aforementioned components. The communication busses 212 may include circuitry (sometimes called a chipset) that interconnects and controls communications between system components. Memory 214 includes high-speed random access memory, such as DRAM, SRAM, DDR RAM or other random access solid state memory devices; and typically includes non-volatile memory, such as one or more magnetic disk storage devices, optical disk storage devices, flash memory devices, or other non-volatile solid state storage devices. Memory 214 optionally includes one or more storage devices remotely located from the CPU(s) 2 . Memory 214 , or alternately the non-volatile memory device(s) within memory 214 , comprises a non-transitory computer readable storage medium. Memory 214 can include mass storage that is remotely located with respect to the central processing unit(s) 202 . In other words, some data stored in memory 214 may in fact be hosted on computers that are external to the back-end server 300 but that can be electronically accessed by the back-end server 300 over an Internet, intranet, or other form of network or electronic cable (illustrated as element 26 in FIG. 2 ) using network interface 204 .
[0101] In some implementations, the memory 214 stores an operating system 240 that includes procedures for handling various basic system services and a communication module 242 for connecting to remote computers, such as server 100 , over network 26 . In some embodiments, memory 114 further stores one or more application programs 244 that are remotely accessed and controlled by an instance of a runtime system 46 . In some embodiments, application programs 244 are run within virtual machines that are optionally running on the back-end server 300 .
[0102] Now that an overview of a system topology 10 in accordance with an aspect of the present disclosure has been described, more details of an exemplary runtime system 46 will be disclosed. Referring to FIG. 3 , the login screen 302 for a runtime system that facilitates project collaboration in a cloud computing environment is disclosed. In some embodiments, the projects are small animal imaging projects and the runtime system enables project members to manage those projects and the imaged specimen data associated with those projects in a cloud computing environment. When a user wants to go work with the various data sets of the projects that the user is associated with, the user logs into the runtime system by providing a login 304 and a password 306 . Each user is associated with credentials. Thus, which aspects and functionality of the runtime system that the user will see when logged into the runtime system is completely dependent on the credentials associated with the user. Thus, if a user is not authorized to see certain data sets within a project, or entire projects hosted by the runtime system, the user will not be able to access such data or projects.
[0103] Turning to FIG. 4 , an exemplary home page 402 for a user that used login screen 302 is disclosed. As seen in the home page 402 of the user that provided credentials in login page 302 , the user is a member of (has credentials that allow the user to gain access to) three different project categories 410 . For each respective project category, there is a corresponding tab 402 depicted on home page 402 that includes the name of the respective project category 410 associated with the tab. In the home page 402 depicted in FIG. 4 , the user has access privileges to three different project categories 410 : “Osteoarthritis”, “Lung Fibrosis”, and “Atherosclerosis”. Currently, as depicted in home page 402 of FIG. 4 , the osteoarthritis project category is selected. Because the osteoarthritis project category is selected, the home page 402 provides an exemplary graphic 426 for the project category. Here, the exemplary graphic 426 is that of a knee joint. Moreover, the panel lists the projects 404 that are associated with the project category 410 , provided that the user has access writes to the projects.
[0104] In panel 402 , the projects 404 associated with the osteoarthritis project category are provided in an upper portion of the panel and, for each respective project 404 in the list, brief summary information 406 , including direct links to most important documents. In the embodiment illustrated in FIG. 4 , the brief summary information includes the species of tissue used for each project 404 , the principle investigator of each project 404 , the number of samples that have been processed in each project 404 , when the project 404 initiated, when the project 404 ended or is projected to end, direct links to important documents associated with the project 404 and any notes associated with the project. Accordingly, exemplary panel 402 of FIG. 4 details that project 2263 is a rat study with 40 specimens. It started on Jan. 12, 2012. The project is currently in progress. Moreover, column 428 specifies that there is a document associated with project 2263 . In other words, such documents are linked in. In the case of project 2263 , the linked in document is a MICROSOFT POWERPOINT file. The user can download the POWERPOINT file to their local system and then open it up on their computer. Alternatively, the user can click on the file causing the file to execute directly from within the runtime system without ever having to download it specifically to the user's local system. In the case of MICROSOFT WORD, POWERPOINT AND EXCEL, the runtime system uses tools provided in the MICROSOFT Office software developer kit that allows for the exportation of images from each of the slides/pages of the document.
[0105] The runtime system compiles the images of a document associated with a project 408 into a view that is provided to the user when the user clicks on the file. In some embodiments, such images are prepared when the file is uploaded into the runtime or at some other time prior to receiving the request to view the document. When viewing the documents through the runtime system, the system provides controls to allow the user to toggle between the slides. Moreover, in some embodiments, the user can magnify portions of the screen. To support this feature, on the back end of the runtime system, when a document is processed, a high resolution and low resolution version of each of the pages of the document is created. When the user is viewing an entire image from the document, the low resolution version is shown and when the user is viewing a magnified portion of the image, the high resolution image is viewed.
[0106] Further provided in the home page 402 is an overview 430 of recent project activity (e.g. project updates, questions/discussions) 408 for each of the projects that the user has access to in the selected project category. Examples of project updates include messages that are sent out to each member of a project when triggering events occurs. Triggering events include, but are not limited to: (i) instances in which a member of a project annotates an object associated with a project (e.g. “John Doe (Pharm X) added a note to the hist_image ‘2R-histo1.jpg” for sample 2R”), samples associated with the project have been scanned, (iii) samples associated with the project have been processed, (iv) results for samples associated with the project have been added, (v) samples associated with the project have been received by a testing agency, and/or (vi) a signed purchase order has been received by the testing agency. In the runtime system, the recent activity in projects associated with the user is also available to registered users through push notifications, e-mails, etc. in some embodiments of the present disclosure.
[0107] Most of the messages in the overview of recent project activity are auto generated. So, for example, when a predetermined threshold amount of data has been processed (e.g., 30 percent), a project a message is automatically generated and sent to the recent activity panel 408 . Project members are able to register for such messages or for different message types. Moreover, project members can specify within the runtime system how they want to be notified when different events happen. In other words, the user can select which types of messages they will receive and how they will receive such messages. So, for example, a user can specify that, whenever a project reaches fifty percent completion, they receive a text message alerting them to this fact. In another example, the user can specify that an e-mail is to be sent to the user whenever the processing lab has a question about particular data for a project on which the user works. Thus, the runtime system provides substantial flexibility on how message notifications are registered on the back end. The recent project activity 408 provides a list of all of the events that have transpired for the project in the selected project category 410 .
[0108] The user can toggle to other views using the tabs below the project tabs. Selection of tab 412 leads to the home page panel, an example of which is illustrated in FIG. 4 and is discussed above. Selection of any one of tabs 414 through 424 leads to a panel associated with the project 410 that is currently selected. For instance, when the project 2263 of the project “Osteoarthritis” is selected, selection of any one of tabs 414 through 424 leads to a corresponding panel for project 2263 . Selection of tab 414 leads to an overview panel for the selected project 410 . An example of such an overview panel for the project 2263 is illustrated in FIG. 14 . Selection of tab 416 leads to a data analysis panel for the selected project 410 . An example of such a data analysis panel for the project 2263 of the project category “Osteoarthritis” is illustrated in FIG. 12 . Selection of tab 418 leads to a visual analysis panel for the selected project 410 . An example of such a visual analysis panel for the project 2263 is illustrated in FIGS. 5-6 , 9 , and 11 . Selection of tab 420 leads to a discussion/notes panel for the selected project 410 . An example of such a discussion/notes panel for the project 2263 is illustrated in FIG. 16 . Selection of tab 422 leads to a gallery panel for the selected project 410 . An example of such a gallery panel for the project 2263 is illustrated in FIG. 17 . Selection of tab 424 leads to a live meeting panel for the selected project 410 . An example of such a live meeting panel for the project 2263 is illustrated in FIG. 18 .
[0109] FIG. 5 illustrates the panel 502 that is displayed by the runtime system when (i) the user selects the visual analysis tab 418 , (ii) the project category 410 - 1 “Osteoarthritis” is selected, (iii) the user has selected project 2263 , and (iv) the user selects the open project tab 430 . Information associated with project 2263 is shown in panel 502 . Panel 502 includes a plurality of object types 504 that are associated with the project. Advantageously, the runtime system supports many different object types 504 including, but not limited to, image types (e.g. two-dimensional imaging data, three-dimensional imaging data), movie types, and various application types. Moreover, the object types 504 that include badges 506 on panel 502 indicate that there are annotations for the data associated with such object types 504 . Objects within the object types are active components that can be contracted and expanded directly from the runtime system.
[0110] The left-hand portion 508 of panel 502 lists out all of the specimens that are part of a project. Exemplary information for each specimen includes sample number, weight, type, dosage, necroscopy, and notes.
[0111] FIG. 6 illustrates panel 502 after a user has selected an object category 504 - 2 “planar movie(s)”. In this instance, an icon for each of the six planar movies 602 that are associated with project 2263 are displayed. When a user selects any of the icons for the movies, the movie corresponding to the selected icon is displayed directly from the runtime system.
[0112] For instance, as illustrated in FIG. 7 , the movie “2R-Bone-Coronal.mp4” is displayed when the user selects movie 602 - 2 in panel 502 of FIG. 6 . Alternatively, as with any of the objects associated with a project, the user can download the movie to their local system for viewing or storage provided that user has sufficient privileges.
[0113] FIG. 8 illustrates panel 502 after a user has selected object category 504 - 2 “histology image(s)” from panel 502 . In this instance, an icon 802 for each of the histological images that are associated with the selected object category 504 - 2 in project 2263 are displayed. When a user selects one of these images 802 , the selected image is displayed directly from the runtime system using, for example, a JAVA plugin to the web browser running on the user's local system. For instance, as illustrated in FIG. 9 , the image “2R-histo2.jpg” is displayed, at lower resolution, when the user selects image 802 - 2 in panel 502 of FIG. 8 . Advantageously, as illustrated in FIG. 9 , the runtime system provides the user with the option to use a magnifying box 902 to zoom into portions of the displayed histological image to view them at full resolution. This option is provided by the runtime system without any requirement that custom software be installed on the user's local system for looking at such images. Thus, using the runtime system, the user can quickly view the data without having to download such data and the applications needed to view the data.
[0114] Turing to FIG. 10 , the runtime system supports several object types 504 that can be made available as part of the visual analysis. As illustrated in FIG. 10 , some of these object types include movies. Other object types include, but are not limited to, histological images and spreadsheets. As illustrated in FIG. 10 , a user can use a notepad 1002 to annotate objects associated with the selected project. In some embodiments, once an object has been annotated, a note indicator 1004 is displayed next to the object to indicate that it has been annotated.
[0115] Advantageously, object types supported by the runtime system also include object types that are referred to herein as live (interactive) content. When an object that is in a live content category is selected, and the user requests that the live (interactive) object be run in its native software application, the object is run in native software running within the runtime system or on a back-end server that is in electronic communication with the runtime system. Advantageously, the object is immediately set to the appropriate view. Depending on the use case, the appropriate view can be a view of the object that was saved when a user associated with the project last viewed the object, a view of the object that was saved when the instant user last accessed the project, or some default view associated with the project.
[0116] FIG. 11 shows a live object being run in live box 1102 using a rendering application without any requirement that the rendering software be installed on the user's local system. In other words, the visualization is controlled remotely from live box 1102 . The user can rotate the data, zoom in and zoom out. The user can toggle on and off different features 1104 . For instance, when the user is not interested in the femur and just want to see the tibia, the user deselect the femur using toggle 1104 - 4 and selects the tibia using toggle 1104 - 5 . In FIG. 11 , a roughness map is being shown because the user has selected toggle 1104 - 3 , which controls cartilage roughage. The roughness map indicates the roughness of the surface. When the user wants to instead view a thickness map, the user deselects toggle 1104 - 3 and selects toggle 1104 - 2 . The cartilage thickness is a different metric created and visualized on this data all in real time. A substantial amount of processing power and interactive visualization power are required to do this. However, because of the advantageous way that the runtime system is set up, such rendering is done without any requirement that the user set up the rendering software on their local system. The runtime system manages all of these calculations using one or more back-end servers that are in electronic communication with the runtime system. In some embodiments, instead of rendering images to a local display, the software driving the image illustrated in FIG. 11 renders the images to an off screen buffer. That buffer is then sent out over a socket to a communicating application that is then reading in that buffer. This provides the advantage of providing an interface this is highly customized. In alternative embodiments, the rending application is run on the back-end server and the relevant portion of the screen that corresponds to that application is captured and sent out over a socket to a communicating application that is then reading in that buffer. In some embodiments, the runtime system that produces the images depicted in FIGS. 3 through 18 is running in a first virtual machine and a rendering application that provides the live image illustrated in FIG. 11 is running in a second virtual machine. This second virtual machine is fired up when needed, for example when the user selects an object that is to be visualized in the rendering software, and then the second virtual machine shuts down when it is no longer needed, for example, because the user has terminated window 1102 .
[0117] FIG. 12 illustrates the panel 1202 that is displayed by the runtime system when (i) the user selects the data analysis tab 416 , (ii) the project category 410 - 1 “Osteoarthritis” is selected, and (iii) the user has selected project 2263 . The statistics that have come out of project 2263 are detailed in panel 1202 . Because this is an osteoarthritis project, the subject of the project is knee joints. More specifically, in this project the cartilage of the knee joint is of interest. As such, several different metrics related to this subject are disclosed. For instance, for each respective cartilage sample 1204 in the cartilage samples of project 2263 , the surface area measurement 1206 of the respective cartilage sample, the volume 1208 of the respective cartilage sample, and an associated damage metric 1210 associated with the respective cartilage sample are disclosed. This data can be downloaded to a spreadsheet when the user clicks button 1212 . Or the data can be sent by e-mail or printed out when similar buttons are selected. Referring to the right hand side of panel 1202 , this data can also be plotted. Thus, instead of just looking at the data in a table view, a user can select a group of data and plot the data. For instance, consider the case in which the user is interested in group one in the group column 1214 and, in particular, the damage metric for group 1 . The user clicks the add plot button 1216 after selecting group 1 using toggle button 1218 and the damage metric using toggle 1218 . When this is done a plot 1220 is added to the plot gallery on the lower right portion of panel 1202 , which contains all of the plots that the user has created. The user can change the toggle buttons and keep adding plots. The runtime system creates the plots on the fly in response to the user's requests. In some embodiments, the runtime system, operating in a virtual machine, uses the MICROSOFT developer kit to create the plot on the fly in response to user request and then turn the resulting plots into image. In this way, the user does not have to set up MICROSOFT EXCEL on their local system and import the data provided in the data analysis pane 1202 . Moreover, the user can select on any of these plots, and the plot will expand out into a full size image. FIG. 13 show such a full size image 1302 created in this manner by the runtime system after the user has selected the image from the image gallery of data analysis panel 1202 .
[0118] FIG. 17 illustrates the gallery panel 1702 that is displayed by the runtime system when (i) the user selects the gallery tab 422 , (ii) the project category 410 - 1 “Osteoarthritis” is selected, and (iii) the user has selected project 2263 . The gallery panel 1702 displays all of the content that is associated with the selected project and that this user has access to. In this instance, object histology image 1704 has associated annotation 1706 . When such an annotation is created, subscribers to annotations of project 2263 would have been notified. The message would show up, for example, in overview 430 of panel 402 of FIG. 4 . Turning to FIG. 17 , users can also go back to annotation 1706 and see what date the annotation was created on and what was being considered when the annotation was created. Moreover, users can reply to the messages communicating the creation of such annotations using the discussions and notes page 1602 illustrated in FIG. 16 . This feature is supported by extensive cross-linking in the runtime system when a data object gets created. Object record which users generated the object as well as other annotation information such as time stamps.
[0119] FIG. 18 illustrates the live meeting panel 1802 that is displayed by the runtime system when (i) the user selects the live meeting tab 424 , (ii) the project category 410 - 1 “Osteoarthritis” is selected, and (iii) the user has selected project 2263 . The live meeting panel 1802 is another way to view the data in the selected project. The live meeting panel 1802 is configured for collaboration among the members of a project. A user can use live meeting panel to present project data to other users in the project. Live meeting panel 1802 includes a white board 1804 , which is a form of digital white board where the user can share objects associated with the project and the users can annotate such objects and talk about them. Moreover, the presenter can preload panel 1802 with select objects 1806 from the project in the left hand portion of panel 1802 . During the presentation, a user can drag objects 1806 from the left hand portion of panel 1802 into the meeting. And then, any user that is participating in the meeting can annotate the objects 1806 that are on the whiteboard 1804 and ask questions. As the users are creating this meta data, database objects that track and store the metadata are getting created and stored and archived so that later on, at some point in the future, a user can go back to the meeting and remember who said what and what was agreed to during the presentation.
[0120] What is occurring during the presentation is that the context is being annotated, where the context is a session that is being shared by the users participating in the meeting. The context knows what images are part of it. So the annotation can follow the links and know which objects it refers to. Thus, the annotations are with respect to a context, where the context has component objects. So, for context, each object has an identifier and, for each object, the identifier stores a position and image size of the object on the white board 1804 . For instance, the context knows that the object having object identifier A is placed at coordinates X, Y on the white board 1804 and that the object has an images size of H, W. Similarly, for each annotation in the context, the context stores the coordinates of the annotation on the white board 1804 , the content of the annotation, and the size of the annotation. The live meeting panel 1802 shows one example of how other project members can be invited to share the presenting users screen. At any point when a first user is analyzing data in a project and discovers something interesting, the user can invite other users to see their session. The users can then discuss the finding and annotate selection object together.
[0121] FIG. 14 illustrates the overview panel 1402 that is displayed by the runtime system when (i) the user selects the overview tab 414 , (ii) the project category 410 - 1 “Osteoarthritis” is selected, and (iii) the user has selected project 2263 . The user can use check boxes 1404 to select a number of specimens in the project. Here, in FIG. 14 , the user has selected three specimens that the user finds of interest for some reason, 1R, 3R, and 5R. The user then clicks a comparison tab (not shown in FIG. 14 ) to launch an assessment comparison 1502 , illustrated in FIG. 15 , of the three specimens. The user can read down the columns 1504 to compare each specimen and all of the relevant information associated with the specimens. And in this view the user can also execute live interactive object. So if a user clicks on a live three dimensional rendering object 1506 in this view the rendering software that generated the three dimensional rendering will fire up three sessions of the software on the back end and the user will be able to compare the corresponding three dimensional object 1506 for each of the three specimens side-by-side. Moreover, the corresponding three-dimensional objects from each of the selected specimens will have synchronized camera views. When the user changes the three-dimensional viewing angle or scale of one of the objects, the corresponding objects will change their viewing angle or scale in an identical manner. In this way, the user can look for a particular feature of interest in all of the corresponding three dimensional objects at the same time and thus compare and contrast their features.
[0122] This feature of the runtime system is particularly advantageous. Such rendering software is complicated to run. Without the disclosed runtime system, the user would be faced with numerous obstacles, such as determining where the data sets are located, whether the latest version of the datasets and the rendering software is being used, and how to get previews side-by-side and synchronized as depicted in FIG. 15 . With the disclosed runtime system, the user doesn't have to think about any of these task. The user simply goes to panel 1402 , selects the specimens, and clicks on any of the live objects in the resulting panel 1502 . Advantageously, the controls for viewing the live objects are intuitive and immediately responsive. Simple mouse commands, display touches, or keystroke commands permit the user to rotate and zoom the objects. The user does not have to think about any of the software complexities that drive the process.
[0123] Moreover, when viewing panel 1502 , the user has the ability to pause the session and minimize the live three dimensional rendering session back to a graphic in which the state of the rendering is saved. In other words, the runtime system will track exactly what state the renderings were in when the user shut down the renderings so that the next time the user click on an object 1506 , the runtime system will take the user right to the state the renderings were in when the user last accessed the objects. Thus, the state is saved with all of the live sessions.
[0124] Referring to FIG. 20 , the runtime system provides a reference library panel 2002 that is accessed when the user selects tab 2004 from the home page 402 . The reference library provides information on the techniques that are used to image data in the various projects supported by the runtime system. In some embodiments, the information provided in panel 2002 is Wikipedia-style information about imaging, including VIRTUAL HISTOLOGY™, and how such techniques work. User can review panel 2002 to see what the servicing laboratory does with project samples. The user can also use table 2006 to access full search capabilities across the information provided through the reference library panel 2002 .
[0125] In some embodiments, the reference library panel 2002 is cross linked to other databases such as PubMed, Wikipedia, and genome databases. As such, the reference library panel 2002 provides a way to gather information relevant to the various projects supported by the runtime system through one interface.
[0126] Another component that is provided in the reference library system 2002 is exemplary specimens. Such exemplary specimens are typically not associated with any of the projects supported by the runtime system but rather are provided to show the capabilities of the imaging techniques used by the laboratory that scans and processes the specimens in the projects that are supported by the runtime system. For example, consider the case in which a user wants to review the exemplary specimens to determine whether the laboratory that processes the specimens used in the various projects supported by the runtime system is capable of visualizing cardiac defects in specimens. In this instance, the user can review the exemplary cardiac data sets provided through library panel 2002 to assess whether the laboratory has such a capability. In some embodiments, library panel 2002 provides such exemplary data sets, as well as segmentations and analyses of such data sets available for any user of the runtime system. In some embodiments, library panel 2002 provides such exemplary data sets, as well as segmentations and analyses of such data sets available to only those users of the runtime system who have sufficient access privileges. In some embodiments, library panel 2002 provides such exemplary data sets, as well as segmentations and analyses of such data sets available for only those users who have paid a subscription or other form of access fee to review such data.
[0127] Referring to FIG. 19 , the runtime system provides a dashboard view panel 1902 that is accessed when the user selects tab 1904 from the home page 402 . A user can review the dashboard view panel to see the stages of different components of the projects associated with the user. In some embodiments, the percent completion of each stage of the projects is shown. The dashboard view panel 1902 is useful for users that are managers that want to see how far along things are on their projects.
[0128] Referring to FIG. 21 , the runtime system provides an upload module 2102 that is accessed when the user selects tab 2104 from the home page 402 ( FIG. 4 ). Users can use the upload module 2102 to upload their own movies and images and documents into the runtime system. The upload module 2102 allows for instances where users are collaborating amongst themselves rather than simply reviewing data set that were logged into the system by a laboratory that services specimens provided by the user. For instance, consider the case in which a company that subscribes to and uses the runtime system have five different researchers each of whom sign on and review data sets, share annotations, and use the other services provided by the runtime system. In this instance, the runtime system provider would not have access to data that the five different researcher upload. Data that such users upload would go into associated with the subscribing company and unless a user is a database administrator with access to the database, others including the runtime system administrator, cannot see the data. In this way, users of the runtime system are ensured that their data is secure in the same way as their internal documents and internal applications at their site. All accesses to the user's database by any user are authenticated and logged. The users know whenever their private data has been accessed and password is regenerated when a user loses their password. In the rare instance where the runtime system must use a client's administrative access key, the client will be informed.
[0129] For clients leading a GLP (Good Laboratory Practices) study, the runtime system 46 follows and adheres to GLP guidelines and regulations to withstand scrutiny from a potential FDA audit.
EXEMPLARY EMBODIMENTS
[0130] In some implementations, a cloud based server computer system includes: one or more remotely located servers that store and run multiple software programs; at least one computer device capable of accessing the Internet; and an application accessible to multiple users through a user's internet web browser that allows for a user to access the multiple software programs without requiring the user to download any software program onto the user's computer; where the application is designed to facilitate a user's evaluation of the software programs.
[0131] In some implementations, the cloud based server computer system is configured to allow the user to upload test datasets to interact with the software programs.
[0132] In some implementations, in the cloud based server computer system described above, the application is accessible through the user's computer or mobile device capable of accessing the Internet.
[0133] In some implementations, the cloud based server computer system is configured to enable multiple users to access the same software programs concurrently.
[0134] In some implementations, a data storage and analysis cloud-based server computer system comprises: one or more remotely located servers that store a user's data and multiple software programs capable of processing and analyzing the data; at least one computer device capable of accessing the internet; and an application accessible to multiple users through a user's internet web browser that allows for a user's data stored on the remote server to be processed and analyzed using at least one software program stored on the remote server without requiring the user to download the data or any software program onto the user's computer.
[0135] In some implementations, the application allows at least two users to concurrently communicate, manipulate data, or visualize datasets.
[0136] In some implementations, the application allows for a user to login to the application using a unique login name and password associated with only one user.
[0137] In some implementations, the application associates data sets with a particular user based upon the unique login name and password provided by the user.
[0138] In some implementations, the application organizes a user's data into projects and a home page that provides details of a plurality of projects associated with a user.
[0139] In some implementations, the application further comprises an overview panel for a project selected from the plurality of projects.
[0140] In some implementations, the application further comprises a data analysis panel for the selected project, the data analysis panel comprising a plurality of measurements for each sample in the plurality of samples associated with the project.
[0141] In some implementations, the application further comprises a visual analysis panel for the selected project, the visual analysis panel including a plurality of objects associated with the selected project.
[0142] In some implementations, the application further comprises a gallery panel for the selected project, for reviewing content that is associated with the selected project.
[0143] In some implementations, the application further comprises a live meeting panel for a selected project, where the live meeting panel comprises a whiteboard that is configured to be viewed by any user associated with the selected project, and where any user associated with the project that is viewing the whiteboard can drag objects associated with the selected project onto the whiteboard and can annotate the whiteboard.
[0144] In some implementations, the application further comprises a real time tracking system to track the status of samples being processed by the first user.
[0145] In some implementations, the data comprises volumetric imaging datasets that can be viewed in both two-dimensional and three-dimensional visualizations using at least one software program stored on the remotely located servers.
[0146] In some implementations, the application allows for the user to interact and view the data through a desktop computer or a mobile device.
[0147] In some implementations, the application allows for the user to select multiple data inputs and view the data in side-by-side comparison.
[0148] In some implementations, the server computer system further comprises metadata tags to encode information about how a project dataset was created.
[0149] In some implementations, the application allows for the user to input annotations that are saved on the remotely located servers.
[0150] In other implementations, a collaborative, cloud-based data storage and analysis system comprises: one or more remotely located servers that store a user's data and multiple software programs capable of processing and analyzing the data; at least one computer device capable of accessing the internet; an application accessible to multiple users through a user's internet web browser that allows for a user's data stored on the remote server to be processed and analyzed using at least one software program stored on the remote server without requiring the user to download the data or any software program onto the user's computer; where the application tightly couples the software programs as needed by the user for seamless integration; where the application can be accessed by multiple users simultaneously; where the application facilitates computing derived values from the original data; where the application facilitates exploration and analysis of the data; where the application can be accessed using various operating systems; and where the user's data can be searched or filtered by the application.
[0151] In some implementations, the application further comprises any combination of two or more of features (i) through (iv): (i) the application tracks which user accesses the data and records the time and date of access; (ii) the application records and stores provenance data, which encodes the applications and parameters that were used in creating a dataset; (iii) the application comprises an electronic laboratory notebook for the user to store data, computations, annotations, or communications; and (iv) multiple users of the system can collaboratively explore data together in real time.
[0152] In some implementations, the application further comprises all of the following features: (i) the application tracks which user accesses the data and records the time and date of access; (ii) the application records and stores provenance data, which encodes the applications and parameters that were used in creating a dataset; (iii) the application comprises an electronic laboratory notebook for the user to store data, computations, annotations, or communications; and (iv) multiple users of the system can collaboratively explore data together in real time.
[0153] In some implementations, the collaborative, cloud-based data storage and analysis is used in a scientific or engineering industry.
[0154] In some implementations, the collaborative, cloud-based data storage and analysis is used in the life science industries.
[0155] In some implementations, the collaborative, cloud-based data storage and analysis is used for preclinical pharmaceutical development.
[0156] In some implementations, the collaborative, cloud-based data storage and analysis is used for medical device development.
REFERENCES CITED AND ALTERNATIVE EMBODIMENTS
[0157] All references cited herein are incorporated herein by reference in their entirety and for all purposes to the same extent as if each individual publication or patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety for all purposes.
[0158] The embodiments disclosed herein can be implemented as a computer program product that comprises a computer program mechanism embedded in a tangible computer readable storage medium. For instance, the computer program product could contain the program modules shown in FIGS. 1 and/or 2 . These program modules can be stored on a CD-ROM, DVD, magnetic disk storage product, or any other nontransitory computer readable data or program storage product.
[0159] Many modifications and variations of the embodiments disclosed herein can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. The specific embodiments described herein are offered by way of example only. The embodiments were chosen and described in order to best explain the principles of the present disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled.
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A method for project collaboration includes: at a computer system, hosting a collaboration software application and a plurality of data sets associated with the collaboration software application; establishing a first remote user session between the computer system and a first client device running on a first operating system; wherein the first client device is associated with a first user; establishing a second remote user session between the computer system and a second client device running on a second operation system, distinct from the first operating system; wherein the second client device is associated with a second user distinct from the first user; merging the first remote user session and the second remote user session into a single remote user session; and enabling, using the single remote user session, the first user and the second user to concurrently control the collaboration software application and the plurality of data sets.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Patent Application No. 60/109,325, filed Nov. 20, 1998, the full disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of heart surgery. In particular, this invention provides a cardiopulmonary bypass device and method for returning oxygenated blood to the aorta artery, after the blood has been drawn from, for example, the vena cava veins or right atrium of a heart. The cardiopulmonary bypass device and method of the invention can advantageously be used in cardiopulmonary bypass performed during minimal invasive cardiovascular surgery with cardioplegia.
2. Description of the Prior Art
Cardiac surgery relates to surgical procedures performed on a patient's heart. To perform such cardiac procedures, the heart is sometimes stopped so that the desired surgical procedure can be performed on a generally stationary heart. Such stopping of the heart is often referred to as cardioplegia. To maintain blood circulation through a patient body while the heart is stopped, a cardiopulmonary bypass is often employed. Traditionally, in the case of open heart surgery, the chest is opened using a median sternotomy to gain access to the heart. In open heart surgery, access to, for example, the aorta, for cross clamping purposes for pulmonary bypass and/or the like, is readily provided. Before stopping the heart, an arterial cannula is typically connected in fluid flow communication with the aorta artery and a venous cannula is typically connected in fluid flow communication with the superior and inferior vena cava veins. The arterial cannula and the venous cannulas typically define apertures of about 0.5 inch in diameter. The cannulae are typically connected to a cardiopulmonary bypass (CPB) system so as to perform cardiopulmonary bypass. In cardiovascular bypass, blood is drawn from the vena cava veins of a patient undergoing coronary surgery. Thereafter, the blood is passed through a venous reservoir and through an oxygenator or artificial lung where it is oxygenated. A major portion of this oxygenated blood is typically filtered and returned to the patient's aorta artery for circulation throughout the body. Thus, the CPB system typically takes over the functions of the heart and the lungs of the patient by oxygenating and pumping the blood through the patient body while the patient's heart is bypassed and stopped.
Once the CPB system is operatively connected to the patient and brought into operation, the ascending aorta artery is typically cross clamped to isolate the coronary arteries from the rest of the arterial system. Thereafter, cardiac arrest is induced by typically injecting 500 to 1000 cc of cardioplegic solution into an aortic root using a needle or cannula which pierces the wall of the ascending aorta artery upstream of the cross clamp. Cardioplegic solution typically comprises aqueous solutions of potassium chloride and often contains additional substances such as dextrose, glutamate, aspartate, and various other electrolytes such as Ca +2 and Mg +2 . The punctures of the 0.5 inch diameter venous cannulae and the arterial cannula on the two vena cava veins and on the aorta artery, respectively, often require repair before the heart can be restarted. This is typically accomplished by means of suturing. After such suturing, and after the heart is then restarted, the sutures need to be closely monitored so as to ensure that the punctures have been adequately repaired thereby to inhibit rupturing and internal bleeding after completion of the surgery.
Typically, the foregoing procedure does not present a large problem when open chest heart surgery is to be performed since the surgeon is provided with ready access to the vena cava veins and the aorta artery. However, it can happen that the surgical procedure is to be performed in a manner other than open surgery. Accordingly, in such a case, and where pulmonary bypass is required, ready access to the vena cava veins and the aorta artery may not be readily available. This is typically the case where, for example, the surgical procedure is to be performed in a minimally invasive surgical manner.
Minimally invasive surgery is a relatively recent and very important development in the field of surgery. Generally, minimally invasive surgical techniques use endoscopic or transluminal surgical approaches in performing surgery so as to inhibit trauma and morbidity associated with relatively more invasive surgical techniques such as the open heart surgical technique described above. Minimally invasive surgical techniques have been, and are in the process of being, developed to perform surgical procedures by means of endoscopic or transluminal techniques. It is desirable that myocardial protection and cardiopulmonary support are catered for in a minimally invasive manner to obviate the need to open the patient's chest, so as to permit the cardiac procedure to be conducted fully in a minimally invasive manner. Current methods of cardioplegia and performing cardiopulmonary bypass do not adequately meet this desire as evidenced in the following prior art U.S. patents, the full disclosures of which are fully incorporated herein by reference: U.S. Pat. No. 4,712,551 to Rayhanabad; U.S. Pat. No. 4,979,937 to Khoransani; U.S. Pat. No. 5,190,538 to Fonger et al.; U.S. Pat. No. 5,466,216 to Brown et al.; and U.S. Pat. No. 5,695,457 to St. Goar et al.
U.S. Pat. No. 4,712,551 to Rayhanabad discloses a vascular shunt having a plurality of branches. The various embodiments of the vascular shunt are depicted in FIGS. 1 and 8 of this patent.
U.S. Pat. No. 4,979,937 to Khoransani discloses a plurality of small cannulas connected to Y-connectors and to larger cannulas for providing blood flow during aortic procedures. More specifically, and as can best be seen with reference to FIGS. 1 and 2 of this patent, there is seen an intercostal and lumbar perfusion apparatus having a main member and a plurality of side members communicating with the main member via a Y-connector. The apparatus disclosed in this patent provides blood flow to distal organs and intercostals during aortic surgery.
U.S. Pat. No. 5,190,538 to Fonger et al. discloses a cannula within the left atrium of the heart for draining blood and returning it via an arterial cannula after passing through an extra-corporeal pump. The atrium of the heart is pierced by a needle assembly to enable insertion of a catheter and the cannula.
U.S. Pat. No. 5,466,216 to Brown et al. discloses a pair of cannulae, respectively, inserted into the aortic root and the coronary sinus of a heart (see FIG. 1 ). A system or assembly interconnects the two cannulae for delivery of blood and cardioplegic solution to the aortic root for antegrade infusion or to the coronary sinus for retrograde infusion.
U.S. Pat. No. 5,695,547 to St. Goar et al. discloses a complete cardioplegia and cardiopulmonary bypass system. The devices disclosed in this patent induce cardioplegic arrest for myocardial protection during cardiac surgery by direct perfusion of the coronary arteries using a transluminal approach from a peripheral arterial entry point.
The prior art above does not teach a method or an apparatus whereby cardiopulmonary bypass can be performed without having to repair cannula punctures in the aorta artery and the vena cava veins after termination of a cardiopulmonary bypass procedure.
It is an object of the present invention to provide a method of performing cardiovascular bypass for cardiac surgery with cardioplegia.
It is another object of the present invention to provide a method of performing cardiopulmonary bypass for minimal invasive cardiovascular surgery with cardioplegia.
It is another object of the present invention to provide a cardiopulmonary bypass system.
It is another object of this invention to provide an apparatus and method whereby cardiopulmonary bypass can be performed without having to repair punctures in the aorta after the cardiopulmonary bypass has been completed. It is a further object of the invention to provide a cardiopulmonary bypass apparatus and method which also inhibits having to repair punctures in the vena cava veins upon completion of the cardiopulmonary bypass procedure.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a method of performing a cardiopulmonary bypass procedure is provided. The method includes accessing a source of blood in a patient body from which source the blood is to be passed through a cardiopulmonary bypass machine, drawing blood from the source through the cardiopulmonary bypass machine and introducing the blood into an aortic artery of the patient body through a plurality of separate passages, after the blood has been passed through the cardiopulmonary bypass machine.
According to another aspect of the invention, there is provided a cardiopulmonary bypass system comprising a cardiopulmonary bypass machine, a tubular member coupled to an outlet port of the cardiopulmonary bypass machine and a plurality of separate needle members connected in fluid flow communication with the tubular member, the needle members being arranged to be connected in fluid flow communication with an aortic artery, during a cardiopulmonary bypass procedure.
According to yet a further aspect of the invention, there is provided a method of performing cardiovascular bypass for cardiac surgery with cardioplegia, the method comprising the steps of:
a) inserting a plurality of needle members into a right atrium of a patient's heart;
b) flowing blood from the right atrium of the patient's heart, through the plurality of needle members, and to a cardiopulmonary bypass machine where the blood is oxygenated to produce oxygenated blood; and
c) flowing the oxygenated blood of step (b) into an aorta artery extending from the patient's heart such that cardiovascular bypass is performed for cardiac surgery with cardioplegia.
The immediate foregoing method may additionally comprise inserting, prior to the flowing step (c), a plurality of a aorta needle members into the aorta artery extending from the patient's heart. The flowing step (c) may comprise flowing oxygenated blood through the aorta needle members and into the aorta artery. Preferably, the aorta artery is occluded (e.g., such as by pinching the aorta artery) at a location between the patient's heart and the aorta needle members. In a preferred embodiment of the invention, the inserting step (a) includes inserting the needle members into a right auricle of the patient's heart. The needle members may each be dimensioned with an inside diameter such that each needle member has blood flowing therethrough at a respective volumetric flow rate. Similarly, the aorta needle members may each be dimensioned with an inside diameter such that each aorta needle member has blood flowing therethrough also at a respective volumetric flow rate. The needle members may communicate with a tubular member which preferably may be dimensioned with an internal diameter such that the blood flowing through the tubular member has a volumetric flow rate that is approximately equal to the sum of the respective volumetric flow rates of the blood flowing through the plurality of needle members. Similarly, the aorta needle members may communicate with a tubular member that may be dimensioned with an internal diameter such that the oxygenated blood flowing through the tubular member has a volumetric flow rate that is approximately equal to the respective volumetric flow rates of the oxygenated blood flowing through the plurality of aorta needle members.
According to yet another aspect of the invention, there is provided a method of performing cardiopulmonary bypass for minimal invasive cardiovascular surgery with cardioplegia, the method comprising the steps of:
(a) providing a plurality of first needle members communicating with a first tubular member which is coupled to a cardiopulmonary bypass assembly;
(b) providing a plurality of second needle members communicating with a second tubular member which is coupled to the cardiopulmonary bypass assembly;
(c) providing a plurality of third needle members communicating with a third tubular member which is coupled to the cardiopulmonary bypass assembly;
(d) inserting a plurality of first needle members into a superior vena cava vein extending to a heart of a patient;
(e) inserting a plurality of second needle members into an inferior vena cava vein extending to the heart of the patient;
(f) inserting the plurality of third needle members into an aorta artery extending from the heart of the patient;
(g) occluding the superior vena cava vein at a location between the first needle members of step (d) and the heart of the patient, causing blood to flow from the superior vena cava vein, through the first needle members, and through the first tubular member to the cardiopulmonary bypass assembly where the blood is oxygenated;
(h) occluding the inferior vena cava vein at a location between the second needle members of step (e) and the heart of the patient, causing blood to flow from the inferior vena cava vein, through the second needle members, and through the second tubular member to the cardiopulmonary bypass assembly where the blood is oxygenated;
(i) occluding the aorta artery at a location between the third needle members of step (f) and the heart of the patient; and
(j) flowing oxygenated blood from the cardiopulmonary bypass assembly, through the third tubular member, and through the third needle members and into the aorta artery such that cardiopulmonary bypass is performed for minimal invasive cardiovascular surgery with cardioplegia.
According to yet a further aspect of the invention, there is provided a cardiopulmonary bypass system comprising a cardiopulmonary bypass assembly, a first tubular member coupled to the cardiopulmonary bypass assembly and a plurality of first needle members coupled to the first tubular member, a second tubular member also coupled to the cardiopulmonary bypass assembly and a plurality of second needle members coupled to the second tubular member.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings, in which:
FIG. 1 shows an elevational view of a human heart;
FIG. 2A shows a schematic diagram of a cardiopulmonary bypass system, in accordance with the invention, which includes needle devices also in accordance with the invention;
FIG. 2B shows, at an enlarged scale, a sectional view taken along arrows 2 B— 2 B in FIG. 2A;
FIG. 3 shows, at an enlarged scale, a sectional view of a superior vena cava vein in fluid flow communication with a human heart of a patient, and further shows a plurality of needle members extending into the superior vena cava vein, in accordance with one aspect of the invention, such that blood can be drawn from the superior vena cava vein through the needle members during cardiopulmonary bypass;
FIG. 4 shows, at an enlarged scale, a sectional view of an inferior vena cava vein in fluid flow communication with a human heart of a patient, and further shows a plurality of needle members extending into the inferior vena cava vein, in accordance with another aspect of the invention, such that blood can be drawn from the inferior vena cava vein during cardiopulmonary bypass in accordance with the invention;
FIG. 5 shows, at an enlarged scale, a sectional view of an aorta artery in fluid flow communication with a human heart of a patient, and shows a plurality of aorta needle members extending into the aorta artery, in accordance with the invention, such that blood can be introduced into the aorta through the needle members, during cardiopulmonary bypass in accordance with the invention;
FIG. 6 corresponds to FIG. 3 and shows the superior vena cava vein being occluded by pinching it at a location between the needle members and the human heart;
FIG. 7 corresponds to FIG. 4 and shows the inferior vena cava vein occluded by pinching at the location between the needle members and the human heart;
FIG. 8 corresponds to FIG. 5 and shows the aorta being occluded by pinching at the location between the aorta needle members and the human heart; and
FIG. 9 corresponds to FIG. 1 and shows a plurality of needle members piercing the right auricle of the right atrium of the human heart.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will now be described with reference to FIGS. 1-9. In FIGS. 1-9, like reference numerals are used to designate similar parts unless otherwise stated. Although the present invention will now be described in the context of both delivering oxygen-depleted blood to a cardiopulmonary bypass machine and returning oxygenated blood from the bypass machine to the patient's circulatory system, e.g., a patient's aorta, without having to repair punctures in the various vessels or body organs to which the invention is applied, it should be understood that the invention will provide distinct advantages over the existing systems and methods for returning oxygenated blood to the patient even if another method of cannulating the patient's venous system is used as a source of blood for the bypass machine. In addition, it should be understood that the practice of this invention is not limited solely to minimally invasive procedures, but instead has application to any operation in which the surgeon desires to acquire a source of blood from, and/or deliver blood or other fluids (such as, e.g., saline or pharmaceutical-laced fluids) to a patient's body, most preferably to the patient's circulatory system.
Referring to FIG. 1, a human heart is generally indicated by reference numeral 8 . Referring to FIG. 2A, a cardiovascular bypass system in accordance with the invention, is generally indicated by reference numeral 10 . The system 10 of the invention utilizes needle assemblies to access the superior and inferior vena cava veins and aorta artery respectively so as to perform cardiopulmonary bypass.
Referring again to FIG. 1, the superior vena cava vein is indicated by reference numeral 14 and the inferior vena cava vein is indicated by reference numeral 16 . The veins 14 , 16 are connected in fluid flow communication with the heart 8 . The superior vena cava 14 and the inferior vena cava 16 feed blood to the heart after the blood has been circulated throughout a patient body (not shown). The right atrium of the heart 8 is shown at 9 , and the right auricle is indicated at 9 a. The aorta artery is indicated at 11 and is connected in fluid flow communication with the heart to feed blood from the heart into the circulation system of the patient body. The right ventricle of the heart is indicated at 13 , the left atrium at 15 , and the left auricle at 15 a. A pulmonary trunk is indicated at 17 .
The cardiovascular bypass system 10 , in accordance with the invention, will now be described in greater detail with reference to FIG. 2 A. The system 10 includes needle assemblies generally indicated at 60 , 64 , and 68 , respectively. The needle assemblies 60 , 64 are arranged to access and draw blood from the superior vena cava 14 and the inferior vena cava 16 , respectively. The needle assembly 60 comprises a plurality of access needles 18 a, 18 b, 18 c, 18 d, generally indicated at 18 , each of which is connected in fluid flow communication with a tube assembly, generally indicated at 70 . The tube assembly 70 comprises tubes 70 a, 70 b, 70 c, 70 d, each of which is connected in fluid flow communication with a single tube 72 . Each of the needles 18 is connected to a free end of one of the tubes of the tube assembly 70 .
Needle assembly 64 includes a plurality of access needles 19 a, 19 b, 19 c, 19 d, which are generally indicated at 19 . The needles at 19 are connected in fluid flow communication with a tube assembly, generally indicated at 74 . The tube assembly 74 is connected in fluid flow communication with a tube 76 . The tube assembly 74 includes a plurality of tube members 74 a, 74 b, 74 c, 74 d, each of which is connected in fluid flow communication with the tube 76 . The needles 19 are connected in fluid flow communication with free ends of the tubes at 74 .
The tubes 72 , 76 are connected in fluid flow communication with a tube 75 . Advantageously, back pressure, uniflow, or check valves 72 a, 76 a, can be provided to inhibit backflow of blood therethrough.
The needle assembly 68 is arranged to feed oxygenated blood to the aorta artery 11 . Needle assembly 68 comprises a plurality of needles 21 a, 21 b, 21 c, 21 d, generally indicated by reference numeral 21 , each of which is connected in fluid flow communication with a tube assembly 78 . The tube assembly 78 includes separate tubes 78 a, 78 b, 78 c, 78 d, each of which is connected in fluid flow communication with a common tube 80 . Conveniently, a backpressure valve 82 can be provided to inhibit back flow of oxygenated blood.
The tubes 75 , 80 are connected in fluid flow communication with a cardiovascular bypass machine, or assembly, generally indicated at 79 . The cardiovascular bypass assembly 79 comprises an oxygenator 100 , a pump 102 , an arterial filter 104 , a suction wand 106 , a blood oxygen saturation measuring and charting device 108 , and a cardiotomy reservoir 110 . It further comprises an inlet 75 a to which the tube 75 is connected in fluid flow communication and an outlet 80 a to which the tube 80 is connected in fluid flow communication.
Referring to FIG. 2B of the drawings, each of the needles 18 , 19 , 21 is typically in the form of a slender surgical needle having a sharp point or end for piercing tissue. The needles 18 , 19 , 21 can be made of any appropriate material, such as steel, stainless steel, or the like. Each of the needles 18 , 19 , 21 typically has an outer diameter D o of less than about 0.4 inches. Preferably, the needles have an outer diameter D o of less than 0.36 inches. Advantageously, each of the needles 18 , 19 , 21 may have an outer diameter D o falling in the range between about 0.3 inches or less.
The outer diameters D o of the needles 18 , 19 , 21 are typically sufficiently small so that when the needles are used to puncture the vena cava veins and the aorta artery respectively, to perform cardiopulmonary bypass in accordance with the invention, the punctures are of a size such that when the needles are withdrawn from the vena cava veins and the aorta artery, the punctures do not need to be repaired, e.g., by means of suturing, or the like. In accordance with conventional cardiopulmonary bypass techniques, the arterial cannula and venous cannulae which are typically used to access the aorta and the vena cava veins, are of a size which, when used during a cardiopulmonary bypass operation, form punctures in the vena cava veins and the aorta artery, respectively, which are of a size which requires repair after the cardiopulmonary bypass operation has been completed. It has been found that when a needle having an outer diameter of greater than about 0.5 inch is used to pierce the vena cava veins or the aorta artery, then repair is typically required to seal the puncture. Such repair is typically performed by means of suturing. Each needle typically has a sharp end, as can best be seen in FIG. 2B as indicated at E with reference to needle 19 a.
It will be appreciated that each of the needle groups 18 , 19 , 21 are shown as having four needles for illustrative purposes only. Naturally, the number of needles used can vary and may depend on the internal diameter D i of each needle, the size of the vena cava veins 14 , 16 and the aorta artery 11 , the blood flow rate of the patient, and the like.
Each of the tubes of the groups 70 , 74 , 78 preferably has an internal diameter corresponding to the internal diameter of the needle attached to the tube. Accordingly, and as can best be seen with reference to FIG. 2B, the tube 74 a has an internal diameter 74 id that is generally equal to the internal diameter D i of the needle 19 a. Preferably, the individual needles of the needle groups 18 , 19 , 21 , and the individual tubes of the tube groups 70 , 74 , 78 are all internally dimensioned with internal diameters such that there is a generally constant, smooth volumetric flow rate (e.g., in cc/unit of time) of blood 27 through the individual needles and their associated tubes. Tubes 72 , 76 have internal diameters such that the sum of the volumetric flow rates of blood flowing through the individual tubes 70 a, 70 b, 70 c, 70 d, and individual tubes 74 a, 74 b, 74 c, 74 d, respectively, generally equal the volumetric flow rate of blood flowing through the tubes 72 and 76 , respectively. Tube 75 is also internally dimensioned with an internal diameter such that the sum of the volumetric flow rates of blood flowing through tubes 72 , 76 is generally equal to the volumetric flow rate of blood flowing through tube 75 . Furthermore, tube 80 typically has an internal diameter such that the volumetric flow rate of blood flowing through the tube 80 is preferably about equal to the sum of the volumetric flow rates of blood flowing through the individual tubes 78 a, 78 b, 78 c, 78 d.
It will be appreciated that the number of needles 18 , 19 , 21 and their internal diameters D i are chosen such that there is a consistent and smooth drawing of blood from the vena cava veins 14 , 16 or from the right atrium 9 , and a consistent and smooth supply of oxygenated blood into the aorta artery 11 , so as to inhibit trauma to the patient. Furthermore, the outside diameters D o of the needles 18 , 19 , 21 are chosen such that after completion of the cardiopulmonary bypass, repair to the vena cava veins and the aorta artery to seal the punctures after the needles have been withdrawn would not be required.
In use, when a cardiopulmonary operation is performed using the system 10 , the needles 18 a, 18 b, 18 c, 18 d of needle assembly 60 and the needles 19 a, 19 b, 19 c, 19 d of needle assembly 64 are introduced, preferably minimally invasively, into the superior vena cava 14 (see FIG. 3) and into the inferior vena cava 16 (see FIG. 4 ), respectively. With reference to FIG. 9, by way of example, the needles 18 can be inserted into the right auricle 9 a of the right atrium 9 of the heart 8 instead of into the superior vena cava 14 . It will be appreciated that, instead, the needles 19 can be inserted into the right auricle. Furthermore, alternatively both the needles 18 , 19 in combination can be inserted into the right auricle 9 a.
The needles 21 a, 21 b, 21 c, 21 d of the needle assembly 68 are inserted into the aorta artery 11 , as can best be seen with reference to FIG. 5 .
Once the respective needles have been inserted into the vena cava veins and the aorta artery, the aorta 11 is typically occluded. Such occlusion can be achieved in any appropriate manner with any appropriate apparatus or device. In one embodiment of the invention, the vena cava veins 14 , 16 are respectively occluded by pinching them with pincher devices 120 , 124 (see FIGS. 6 and 7) at the location on the vena cava vein 14 between the needles 18 a, 18 b, 18 c, 18 d and the heart 8 , and at a location on the vena cava vein 16 between needles 19 a, 19 b, 19 c, 19 d and the heart 8 , respectively. The aorta artery 11 is preferably occluded by pinching it with pincher 128 (see FIG. 8) at a location on the aorta artery 11 between needles 21 a, 21 b, 21 c, 21 d and the heart 8 .
To perform the cardiopulmonary bypass, blood is then drawn from the superior vena cava 14 and the inferior vena cava 16 through the needle groups 18 , 19 , respectively. The blood drawn from the vena cava veins 14 , 16 then flows from the needles 18 , 19 through tube assembly 70 and tube assembly 74 and then into the tube 72 , 76 , and then into the tube 75 . The blood is then fed to the oxygenator 100 by means of the tube 75 , where oxygen is added to the blood and carbon dioxide is removed from the blood thereby to simulate the function of the patient's lungs.
Upon exiting the oxygenator 100 , a main portion of the oxygenated blood flows to the pump 102 which pumps the blood to the arterial filter 104 . The effectiveness of the oxygenator 100 is measured by an inline connection (not shown) to the blood oxygen saturation measuring and charting device 108 . At the arterial filter 104 , particulate matter and micro-air emboli from the oxygenated blood are removed and the filtered oxygenated blood is returned to the body of the patient through the tube 80 . From the tube 80 , blood flows through the tube assembly 78 and then through the needles 21 and into the aorta artery 11 . In this manner, blood is circulated through the body while the heart is stopped, the cardiopulmonary system 10 simulating heart and lung function of the patient. Any blood which escapes the patient's circulatory system during the operation, is typically sucked from the chest or pleural cavity by means of a suction wand 106 . The sucked blood is directed to the cardiotomy reservoir 110 . In the cardiotomy reservoir 110 , the blood is defoamed and filtered and fed to the oxygenator 100 to be oxygenated and returned to the patient, in the manner described above.
Instead of drawing blood from the vena cava veins as described above, and as already mentioned, blood can be withdrawn from the atrium 9 of the heart 8 . As can best be seen with reference to FIG. 9, the needles of the needle group 18 can be inserted into the right auricle 9 a of the right atrium 9 of the heart 8 . Blood is then caused to flow through needles 18 , through tube assembly 70 and tube 72 , and then through tube 75 and into the cardiovascular bypass assembly 79 where the blood is oxygenated, processed and returned to the patient in accordance with the manner described above.
Accordingly, in the manner described above, a method of performing cardiovascular bypass is provided to facilitate cardiac surgery with cardioplegia. While the methods described above have been described by employing needles 18 , tube assembly 70 and tube 72 , it is to be appreciated that the same method may be conducted by employing needles 19 , or a combination of needles 18 , 19 , and any tube assembly and tube(s) associated therewith. The method(s) of the present invention for performing cardiovascular bypass may be performed for the purpose of performing any type of cardiac surgery with cardioplegia. The cardiopulmonary bypass system of the invention can advantageously be used to perform cardiopulmonary bypass in accordance with the above method(s) when cardiovascular surgery is to be performed with cardioplegia, in a minimally invasive manner.
Thus, while the present invention has been described with reference to particular embodiments, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure and it will be appreciated that in some instances some features of the invention will be employed without a corresponding use of other features without departing from the scope and spirit of the invention as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope and spirit of the present invention. It is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplates for carrying out this invention, but that the invention will include all embodiments and equivalents falling within the scope of the appended claims.
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A method and system for performing a cardiopulmonary bypass procedure are provided. The method includes accessing a source of blood in a patient body from which source the blood is to be passed through a cardiopulmonary bypass machine, drawing blood from the source through the cardiopulmonary bypass machine and introducing the blood into an aortic artery of the patient body through a plurality of separate passages, after the blood has been passed through the cardiopulmonary bypass machine. The system comprises a cardiopulmonary bypass machine, a tubular member coupled to an outlet port of the cardiopulmonary bypass machine and a plurality of separate needle members connected in fluid flow communication with the tubular member, the needle members being arranged to be connected in fluid flow communication with an aortic artery, during a cardiopulmonary bypass procedure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a portable apparatus including an apparatus main body holder for attachably and detachably holding an apparatus main body of a portable type, for example, a pedometer, a portable type game machine, an audio player, a portable telephone or the like, and an apparatus main body holder for mounting an apparatus main body of a portable type attachably and detachably to a mounted object, for example, a clothing, a belt, a bag or the like of a person carrying the object.
2. Description of the Related Art
There is known a holder clip including a holder main body including a holding portion, a stopper piece, a clip piece, a first coil spring, and a second coil spring for insertably and detachably holding a portable apparatus (refer to, for example, Patent Reference 1).
The holder main body includes the holding portion insertably and detachably fitted with a portable apparatus, and a back face plate forming a back face of the holding portion, and extended from an opening of the holding portion along a direction of inserting and detaching the portable apparatus. The stopper piece is pivotably supported at the back face plate by a pin. One end portion of the stopper piece deviated from the holding portion is formed with an engaging piece and a pivoting shaft is provided between the engaging piece and the pin. The engaging piece is provided by avoiding the back face plate and is engaged with and disengaged from a hole of the portable apparatus. The clip piece covers the stopper piece from a back face side and pivotably supported by the pivoting shaft. The clip piece includes a projected portion capable of pressing other end portion (front end portion) of the stopper piece disposed on a side of the holding portion.
The first coil spring and the second coil spring are attached to the pivoting shaft. The first coil spring urges a front end portion of the clip piece to the back face plate, thereby, the projected portion of the clip piece presses other end portion of the stopper piece. The second coil spring urges the front end portion of the stopper piece to the back face plate, thereby, the engaging piece of the stopper piece is arranged at a position of being engaged with the hole of the portable apparatus. An urge force of the first coil spring is larger than an urge force of the second coil spring.
By the foregoing urge forces, in a state of not holding the portable piece, the clip piece presses the front end portion of the stopper piece by the projected portion by the force of the second coil spring, and therefore, the engaging piece of the stopper piece is escaped to a position of not hampering the portable apparatus from being inserted to and detached from the holding portion. Further, by pinching a mounted object between the clip piece and the back face plate by pivoting the clip piece after fitting the portable apparatus to the holding portion, the stopper piece is pivoted by the force of the first coil spring and the engaging piece is engaged with the hole of the portable apparatus. Thereby, the holder clip of Patent Reference 1 can hold the portable apparatus at the holder main body.
The holder clip of Patent Reference 1 is separately provided with the coil spring for urging the clip piece to the back face plate of the holder main body and pinching the mounted object therebetween, and the coil spring for urging the stopper piece and engaging the engaging piece with the hole of the portable apparatus. Therefore, the holder clip of Patent Reference 1 has a large number of parts, and its construction and integration are complicated.
Further, in a state in which the holder clip of Patent Reference 1 is not mounted to the mounted object, the engaging piece of the stopper piece is escaped to the position of not hampering the portable apparatus from being inserted to and detached from the holding portion. Therefore, in the nonmounted state, the portable apparatus cannot be held so as not to detach from the holding portion of the holder main body.
Further, according to the holder clip of Patent Reference 1, a depth of engaging the engaging piece of the stopper piece with the hole of the portable apparatus main body depends on a thickness of the mounted object pinched by the clip piece and the back face plate of the holder main body. Therefore, when the mounted object is thin, a reliability of holding the portable apparatus by the engaging piece is deteriorated and there is a concern that the portable apparatus may become detached from the holder main body.
[Patent Reference 1] JP-A-2003-153720 (paragraphs 0011-0041, FIG. 1-FIG. 6)
SUMMARY OF THE INVENTION
It is an object of the invention to provide an apparatus main body holder of a portable apparatus having a simple construction and having a high reliability of holding the apparatus main body in a state of being attached to the mounted object and in a state of not being mounted to the mounted object, and a portable apparatus including the apparatus main body holder.
An apparatus main body holder of a portable apparatus of the invention is that an apparatus main body holder of a portable apparatus holding an apparatus main body attachably and detachably to and from the portable apparatus, the apparatus main body holder including a holder main body having a base wall, and a holding portion provided on a surface side of the base wall for holding the apparatus main body inserted to and detached from the base wall to slide along a surface of the base wall, a clip piece pivotably attached to the holder main body, stopper means provided movably over a restricting position of preventing the apparatus main body held by the holding portion from being drawn out from the holding portion in a direction reverse to a direction of being inserted to the holding portion, and a releasing position for releasing the restriction, and an urging member for urging the clip piece to be brought into contact with the holder main body and arranging the stopper means at the restricting position by urging the stopper means.
Although according to the invention, the holder main body is preferably formed by a hard synthetic resin, the holder main body can also be made by a metal and can be made by an elastic material of a synthetic resin or the like having an elasticity of polyurethane resin or the like.
According to the invention, the holding portion of the holder main body comprises a cylindrical portion fitted with the apparatus main body of the portable apparatus along with the base wall and providing a portion for rectifying a depth of fitting the apparatus main body to the cylindrical portion at an end portion of the cylindrical portion other than a holding portion explained in an embodiment described later. Alternatively, the holding portion includes a pair of holding walls forming a section in an L-like shape having portions covered to edges of a surface of the apparatus main body on a side opposed to a back face opposed to the base wall of the apparatus main body, and a portion for rectifying a depth of fitting the apparatus main body between the holding walls. When the holding portions are adopted, there is achieved an advantage of not needing the engaging groove or the like for engaging with the holding portion at the apparatus main body. According to the invention, the holding portion may contain a total of the apparatus main body of the portable apparatus, or may hold the apparatus main body by covering a portion of the apparatus main body.
According to the invention, the clip piece can be provided at a position deviated from the base wall, for example, an outer face of the holding portion other than providing the clip piece at the back face of the base wall as explained in en embodiment described later, in this case, the clip piece is attached pivotably to, for example, an outer face of the holding portion.
According to the invention, in order to promote a function of pinching a mounted object of a clothing or the like, it is preferable that the holder main body and the clip piece are provided with recesses and projections brought in mesh with the mounted object to deform the mounted object in a zigzag shape.
According to the invention, it is not necessarily needed that the stopper means is engaged with the engaged portion of the apparatus main body at the restricting position, and a more or less clearance can also be provided. According to the invention, it is preferable to utilize a one side face disposed in a direction of inserting and detaching the apparatus main body to and from the holding portion as the engaged portion, in details, the stopper means may preferably be engaged with and detached from the side face of the apparatus main body disposed on a rear side in a direction of inserting the apparatus main body to the holding portion. A way of engaging the stopper means with the one side face of the mode differs by a position of the clip piece. For example, when the clip piece is provided at the base wall, the stopper means can be engaged with and disengaged from the one side face by making the stopper means come to and go away from the base wall, further, when the clip piece is provided at an outer face of the holding portion, the stopper means can be engaged with and disengaged from the one side face by making the stopper means come to and go away from, for example, the side wall of the holding portion orthogonal to the base wall.
According to the invention, the stopper means may not be provided with an operating portion for detaching the stopper means from the engaged portion of the apparatus main body. When the stopper means is provided with an operating portion separate from the engaging portion engaged with or proximate to the engaged portion of the apparatus main body to be opposed, the operating portion can be provided as a lever continuous from the engaging portion and projected in, for example, a side direction of the holder main body. Although the stopper means includes the engaging portion engaged with or proximate to the one side face (engaged portion) of the apparatus main body to be opposed, when there is not the operating portion separate therefrom, the engaging portion can be engaged with and disengaged from the one side face by pushing to move the engaging portion as the operating portion.
Although according to the invention, as the urging member, a torsional coil spring can preferably be used, the invention is not restricted thereto. For example, a general coil spring or leaf spring or the like can be used, and an elastic member of a synthetic rubber or the like can also be used. Further, when the urging member is a spring, the spring can be formed by a metal or a synthetic resin.
According to the apparatus main body holder of a portable apparatus of the invention, the urging member urges or biases both the clip piece and the stopper means, and therefore, exclusive urging members for these respective parts are not needed, and a number of parts for the main body holder is reduced and its construction can be simplified.
Further, according to the apparatus main body holder of a portable apparatus of the invention, the stopper means is arranged at the restricting position by urging by the urging member, and an urge force of the urging member for the stopper means is not smaller than an urge force in a state of not pinching the mounted object by the holder main body and the clip piece. Therefore, even in a state in which the apparatus main body holder is not mounted to the mounted object, the apparatus main body of the portable apparatus can be held with a high reliability so as not to be detached from the holding portion.
Along therewith, according to the apparatus main body holder of a portable apparatus of the invention, when the holder main body and the clip piece pinch the mounted object, the urge force of the urging member is increased regardless of a thickness of the mounted object. Thereby, the stopper means can be arranged properly at the restricting position regardless of the thickness of the mounted object. Therefore, the apparatus main body of the portable apparatus can be held with a high reliability so as not to be detached from the holding portion.
A preferable embodiment of the apparatus main body holder of a portable apparatus of the invention is that the stopper means is engageable and disengageable with and from an engaged portion provided to the apparatus main body held by the holding portion and the stopper means is caught by the engaged portion from a rear side in a direction of inserting the apparatus main body to the holding portion.
In the preferable mode, when the apparatus main body includes the engaged portion of a hole, a stepped portion or the like, the stopper means is engaged with and disengage from the engaged portion, further, when the side face of the apparatus main body disposed in the direction of inserting and detaching the apparatus main body to and from the holding portion is utilized as the engaged portion, in details, the stopper means can be engaged with and disengaged from the side face of the apparatus main body disposed on the rear side in the direction of inserting the apparatus main body to the holding portion.
In the preferable mode, when the stopper means is disposed at the restricting position, the stopper means is engaged therewith in a state of being caught by the engaged portion of the apparatus main body inserted to the holding portion, and the engaging state is maintained by the urge force of the urging member. Therefore, a rattle in a direction of inserting and detaching the apparatus main body to and from the holding portion can be restrained.
A preferable embodiment of the apparatus main body holder of a portable apparatus of the invention is that the clip piece is arranged on a back side of the base wall, the stopper means is provided to come to and go away from a surface of the base wall, the urging member is arranged on a back side of the holder main body and the clip piece is urged to the back face of the holder main body by the urging member.
According to the preferable embodiment, an anticipated effect of the invention can be achieved by an operation the same as those of the respective inventions already explained.
A preferable embodiment of the apparatus main body holder of a portable apparatus of the invention is that the stopper means is formed by a part formed separately from the holder main body and the clip piece, and the stopper means is rotatably attached to the holder main body by way of a shaft.
According to the preferable embodiment of the invention, in comparison with a case of providing the stopper means integrally with the holder main body or the clip piece, the stopper means can be formed without being restricted by a material or a strength of the holder main body or the clip piece. In accordance therewith, the stopper means can be made by a material of a color different from that of the holder main body, in this case, an optical recognizing performance of the stopper means can be promoted. Further, the stopper means is pivoted centering on the shaft, and a reliability of an operation of a movement over the restricting position and the releasing position is high.
A preferable embodied of the apparatus main body holder of a portable apparatus of the invention is that the stopper means is integrally formed with the holder main body.
According to the preferable mode, the number of parts is further reduced and a constitution can further be simplified.
A preferable embodiment of the apparatus main body holder of a portable apparatus of the invention is that the stopper means is formed integrally with the clip piece.
According to the preferable mode, the number of parts is further reduced and the constitution can further be simplified.
A preferable embodiment of the apparatus main body holder of a portable apparatus of the invention is that the stopper means includes an engaging portion engaged and disengaged with and from a side face on a rear side in a direction of inserting the apparatus main body to the holding portion by coming out and going away to and from a surface of the base wall.
According to the preferable mode, the engaging portion of the stopper means is engaged with the side face on the rear side in the direction of inserting the apparatus main body by being arranged at the restricting position by being projected from the surface of the base wall. Therefore, a carrying person is easy to recognize the engaging portion, and therefore, an operability in a case of pushing to move the engaging portion to the releasing position is excellent. Further, according to the preferable embodiment, the side face on the rear side in the direction of inserting the apparatus main body is utilized as the engaged portion of the apparatus main body engaging the engaging portion at the restricting position, and therefore, it is not necessary to provide the engaged portion constituted by a hole, a stepped portion or the like particularly at the apparatus main body, which is preferable in not restricting a design of the apparatus main body.
A preferable embodiment of the apparatus main body holder of a portable apparatus of the invention is that the stopper means includes a pressing portion brought into contact with the back face of the apparatus main body.
According to the preferable mode, the end portion on the rear side in the direction of inserting the apparatus main body to the holding portion of the apparatus main body of the portable apparatus held by the holding portion can be urged from the back side of the apparatus main body to the surface side of the apparatus main body by the urge force of the urging member by way of the pressing portion of the stopper means. Therefore, the apparatus main body is pressed to the holding portion in the thickness direction, and therefore, the apparatus main body held by the holding portion can be restrained from being rattled in the thickness direction.
A preferable embodiment of the apparatus main body holder of a portable apparatus of the invention is that an end portion of the holder main body disposed on the rear side in the direction of inserting the apparatus main body to the holding portion forms a holder main body grabbing end portion surrounding a surrounding of the stopper means, and the holder main body grabbing end portion is provided with a through hole to and from which the engaging portion comes and goes away.
According to the preferable mode, the apparatus main body can be prevented from being detached unpreparedly from the holding portion by disengaging the engagement of the engaging portion and the apparatus main body in accordance with enabling the engaging portion of the means not to be brought into contact with other object unpreparedly by the holder main body grabbing end portion surrounding a surrounding of the stopper means. Further, when the clip piece is pivoted, the operation can be carried out by touching the finger to the clip piece and the holder main body grabbing end portion, and therefore, the clip piece can be restrained from being operated to pivot by touching the finger to the apparatus main body and the clip piece by the operation.
A preferable embodiment of the apparatus main body holder of a portable apparatus of the invention is that the holder main body grabbing end portion is formed by an end portion of the base wall, and a clip piece grabbing end portion provided to the clip piece is arranged on a back side of the holder main body grabbing end portion to be opposed to the holder main body grabbing end portion.
According to the preferable mode, when the clip piece is operated to pivot by touching the finger to the clip piece and the holder main body grabbing end portion, the finger is easy to be touched thereto, and therefore, the operation of pivoting the clip piece is easy.
Further, an apparatus main body holder of a portable apparatus of the invention is that an apparatus main body holder of a portable apparatus holding the apparatus main body attachably and detachably to and from the portable apparatus, the apparatus main body holder including holder main body having a base wall, and a holding portion provided on a surface side of the base wall for holding the apparatus main body inserted to and detached from the base wall to slide along a surface of the base wall, a clip piece pivotably attached to the holder main body, stopper means formed integrally to the holder main body, capable of moving the apparatus main body held by the holding portion over a restricting position of preventing the apparatus main body from being brought to the holding portion in a direction reverse to a direction of inserting the apparatus main body to the holding portion and a releasing position of releasing the restriction and arranged at the restricting position by a flexibility of the stopper means per se, and an urging member for urging the clip piece to be brought into contact with the holder main body.
According to the apparatus main body holder of a portable apparatus of the invention, the stopper means can be moved to the restricting position and the releasing position by a flexibility of its own, the urging member can be omitted for urging the stopper means to the restricting position, and therefore, only the urging member for urging the clip piece is needed. Exclusive urging members for respectively urging the stopper means and the clip piece in this way are not needed, and therefore, the number of parts is reduced and the constitution can be simplified.
Further, according to the apparatus main body holder of a portable apparatus of the invention, the urging force by the urging member is regardless of arranging the stopper means to the restricting position. Therefore, even in a state in which the apparatus main body holder is not mounted to the mounted object, the apparatus main body of the portable apparatus can be maintained with a high reliability so as not to be detached from the holding portion, regardless of the thickness of the mounted object, the stopper means can be arranged properly at the restricting position, and therefore, even in a state of mounting the apparatus main body holder to the mounted object, the apparatus main body of the portable apparatus can be held with a high reliability so as not to be detached from the holding portion.
Further, the portable apparatus of the invention is that an apparatus main body provided with an operating portion and a display on a surface thereof, and the apparatus main body holder according to any one of the respective inventions for insertably and detachably holding the apparatus main body.
According to the invention, there can be provided the portable apparatus including the apparatus main body holder of the portable apparatus having a simple constitution and having a high reliability of holding the apparatus main body in a state of being mounted to the mounted object and in state of not being mounted to the mounted object.
A preferable embodiment of the portable apparatus of the invention is that the operating portion and the display are exposed in a state of holding the apparatus main body at the holding portion of the apparatus main body holder.
According to the preferable embodiment, in a state of holding the apparatus main body at the holding portion, the operating portion of the apparatus main body can be operated and the display can optically be recognized. Further, the optical recognition can be realized by, for example, a constitution of holding the holding portion by a pair of holding side walls opposed to each other, further, when the holding portion includes a portion of covering the surface of the apparatus main body, optical recognition can be realized by a constitution of providing a window opposed to the display or the operating portion at the portion.
A preferable embodiment of the portable apparatus of the invention is that side faces of the apparatus main body in parallel with each other are provided with engaging grooves extended in a direction of being inserted to and detached from the apparatus main body holder, the holding portion is formed by a pair of holding side wall portions opposed to each other heights of which are made to be lower than a height of the side face of the apparatus main body, and a holding end wall spanning the holding side wall portions, and a projected streak engaged with the engaging groove is formed at the holding side wall portion.
According to the preferable embodiment, the holding side wall of the holding portion is not provided at the height larger than the thickness of the apparatus main body, and therefore, the thickness of the portable apparatus in the state of holding the apparatus main body of the apparatus main body holder can be thinned.
A preferable embodiment of the portable apparatus of the invention is that an end portion of the base wall provided to the apparatus main body holder disposed on a rear side in a direction of inserting the apparatus main body to the holding portion provided to the apparatus main body holder is formed with a holder main body grabbing end portion surrounding a surrounding of the engaging portion of the stopper means provided to the apparatus main body holder, and the holder main body grabbing end portion is provided with a through hole to and from which the engaging portion comes and goes away, and a clip piece grabbing end portion provided to the clip piece provided to the apparatus main body holder is arranged on a back side of the holder main body grabbing end portion to be opposed to the holder main body grabbing end portion.
According to the preferable mode, by the holder main body grabbing end portion surrounding the surrounding of the stopper means, the apparatus main body can be prevented from being detached unpreparedly from the holding portion by disengaging the engagement of the engaging portion and the apparatus main body in accordance with enabling the engaging portion of the means from being unpreparedly brought into contact with other article by the holder main body grabbing end portion surrounding the surrounding of the stopper means. Further, when the clip piece is pivoted, the operation is carried out by touching the finger to the clip piece and the holder main body grabbing end portion, and therefore, the clip piece can be restrained from being operated to pivot by touching the finger to the apparatus main body and the clip piece by the operation. Further, when the clip piece is operated to pivot by touching the finger to the clip piece and the holder main body grabbing end portion, the finger is easy to be touched thereto, and therefore, the pivoting operation of the clip piece is easy. Furthermore, in accordance with enabling the clip piece to be operated to pivot without touching the finger to the apparatus main body as described above, the display of the apparatus main body can be prevented from being stained by the finger, or the operating portion of the apparatus main body can be prevented from being operated erroneously.
According to the invention, there can be provided the apparatus main body holder of the portable apparatus and the portable apparatus including the apparatus main body holder having simple constitutions and achieving an effect in which a reliability of holding the apparatus main body in the state of mounting to the mounted object and in the state of not being mounted to the mounted object is high.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view showing a portable apparatus according to a first embodiment of the invention in a state of holding an apparatus main body thereof by an apparatus main body holder.
FIG. 2 is a sectional view showing the portable apparatus of FIG. 1 .
FIG. 3 is a sectional view of the portable apparatus taken along a line F 3 -F 3 in FIG. 2 .
FIG. 4 is a sectional view of the portable apparatus taken along a line F 4 -F 4 in FIG. 2 .
FIG. 5 is a perspective view showing a stopper member provided to the portable apparatus of FIG. 1 .
FIG. 6 is a sectional view showing the portable apparatus of FIG. 1 in a state of inserting the apparatus main body to the apparatus main body holder.
FIG. 7 is a sectional view showing the portable apparatus of FIG. 1 in a state of being mounted to a mounted object.
FIG. 8 is a sectional view enlarging to show F 8 portion in FIG. 2 .
FIG. 9 is a sectional view showing a portable apparatus according to a second embodiment of the invention in a state of holding an apparatus main body thereof by an apparatus main body holder.
FIG. 10 is a perspective view showing a one end portion of the apparatus main body holder of the portable apparatus of FIG. 9 .
FIG. 11 is a sectional view showing a portable apparatus according to a third embodiment of the invention in a state of holding an apparatus main body thereof by an apparatus main body holder.
FIG. 12 is a perspective view showing one end portion of the apparatus main body holder of the portable apparatus of FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the invention will be explained in reference to FIG. 1 through FIG. 8 .
In FIG. 1 and FIG. 2 , notation 1 designates a portable apparatus, for example, a pedometer. The pedometer 1 is formed by including an apparatus main body 2 and an apparatus main body holder 11 (in the following, abbreviated as holder) for attachably and detachably holding the apparatus main body 2 .
Although the apparatus main body 2 forms a main body of, for example, the pedometer 1 and can be used by itself, in a mode of being used while being carried, in the present embodiment the apparatus main body 2 is used by being held by the holder 11 generally for carrying convenience. The apparatus main body 2 is formed substantially in the shape of, for example, a parallelepiped, and contains parts (not illustrated) for achieving a function necessary for the pedometer 1 , for example, an acceleration sensor, various electronic parts for processing and operating a signal of the sensor and storing an operation result, and a part or the like for controlling a display.
The apparatus main body 2 is provided with a display, for example, a display 3 using a liquid crystal, and a plurality of operating portions 4 for instructing switching of an input, starting and stopping to measure a step number or the like. The display 3 and the operating portions 4 are exposed at a surface of the apparatus main body 2 . The operating portions 4 are of a touch type.
The apparatus main body 2 includes a pair of side faces 2 a extended in a longitudinal direction thereof and in parallel with each other, a side face (the side face is referred to as one side face in order to facilitate identification as follows) 2 b disposed at one end in the longitudinal direction, and a side face (the side face is referred to as other side face to facilitate identification as follows) 2 c disposed at other end in the longitudinal direction. The one end face 2 b and the other end face 2 c are in parallel with each other.
Engaging grooves 5 are respectively provided at the pair of side faces 2 a of the apparatus main body 2 at a height position of a middle in a thickness direction of the apparatus main body 2 . The engaging grooves 5 are extended in a direction of inserting and detaching the apparatus main body 2 to and from the holder 11 , in other words, over a total length of the side faces 2 a . An engaging groove 6 is provided at the one end face 2 b of the apparatus main body 2 and an engaging groove 7 is provided also at the other end face 2 c of the apparatus main body 2 at the height position of the middle in the thickness direction of the apparatus main body 2 . The engaging grooves 6 , 7 are formed at the height the same as that of the engaging groove 5 and are respectively continuous to both ends in the longitudinal direction of the engaging grooves 5 .
As shown by FIG. 2 , the holder 11 is provided with a holder main body 12 , a clip piece 21 , stopper means, for example, a stopper member 31 (stopper means) and an urge (urging) member, for example, a torsional coil spring 41 .
The holder main body 12 is a molded product of a synthetic resin and includes a base wall 13 , a holding portion 16 , and a main body side pinching portion 19 .
The base wall 13 is formed to be longer than the total length of the apparatus main body 2 and a width along a direction orthogonal to the longitudinal direction is substantially the same as a width of the apparatus main body 2 . One end in the longitudinal direction of the base wall 13 is constituted to be used as a holder main body grabbing end portion (hereinafter, abbreviated as grabbing end portion) 13 a.
The grabbing end portion 13 a is opened with a through hole 14 penetrating the grabbing end portion 13 a in a thickness direction. As shown by FIG. 1 and FIG. 4 , bearing projected portions 13 b are projected integrally from both side edges of the base wall 13 to a back side of the base wall 13 to be proximate to the grabbing end portion 13 a . A shaft 15 (refer to FIG. 2 and FIG. 4 ) arranged on the back side of the base wall 13 is attached over to the both bearing projected portions 13 b . Both end portions of the shaft 15 are pres-fitted to the bearing projected portions 13 b . Further, notation 15 a in FIG. 4 designates a sleeve fitted to the shaft 15 .
As shown by FIG. 1 through FIG. 3 , the holding portion 16 is formed by, for example, a pair of holding side walls 17 opposed to each other, and a holding end wall 18 . A height of the holding side wall 17 and the holding end wall 18 is lower than a thickness of the apparatus main body 2 .
The holding side walls 17 are formed to project from both side edges of the base wall 13 to surface sides and include projected streaks (projections) 17 (refer to FIG. 3 ) to be engaged with the engaging groove 5 at front end portions thereof. The projected streak 17 a is made to function as a rail for guiding the apparatus main body 2 for being inserted to and detached from the holding portion 16 . The holding side wall 17 is extended from the bearing projected portion 13 b over to an end of the base wall 13 on a side opposed to the grabbing end portion 13 a . End portions of the holding side walls 17 on the side of the grabbing end portion 13 a are formed skewedly as shown by FIG. 1 . The holding end wall 18 is projected from the opposed side of the base wall 13 to a surface side and formed over to the both holding side walls 17 . The holding end wall 18 includes a projected edge 18 a (refer to FIG. 2 ) to be engaged with the engaging groove 6 or 7 at a front end portion thereof.
As shown by FIG. 2 and FIG. 3 , the main body side pinching portion 19 is formed at the back face of the base wall 13 . The main body side pinching portion 19 constitutes a shape of continuous recesses and projections, preferably, a saw teeth shape.
The clip piece 21 is formed by a synthetic resin and is pivotably attached to the holder main body 12 . Specifically, as shown by FIG. 4 , the clip piece 21 is pivotably supported by the shaft 15 attached to the back side of the holder main body 12 .
According to the clip piece 21 , one end side portion thereof is made to constitute a main portion opposed to the back face of the base wall 13 and other end side portion is made to constitute a clip piece side grabbing end portion 21 a by constituting a boundary therebetween by the shaft 15 . The clip piece side grabbing end portion 21 a is skewedly continuous to the main portion. The clip piece 21 is supported by the shaft 15 such that the clip piece side grabbing end portion 21 a is arranged to be opposed to the back side of the grabbing end portion 13 a of the holder main body 12 .
As shown by FIG. 2 and FIG. 3 , the clip piece 21 includes a clip piece side pinching portion 22 . The clip piece side pinching portion 22 is made to constitute a shape of recesses and projections in correspondence with the main body side pinching portion 19 , for example, a saw teeth shape.
The stopper member 31 is a molded product of a synthetic resin and is constituted by a part separate from the holder 11 and the clip piece 21 and is provided with a color separate from those of holder 11 and the clip piece 21 to be made to be identified easily. As shown by FIG. 5 and the like, the stopper member 31 includes an arm portion 32 , and an engaging portion 33 and a pressing portion 34 formed at a free end side portion of the arm portion 32 . As shown by FIG. 4 , a base end portion of the arm portion 32 is supported by the shaft 15 . Thereby, the stopper member 31 is pivotably attached to the holder 11 by way of the shaft 15 and is opposed to the clip piece side grabbing end portion 21 a of the clip piece 21 .
The engaging portion 33 is smaller than the through hole 14 . The engaging portion 33 is made to come to and go from a surface 13 c of the base wall 13 by passing the through hole upon being pivoted by the arm portion 32 . Therefore, the grabbing end portion 13 a surrounds the engaging portion 33 .
In this specification, a state in which the engaging portion 33 is projected from the surface 13 c of the base wall 13 is referred such that the engaging portion 33 is arranged at a restricting position, and a state in which the engaging portion 33 comes to be below being flush with the surface 13 c of the base wall 13 is referred such that the engaging portion 33 is arranged at a releasing position. The engaging portion 33 arranged at the restricting position restricts the apparatus main body 2 held by the holding portion 16 as described later so as not to draw out from the holding portion 16 in a direction reverse to a direction of inserting to the holding portion 16 , and the engaging portion 33 arranged at the releasing position releases such restriction.
The pressing portion 34 is formed continuously to a root of the engaging portion 33 and a height of the pressing portion 34 is lower than that of the engaging portion 33 . Also the pressing portion 34 comes to and goes from the surface of the base wall 13 by passing the through hole 14 by pivoting the arm portion 32 .
A distance L (refer to FIG. 2 ) from a corner of substantially 90° made by the engaging portion 33 and the pressing portion 34 to the holding end wall 18 is equal to a total length of the apparatus main body 2 . Therefore, in a state in which the apparatus main body 2 is inserted to and held by the holding portion 16 , as shown by FIG. 2 and FIG. 8 , the engaging portion 33 is caught by and engaged with the one end face 2 b or the other end face 2 c of the apparatus main body 2 and the pressing portion 34 is brought into contact with the back face of the apparatus main body 2 in the same state.
The torsional coil spring 41 is provided to be wound to the shaft 15 as shown by FIG. 4 . As shown by FIG. 2 , the torsional coil spring 41 urges the clip piece 21 to the holder main body 12 , and specifically to the back face of the base wall 13 , by bringing one end portion thereof into contact with the clip piece side grabbing end portion 21 a . Further, the torsional coil spring 41 urges the stopper member 31 by bringing other end portion thereof into contact with the arm portion 32 such that the stopper member 31 is arranged at a position of being engaged with the apparatus main body 2 , that is, such that the engaging portion 33 is projected from the surface 13 c of the base wall 13 .
According to the holder 11 of the pedometer 1 explained above, the clip piece 21 and the stopper member 31 are urged by the single torsional coil spring 41 , and therefore, exclusive urging members for respectively urging the clip piece 21 and the stopper member 31 are not needed. Therefore, in accordance with reducing a number of parts constituting the holder 11 and a number of integrating steps, a constitution of the holder 11 becomes simple and fabrication cost can be reduced.
Further, by an urge force of the torsional coil spring 41 , the engaging portion 33 and the pressing portion 34 of the stopper member 31 maintain a state of being projected from the surface 13 c of the base wall 13 by passing the through hole 14 of the base wall 13 . The state is maintained even in a state of not mounting the holder 11 to the mounted object. Therefore, the apparatus main body 2 can be held even by the holder 11 which is not mounted to the mounted object by a procedure described later. Thereby, there is no need for separately storing the apparatus main body 2 and the holder 11 when the pedometer 1 is not used, the pedometer 1 can be stored by holding the apparatus main body 2 with the holder 11 , and therefore, it is easy to prevent the apparatus main body 2 and the holder 11 from being lost.
Next, the procedure of holding the apparatus main body 2 using the holder 11 will be explained.
First, the apparatus main body 2 is inserted between the pair of holding side walls 17 of the holding portion 16 to slide along the surface 13 c of the base wall 13 by constituting a head by either of the one end face 2 b or the other end face 2 c of the apparatus main body 2 , for example, constituting the head by the one end face 2 b as shown by FIG. 6 . In this case, the apparatus main body 2 is inserted to the holding portion 16 while fitting the engaging groove 5 of the side face 2 a of the apparatus main body 2 to the projected streak 17 a of the holding side wall 17 . By progressing the insertion, the back face of the apparatus main body 2 is brought into contact with the engaging portion 33 of the stopper member 31 , and therefore, at this time point and thereafter, the stopper member 31 is pivoted such that the stopper member 31 is pressed in a direction of coming below the surface 13 c of the base wall 13 against the urge force of the torsional coil spring 41 .
Further, in accordance with butting a side face on a front side in a direction of inserting the apparatus main body 2 , that is, the one end face 2 b to the holding end wall 18 to hamper further insertion, the projected edge 18 a of the holding end wall 18 and the engaging groove 6 of the one end face 2 b are fitted. Simultaneously therewith, the apparatus main body 2 rides over the engaging portion 33 of the stopper member 31 , and therefore, the engaging portion 33 is projected from the surface 13 c of the base wall 13 by the urge force of the torsional coil spring 41 to be arranged at the restricting position.
Thereby, the engaging portion 33 is engaged with a side face on a rear side in the direction of inserting the apparatus main body 2 , that is, the other end face 2 c constituting the side face on a side opposed to the direction of inserting the apparatus main body 2 to the holding portion 16 . Along therewith, the pressing portion 34 is brought into contact with the back face of the apparatus main body on a side of the other end face 2 c . FIG. 2 shows a state in which the apparatus main body 2 is inserted to and held by the holder 11 in this way. Further, as described above, the urge force of the torsional coil spring 41 is utilized for catching the engaging portion 33 by the side face of the rear side in the direction of inserting the apparatus main body 2 , and therefore, a particular operation is not needed for preventing the apparatus main body 2 from being drawn out from the holding portion 16 .
In the holding state, a movement in a thickness direction of the apparatus main body 2 is restrained by engaging the projected streak 17 a of the holding side wall 17 and the engaging groove 5 of the apparatus main body 2 . Similarly, a movement in a width direction of the apparatus main body 2 is restrained by the holding side wall 17 . Further, a movement to the front side in the direction of inserting the apparatus main body 2 is restrained by the holding end wall 18 , and a movement to the rear side in the direction of inserting the apparatus main body 2 , in other words, a movement in a direction of drawing out the apparatus main body 2 from the holding portion 16 is restrained by the engaging portion 33 of the stopper member 31 .
Further, the apparatus main body 2 is pinched by the holding end wall 18 and the engaging portion 33 of the stopper member 31 from the longitudinal direction by the urge force of the torsional coil spring 41 , and therefore, the apparatus main body 2 can be held so as not to be rattled in the longitudinal direction. Further, by the urge force of the torsional coil spring 41 , the pressing portion 34 brought into contact with the back face of the rear side in the direction of inserting the apparatus main body 2 presses the apparatus main body 2 in a direction of separating from the surface 13 c of the base wall 13 , and therefore, the apparatus main body 2 is pinched in the thickness direction by a portion of engaging the projected streak 17 a of the holding side wall 17 and the engaging groove 5 of the apparatus main body 2 and the pressing portion 34 . Therefore, the apparatus main body 2 can be held so as not to be rattled in the thickness direction. Therefore, a function of holding the holder 11 relative to the apparatus main body 2 is excellent.
When the apparatus main body 2 held by the holder 11 is carried by being mounted to a mounted object A (refer to FIG. 7 ), the clip piece 21 may be opened and closed relative to the holder main body 12 by touching the finger to the grabbing end portion 13 a of the holder main body 12 and the clip piece side grabbing end portion 21 a of the clip piece 21 to pinch the mounted object A therebetween. FIG. 7 shows a state of mounting the pedometer 1 to the mounted object A.
In the mounting state, the urge force of the torsional coil spring 41 is increased in accordance with a thickness of the mounted object A. Therefore, a state of holding the apparatus main body 2 relative to the holding portion 16 can further be stabilized. Along therewith, regardless of the thickness of the mounted object A, a reliability of holding the apparatus main body 2 at the holding portion 16 is not deteriorated, and therefore, a concern of detaching the apparatus main body 2 from the holding portion 16 in carrying the holding portion 16 can be resolved. Therefore, it is not necessary to increase a margin of engaging the engaging portion 33 with the apparatus main body 2 in consideration of a reduction in a holding force, further, to increase the urge force in accordance therewith, and therefore, an operation performance of attaching and detaching the apparatus main body 2 to and from the holding portion 16 is not deteriorated.
The surface of the apparatus main body 2 held by the holding portion 16 is exposed from the holder 11 in carrying or not carrying the pedometer 1 . Therefore, the operation of the operating portion 4 and optical recognition of the display 3 at the surface of the apparatus main body 2 can easily be carried out.
Meanwhile, the base wall 13 includes the grabbing end portion 13 a disposed to be orthogonally continuous to the other end face 2 c by constituting a reference by the other end face 2 c constituting a side face on a rear side in the direction of inserting the apparatus main body 2 held by the holding portion 16 . Therefore, the pedometer 1 can be operated to attach and detach to and from the mounted object A by touching the finger to the grabbing end portion 13 a and the clip piece side grabbing end portion 21 a opposed to each other as described above.
Thereby, attaching and detaching operation is not obliged to carry out by touching the finger to the clip piece side grabbing end portion 21 a and the held apparatus main body 2 , and therefore, the surface of the apparatus main body 2 can be prevented from being pressed. Therefore, the display 3 of the apparatus main body 2 is restrained from being stained by the finger. Further, when the apparatus main body 2 is held by the holding portion 16 by constituting the head by the other end face 2 c conversely to FIG. 2 , the apparatus main body 2 can be restrained from being operated erroneously by unpreparedly pressing the operating portion 4 of the apparatus main body 2 .
Further, the grabbing end portion 13 a includes the through hole 14 through which the engaging portion 33 passes and surrounds the engaging portion 33 , and therefore, other object can be restrained from being brought into contact with the engaging portion 33 by the grabbing end portion 13 a in carrying or storing the pedometer 1 . Thereby, the apparatus main body 2 can be prevented from being detached from the holding portion 16 by releasing the apparatus main body 2 from being caught by the engaging portion 33 in accordance with pressing down the engaging portion 33 unpreparedly.
In the holder 11 of the above-described constitution, the stopper member 31 for preventing the apparatus main body 2 inserted to the holding portion 16 from being drawn out to a side opposed to the direction of inserting the apparatus main body 2 inserted to the holding portion 16 is a part separate from the holder main body 12 and the clip piece 21 . Therefore, in comparison with a case of providing a constitution in correspondence with the stopper member 31 integrally with the holder main body 12 or the clip piece 21 , the stopper member 31 can be optimized to form without being restricted by a material or a strength of the holder main body 12 or the clip piece 21 . In accordance therewith, the stopper member 31 can also be made by a material of a color different from that of the holder main body 12 , and in this case, the stopper member 31 is easy to be recognized optically, and therefore, an operability can be promoted. Further, the stopper member 31 is attached to the shaft 15 , and therefore, a reliability of an operation of moving over to the restricting position and the releasing position is high.
Further, according to the pedometer 1 of the above-described constitution, the engaging portion 33 of the stopper member 31 for restraining the apparatus main body 2 from being drawn out from the holding portion 16 is arranged at the restricting position by being projected from the surface 13 c of the base wall 13 . Therefore, a carrying person will recognize the engaging portion 33 , and therefore, an operability in a case of moving the engaging portion 33 to the releasing position below the surface 13 c of the base wall 13 by pushing the engaging portion 33 is excellent. Further, an engaged portion of the apparatus main body 2 engaged with the engaging portion 33 arranged at the restricting position is constituted by the side face of the rear side in the direction of inserting the apparatus main body 2 to the holding portion 16 (other end face 2 c ), and therefore, it is not necessary to particularly provide an engaged portion constituted by a hole, a stepped portion or the like at the apparatus main body 2 . Thereby, a design of the apparatus main body 2 is not restricted by a relationship with the engaging portion 33 .
A second embodiment of the invention will be explained in reference to FIG. 9 and FIG. 10 . The second embodiment is the same as the first embodiment except an item explained below. Therefore, constitutions the same as those of the first embodiment are attached with the same notations and an explanation thereof will be omitted, and an explanation will be given of the item different from that of the first embodiment as follows. The second embodiment differs from the first embodiment in the construction of the stopper means.
That is, the stopper means 31 is integrally provided to a side of the grabbing end portion 13 a of the base wall 13 . The root of the arm portion 32 of the stopper means 31 is integrally communicated with the base wall 13 , the stopper means 31 can flexibly be deformed to pivot by constituting a fulcrum by the root, thereby, the engaging portion 33 of the stopper means 31 is projected from the surface 13 c of the base wall 13 and comes to be below the surface 13 c by being pressed by the back side of the base wall 13 . The through hole 14 provided at the base wall 13 surrounds the stopper means 31 except the root of the arm portion 32 . Further, the one end portion 41 a of the torsional coil spring 41 is brought into contact with the back face of the arm portion 32 and the stopper means 31 is urged in a direction of projecting the engaging portion 33 from the surface 13 c of the base wall 13 . Further, according to the embodiment, a devise of, for example, thinning a wall thickness around the root of the arm portion 32 can be adopted in order to further facilitate to flexibly deform the arm portion 32 . The second embodiment is the same as the first embodiment except the item explained above.
Therefore, also in the pedometer 1 of the second embodiment, the problem of the invention can be resolved by the reasons already explained in the first embodiment. Further, according to the second embodiment, the stopper means 31 is integrally provided with the base wall 13 of the holder 11 , and therefore, the stopper means 31 need not be formed separately from the holder main body. Therefore, an advantage in further reducing the number of parts and the number of steps of integrating the holder 11 is achieved.
Further, according to the second embodiment, the invention can also be carried out by arranging the one end portion 41 a of the torsional coil spring 41 so as not to be opposed to the stopper means 31 integrally formed with the base wall 13 . In this case, the stopper means 31 is arranged at the restricting position of being projected from the surface 13 c of the base wall 13 by passing the through hole 14 normally by its own flexibility, and is arranged at the releasing position below the surface 13 c upon bending by being pressed.
The problem of the invention can be resolved even when the invention is carried out in such a mode. That is, the stopper means 31 can be moved to the restricting position and the releasing position by its own flexibility, and therefore, an urging member for urging the stopper means 31 to the restricting position can be omitted. Therefore, as the urging member, only one torsional coil spring 41 for urging the clip piece 21 is needed. In this way, exclusive urging members for respectively urging the stopper means 31 and the clip piece 21 are not needed, and therefore, the construction can be simplified by reducing the number of parts.
Further, the urge force of the torsional coil spring 41 is presented regardless of arranging the stopper means 31 at the restricting position. Therefore, even when the holder 11 is not mounted to the mounted object, the apparatus main body 2 can be held with a high reliability so as not to be detached from the holding portion 16 . Furthermore, the stopper means 31 can be arranged properly at the restricting position regardless of the thickness of the mounted object, and therefore, even when the holder 11 is mounted to the mounted object, the apparatus main body 2 can be held with high reliability so as not to be detached from the holding portion 16 .
A third embodiment of the invention will be explained in reference to FIG. 11 and FIG. 12 . The third embodiment is the same as the first embodiment except an item explained below. Therefore, constitutions are the same as those of the first embodiment are attached with the same notations and an explanation thereof will be omitted, and an explanation will be given of an item different from that of the first embodiment as follows. The third embodiment differs from the first embodiment in the constitution of the stopper means.
That is, the stopper means 31 is provided integrally with a main portion 21 b of the clip piece 21 . The stopper means 31 is passed through the through hole 14 of the base wall 13 . Further, the arm portion of the stopper means explained in the first embodiment is carried by a portion of the main portion 21 b from the shaft 15 to the engaging portion 33 in FIG. 11 . A side face of the engaging portion 33 on the side the pressing portion 34 provided to the stopper means 31 is formed by a shape of an arc drawn by a radius r centering on the shaft 15 . Thereby, when the stopper means 31 goes in and comes out from the surface 13 c of the base wall 13 , the stopper means 31 is made to be able to operate to go in and come out from the surface 13 c of the base wall 13 by avoiding an interference of the stopper means 31 with the side face of the rear side in the direction of inserting the apparatus main body 2 held by the holding portion 16 (other end face 2 c in FIG. 11 ). The third embodiment is the same as the first embodiment except the item explained above.
Therefore, even in the pedometer 1 of the third embodiment, the problem of the invention can be resolved by the reason already explained in the first embodiment. Further, according to the third embodiment, the stopper means 31 is provided integrally with the clip piece 21 , and therefore, the stopper means 31 need not be formed separately from the clip piece 21 . Therefore, an advantage of further reducing the number of parts and the number of steps of integrating the holder 11 is achieved.
Further, the invention is not restricted by the respective embodiments. For example, the invention can be carried out by omitting a portion in correspondence with the holder main body holding end portion in the respective embodiments.
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A main body holder has a base wall with a through-hole, a holding portion, and a pivotally attached clip piece. A stopper member is movably disposed within the base wall through-hole for movement between a restricting position and a releasing position. In the restricting position, the stopper member projects from the base wall and is configured to engage and securely hold the main body of a portable apparatus on the holding portion so that the apparatus main body is only partially disposed over the base wall through-hole in a state in which the apparatus main body is fully received by the holding portion. In the releasing position, the stopper member extends into the through-hole and does not project from the base wall so that the apparatus main body is allowed to be slid relative to the holding portion. An urging member urges the clip piece into contact with the holding portion and urges the stopper member to the restricting position.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application is a continuation of U.S. patent application Ser. No. 14/206,153, filed Mar. 12, 2014, which is a continuation of PCT/EP2012/068004, filed Sep. 13, 2012, which claims priority to European Application No. 11181524.7, filed Sep. 15, 2011, the entire teachings and disclosure of which are incorporated herein by reference thereto.
FIELD OF THE INVENTION
[0002] The invention concerns a strip consisting of an aluminium material for production of components with high forming requirements, a method for production of the strip and the use of sheets produced from the strip according to the invention.
BACKGROUND OF THE INVENTION
[0003] In particular in automotive vehicle construction, but also in other application fields, for example aircraft construction or rail vehicle construction, metal sheets of aluminium alloy are required which are not only distinguished by particularly high strength values, but at the same time have a very good formability, and which enable high degrees of deforming. In automotive vehicle construction, typical application fields are the bodywork and chassis components. In the case of visible painted components, for example metal bodywork sheets which are visible from the outside, additionally the forming of the materials has to be carried out in such a manner that after painting, the surface appearance is not impaired by defects such as flow figures or roping. This is for example particularly important for the use of aluminium alloy sheets for production of bonnets and other bodywork components of an automotive vehicle. However, the choice of materials is restricted with regard to the aluminium alloy. In particular AlMgSi alloys, the main alloy constituents of which are magnesium and silicon, have relatively high strengths in state T6 with, at the same time, good formability in state T4, and excellent corrosion resistance. AlMgSi alloys are alloy types AA6XXX, for example alloy type AA6016, AA6014, AA6181, AA6060 and AA6111. Conventionally, aluminium strips are produced from an AlMgSi alloy by casting of a rolling ingot, homogenising of the rolling ingot, hot rolling of the rolling ingot and optional cold rolling of the hot strip. The homogenisation of the rolling ingot is carried out at a temperature of 380 to 580° C. for more than one hour. Owing to a final solution annealing operation at a typical temperature of 500 to 570° C. with subsequent quenching and natural ageing at around room temperature for at least three days, the strips can be delivered in state T4. State T6 is set after quenching, by means of artificial ageing at temperatures between 100° C. and 220° C.
[0004] It is problematic that, in hot-rolled aluminium strips of AlMgSi alloys coarse Mg 2 Si precipitations are present, which are broken and comminuted in the subsequent cold rolling due to the high degrees of forming. Hot strips of an AlMgSi alloy are usually produced in thicknesses of 3 to 12 mm and supplied to cold rolling with high forming strains. Since the temperature range in which the AlMgSi phases are formed is passed very slowly in conventional hot rolling, namely after coiling of the hot strip, these phases form very coarsely. The temperature range for forming the above phases is alloy-dependent. However, it lies between 550 and 230° C., i.e. in the range of the hot-rolling temperatures. It could be proven experimentally that these coarse phases in the hot strip have a negative influence on the elongation of the end product. This means that the formability of aluminium strips made of AlMgSi alloys could previously not be fully exploited.
[0005] In the published European patent application EP 2 270 249 A1, belonging to the same Applicant, the AlMgSi alloy strip has a temperature of maximum 130° C. directly after exiting from the last hot-rolling pass and is coiled with this or a lower temperature. By quenching the hot strip in this method, aluminium strips can be produced in state T4, which in state T4 have an elongation at break A 80 of over 30% or a uniform elongation A g of more than 25%. In addition in state T6, very high values for the uniform elongation A g and elongation at break A 80 were achieved. In the said application fields, however, in addition the problem arises that frequently tight bends and flanging are required. A typical application comprising bending and flanging and high requirements for formability is for example an inner door panel of a motor vehicle. Although good results were achieved in bending tests with former AlMgSi alloy strips, but a further improvement of the bending behaviour, in particular taking into account the said application, would be desirable.
[0006] On this basis, the present invention faces the object of producing a strip consisting of an aluminium material for production of components with high forming requirements, which strip has an improved bending behaviour.
SUMMARY OF THE INVENTION
[0007] According to a first teaching of the present invention, the object outlined above is achieved in that the strip comprises a core alloy of an AlMgSi alloy and at least one external aluminium alloy layer arranged on one or both sides and made of a non-hardenable aluminium alloy, wherein the at least one external aluminium alloy layer has a lower tensile strength than the core layer of the AlMgSi alloy in state T4, wherein the strip in state T4 has a uniform elongation A g of more than 23% transverse to the rolling direction, and with a thickness of 1.5 to 1.6 mm, a bend angle of less than 40° in the bending test transverse to the rolling direction.
[0008] Surprisingly it has been found that a strip of aluminium alloy composite material with a core layer of an AlMgSi alloy and at least one external aluminium alloy layer arranged on one or both sides and consisting of a non-hardenable aluminium alloy which has a lower tensile strength in state T4 than the AlMgSi alloy, leads to a significantly improved bending behaviour in state T4 than the uncoated AlMgSi alloy strip. Preferably the elongation at break A 80 of the external aluminium alloy layers in the recrystallised state, i.e. also in state T4, is greater than that of the core alloy layer of an AlMgSi alloy in state T4. On tight bending of the strip, a significantly flatter and cleaner bending edge is achieved up to the maximum achievable bend angle. Previously, with bends required for example on flanging, the problem occurred that cracks or roughness occurred in the region of the bend edge. It is assumed that the softer external aluminium alloy layers allow a “spreading” of unevenness on bending, so that significantly smaller bend angles are achieved with almost identical mechanical properties compared with an uncoated strip of an AlMgSi alloy. For the external layers, in particular film alloys can be used, for example of type AA8XXX i.e. AA8011, AA8006, AA8079 etc., but also other low-alloyed aluminium alloys of type AA1XXX, such as for example AA1200 or an aluminium alloy of type AA5005 or AA5005A, which in state 0, i.e. for example after solution annealing and quenching, have tensile strengths in the recrystallised state of less than 180 MPa. The bend angle of less than 40° achieved in bending tests transverse to the rolling direction allows a better flanging and bending behaviour of the produced strip during use, for example in motor vehicle construction.
[0009] Recognised methods from the automotive industry were used to determine the maximum achievable bend angle. For the bending test, first specimens of size 270 mm×60 mm are cut from the strip transverse to the bending direction and subjected to pre-elongation perpendicular to the bending line, i.e. perpendicular to the rolling direction. The pre-elongation is 10%. Then via a bending punch, the specimen is bent between two rollers with a diameter of 30 mm. The roller spacing is twice the strip thickness (table 2), preferably also twice the strip thickness of the specimen plus 0.5 mm (table 3). On bending of the specimen by the bending punch with a punch radius of 0.4 mm, the force with which the bending punch bends the specimen is measured and the bending process ended after exceeding a maximum and falling by 30 N from this maximum. Then the opening angle of the bent specimen is measured. The bending behaviour of the specimen is usually measured transverse to the rolling direction in order to obtain a reliable conclusion on the bending behaviour in the production of components with high forming requirements. As already stated, surprisingly it was found that the specimens produced from the strip according to the invention allowed significantly smaller bend angles than the specimens produced from conventional uncoated AlMgSi alloy strip, and to this extent could be processed better into components, for example a door inner panel.
[0010] According to a first embodiment of the strip according to the invention, a further improved bending behaviour and hence a wider area of application can be achieved in that the strip in state T4 has a uniform elongation of A g of more than 25%.
[0011] As well as the good uniform elongation properties of the strip according to the invention, for further processing into a finished, usable product, it is advantageous if the strip in state T4 has a yield point Rp0.2 of 70 to 140 MPa, and a tensile strength Rm of 170 to 220 MPa. Said strength values firstly guarantee adequate stiffness in the production of different components by forming, for example by deep drawing or bending. In addition the forming forces required are moderate because of the yield point Rp0.2 of 70 to 140 MPa.
[0012] Even greater degrees of forming can be achieved according to a next embodiment of the strip according to the invention, in that the strip has an elongation at break A 80 transverse to the rolling direction of at least 27%, preferably at least 29%.
[0013] According to a further advantageous embodiment of the strip according to the invention, the thickness of the external aluminium alloy layers arranged on one or both sides is in each case 5 to 15% of the final thickness of the strip. This guarantees that the forming properties and the strength properties of the core alloy layer of an AlMgSi alloy substantially determine the production method and later product properties, so that the benefits of the hardenable core alloy are utilised.
[0014] In addition, according to a further embodiment of the strip according to the invention, to reach the maximum achievable bend angle it is advantageous if the external aluminium alloy layers have a mean grain size of less than 50 μm, preferably less than 25 μm. It could be found that the finer the grain of the external aluminium alloy layer, the smaller the achievable bend angle.
[0015] According to a further embodiment example, if the at least one external aluminium alloy layer consists of an aluminium alloy of type AA8079, for example a particularly fine-grained aluminium alloy layer can be produced which influences the bending behaviour optimally. The aluminium alloy AA8079 has the following alloy constituents in w. %:
[0016] 0.05%≦Si≦0.30%,
[0017] 0.7%≦Fe≦1.3%,
[0018] Cu≦0.05%,
[0019] Zn≦0.10%,
[0000] remainder Al and unavoidable contaminants individually maximum 0.05 and in total maximum 0.15%. AA8079 is a typical film alloy, as are aluminium alloys AA8011 and AA8006.
[0020] According to a further alternative embodiment, the at least one external aluminium alloy layer consists of an aluminium alloy of type AA5005A which has the following constituents in w. %:
[0021] Si≦0.3%,
[0022] Fe≦0.45%,
[0023] Cu≦0.05%,
[0024] Mn≦0.15%,
[0025] 0.7%≦Mg≦1.1%,
[0026] Cr≦0.1%,
[0027] Zn≦0.20%,
[0000] remainder Al and unavoidable contaminants individually maximum 0.05%, in total maximum 0.15%.
[0028] This aluminium alloy, also designated AlMg1, firstly achieves a slightly improved strength of the aluminium composite material and in addition is compatible with other aluminium materials which are used in particular in motor vehicle construction.
[0029] According to a next embodiment of the strip according to the invention, the core layer consists of an aluminium alloy type AA6XXX, preferably AA6014, AA6016, AA6060, AA6111 or AA6181. The common feature of all alloy types AA6XXX is that they are characterised by a particularly high forming behaviour due to the high elongation values in state T4, and high strengths or yield points in usage state T6, in particular after artificial ageing at 205° C./30 min.
[0030] An aluminium alloy type AA6016 has the following alloy constituents in weight percent:
[0031] 0.25%≦Mg≦0.6%,
[0032] 1.0%≦Si≦1.5%,
[0033] Fe≦0.5%,
[0034] Cu≦0.2%,
[0035] Mn≦0.2%,
[0036] Cr≦0.1%,
[0037] Zn≦0.1%,
[0038] Ti≦0.1%,
[0000] and remainder Al and unavoidable contaminants total maximum 0.15%, individually maximum 0.05%.
[0039] For magnesium contents of less than 0.25 w. %, the strength of the aluminium strip provided for structural applications is too low, and on the other hand the formability deteriorates with magnesium contents above 0.6 w. %. Silicon in conjunction with magnesium is substantially responsible for the hardenability of the aluminium alloy and hence also for the high strengths which can be achieved in applications, for example after paint baking. With Si contents of less than 1.0 w. %, the hardenability of the aluminium strip is reduced so that in applications, only reduced strengths can be achieved. Si contents of more than 1.5 w. % lead to no improvement in the hardening behaviour. The Fe proportion should be limited to maximum 0.5 w. % in order to prevent coarse precipitations. A restriction of the copper content to maximum 0.2 w. % leads above all to an improved corrosion resistance of the aluminium alloy in the specific application. The manganese content of less than 0.2 w. % reduces the tendency to form coarser manganese precipitations. Although chromium ensures a fine microstructure, it must be limited to 0.1 w. % in order to again avoid coarse precipitations. The presence of manganese however improves the weldability by reducing the crack tendency or quenching sensitivity of the aluminium strip according to the invention. A reduction in the zinc content to maximum 0.1 w. % in particular improves the corrosion resistance of the aluminium alloy or finished sheet in the application concerned. In contrast, titanium ensures a finer granulation during casting but should be restricted to maximum 0.1 w. % to guarantee a good castability of the aluminium alloy.
[0040] An aluminium alloy of type AA6060 has the following alloy constituents in weight percent:
[0041] 0.35%≦Mg≦0.6%,
[0042] 0.3%≦Si≦0.6%,
[0043] 0.1%≦Fe≦0.3%,
[0044] Cu≦0.1%,
[0045] Mn≦0.1%,
[0046] Cr≦0.05%,
[0047] Zn≦0.10%,
[0048] Ti≦0.1%, and
[0000] remainder Al and unavoidable contaminants, maximum total 0.15%, individually maximum 0.05%.
[0049] The combination of precisely predefined magnesium content with an Si content which is reduced in comparison with the first embodiment, and a tightly specified Fe content, gives an aluminium alloy with which the formation of Mg 2 Si precipitations can be prevented particularly well after hot rolling with the method according to the invention, so that a sheet with improved elongation and high yield point can be produced in comparison with conventionally produced sheets. The lower upper limits of the alloy constituents Cu, Mn and Cr reinforce the effect of the method according to the invention. With regard to the effects of the upper limits of Zn and Ti, reference is made to the statements on the first embodiment of the aluminium alloy.
[0050] An aluminium alloy type AA6014 has the following alloy constituents in weight percent:
[0051] 0.4%≦Mg≦0.8%,
[0052] 0.3%≦Si≦0.6%
[0053] Fe≦0.35%,
[0054] Cu≦0.25%,
[0055] 0.05%≦Mn≦0.20%,
[0056] Cr≦0.20%,
[0057] Zn≦0.10%,
[0058] 0.05%≦V≦0.20%,
[0059] Ti≦0.1%, and
[0000] remainder Al and unavoidable contaminants to maximum total 0.15%, individually maximum 0.05%.
[0060] An aluminium alloy type AA6181 has the following alloy constituents in weight percent:
[0061] 0.6%≦Mg≦1.0%,
[0062] 0.8%≦Si≦1.2%,
[0063] Fe≦0.45%,
[0064] Cu≦0.10%,
[0065] Mn≦0.15%,
[0066] Cr≦0.10%,
[0067] Zn≦0.20%,
[0068] Ti≦0.1%, and
[0000] remainder Al and unavoidable contaminants to the maximum total 0.15%, individually maximum 0.05%.
[0069] An aluminium alloy type AA6111 has the following alloy constituents in weight percent:
[0070] 0.5%≦Mg≦1.0%,
[0071] 0.7%≦Si≦1.1%,
[0072] Fe≦0.40%,
[0073] 0.50%≦Cu≦0.90%,
[0074] 0.15%≦Mn≦0.45%,
[0075] Cr≦0.10%,
[0076] Zn≦0.15%,
[0077] Ti≦0.1%, and
[0000] remainder Al and unavoidable contaminants to the maximum total 0.15%, individually maximum 0.05%. The alloy AA6111 in principle has higher strength values in usage state T6 because of the increased copper content, but should be regarded as more susceptible to corrosion.
[0078] All aluminium alloys listed are specifically adapted in their alloy constituents to different applications. As already stated, strips of these aluminium alloys, which were produced using the method according to the invention, have particularly high uniform elongation values in state T4 paired with a particularly pronounced increase in the yield point, for example after artificial ageing at 205° C. /30 min. This also applies to aluminium strips subjected to heat treatment after solution annealing in state T4.
[0079] According to a second teaching of the present invention, the object outlined above for a method for production of a strip from an aluminium composite material is achieved in that a rolling ingot is cast from an AlMgSi alloy, the rolling ingot undergoes homogenisation, a cladding layer applied at least on one or both sides of the rolling ingot, and the rolling ingot together with the applied cladding layers brought to hot rolling temperature, hot rolled, then optionally cold rolled to final thickness, and the finished rolled strip solution annealed and quenched, wherein the at least one cladding layer consists of a non-age-hardenable aluminium alloy which has a lower tensile strength in state T4 than the core layer of an AlMgSi alloy, the hot strip immediately after being discharged from the last hot-roll pass has a temperature of maximum 250° C., preferably a temperature of maximum 230° C., in particular preferably a temperature of 230 to 200° C., and the hot strip is coiled with this or a lower temperature. In principle the strip can also be cooled to a temperature of less than 200° C. In addition it is conceivable that the strip is made from an aluminium composite material by use of simultaneous casting and then hot rolled according to the invention.
[0080] It has been shown that quenching of the hot strip, even after roll cladding in which hot-rolling temperatures are used, leads to a particularly favourable microstructure of the hot strip which in particular has high elongation at break values A 80 , uniform elongation values A g and in additional has an improved bending behaviour because of the external aluminium alloy layers. The temperature corridor of the hot strip immediately after exiting the last hot-roll pass, which extends from 135° C. to 250° C., allows a high production rate with simultaneously good process reliability even in production of aluminium composite materials.
[0081] According to a further embodiment of the method according to the invention, a process-reliable cooling is achieved in that the hot strip is quenched to coiling temperature using at least one plate cooler and the hot-roll pass itself, loaded with emulsion. A plate cooler consists of an arrangement of cooling or lubricating nozzles which spray a rolling emulsion onto the aluminium alloy strip. The plate cooler can be present in a hot rolling mill in order to cool the rolled hot strips to rolling temperature before hot rolling, and to be able to achieve a higher production speed.
[0082] According to a further embodiment of the method according to the invention, if the hot-rolling temperature of the hot strip before the cooling process during hot rolling, in particular before the penultimate hot-roll pass, is at least 230° C., preferably above 400° C., particularly small MgSi precipitations can be produced in the quenched hot strip since at these temperatures, the majority of the alloy constituents magnesium and silicon are present in the dissolved state in the aluminium matrix. This advantageous state of the hot strip is achieved in particular at temperatures of 470° C. to 490° C. before the start of the cooling process, which preferably takes place within the last two roll passes, and is quasi-set by quenching.
[0083] According to a further embodiment of the method according to the invention, the hot-rolling temperature of the hot strip after the penultimate roll pass is 290 to 310° C. It has been found that these temperatures firstly allow adequate setting of the precipitates and secondly, at the same time, the last roll pass can be carried out without problems. On exit, according to a next advantageous embodiment, the hot strip has a temperature of 230 to 200° C., so that a maximum process speed can be achieved on hot rolling without deterioration of the properties in state T4 of the finished strip made of aluminium composite material.
[0084] According to a further embodiment of the method according to the invention, the finished rolled aluminium strip is subjected to heat treatment, wherein the aluminium strip is heated to more than 100° C. after solution annealing and quenching, and then coiled and aged at a temperature of more than 55° C., preferably more than 85° C. This embodiment of the method, after natural ageing with a shorter warming phase at lower temperatures, allows state T6 to be set in the strip or sheet, in which state the strips or sheets formed into components are used in the application. This rapidly hardening aluminium strip is for this merely brought to temperatures of around 180° C. for only 20 minutes in order to achieve the higher yield point values in state T6.
[0085] The thickness of the finished hot strip is 3 to 12 mm, preferably 5 to 8 mm, so conventional cold-rolling mills can be used for cold rolling.
[0086] According to a further embodiment of the method according to the invention, the core layer of the strip according to the invention consists of an aluminium alloy of type AA6XXX, preferably AA6014, AA6016, AA6060, AA6111 or AA6181, and the external aluminium alloy layers consist of an alloy type AA8XXX, AA8079, AA1XXX, AA1200, AA5005 or AA5005A. For the benefits of the individual alloy types, reference is made to the statements above. Evidently both external aluminium alloy layers of different thicknesses and/or external aluminium layers consisting of different aluminium alloy layers can be used. In addition the combination of said alloy types in the aluminium alloy composite material gives an excellent bending behaviour with simultaneously very high forming capacity in state T4.
[0087] Finally, according to a third teaching of the present invention, the object outlined above is achieved by the use of a sheet made from a strip according to the invention as a component, chassis or structural part or panel in automotive, aircraft or railway vehicle construction, in particular as component, chassis part, external or internal panel in automotive engineering, preferably as a bodywork element. As already explained above, the strip according to the invention of aluminium material is distinguished not only by its extraordinary forming properties, in particular a very high uniform elongation A g transverse to the rolling direction, but in addition with the strip according to the invention, extreme bend angles can be achieved which occur in said applications, in particular in flanged folds. Furthermore small radii in the component can be realised in a better way.
BRIEF DESCRIPTION OF THE DRAWINGS
[0088] The invention will now be explained in more detail below with reference to embodiment examples in conjunction with the drawing. The drawing shows:
[0089] FIGS. 1 a )- e ) diagrammatically, the sequence of the embodiment example of the method according to the invention;
[0090] FIG. 2 a longitudinal ground section of a strip according to the invention, anodised, according to Barker with polarised light;
[0091] FIG. 3 in a perspective view, the experiment arrangement for performance of the bending test;
[0092] FIG. 4 in a perspective diagrammatic depiction, the arrangement of the bending punch in relation to the rolling direction on performance of the bending test; and
[0093] FIG. 5 diagrammatically, measurement of the bend angle on a bent specimen according to a further embodiment example.
DETAILED DESCRIPTION OF THE INVENTION
[0094] FIGS. 1 a ) to e ) show first a diagrammatic flow diagram of an embodiment example of the method according to the invention for production of a strip according to the present invention, with steps a) production and homogenising of the rolling ingot, b) application of the cladding layers to the rolling ingot, c) hot rolling or roll cladding of the rolling ingot, d) cold rolling, and e) solution annealing with quenching.
[0095] First a rolling ingot 1 is cast from an aluminium alloy with the following alloy constituents in w. %:
[0096] 0.25%≦Mg≦0.6%,
[0097] 1.0%≦Si≦1.5%,
[0098] Fe≦0.5%,
[0099] Cu≦0.2%,
[0100] Mn≦0.2%,
[0101] Cr≦0.1%,
[0102] Zn≦0.1%,
[0103] Ti≦0.1%, and
[0000] remainder Al and unavoidable contaminants to maximum total 0.15%, individually maximum 0.05%.
[0104] The rolling ingot produced in this way is homogenised at a homogenisation temperature of 550° C. for 8 hours in a furnace 2 , so that the added alloy constituents are distributed particularly homogeneously in the rolling ingot, FIG. 1 a ). FIG. 1 b ) now shows that aluminium alloy layers 1 a and 1 b are applied on the rolling ingot 1 so that these can be welded to the rolling ingot by hot rolling. The aluminium alloy layers 1 a and 1 b for example consist of aluminium alloys type AA8079 or AA5005A, which in material state 0 (corresponding to state T4) after solution annealing have a lower tensile strength Rm than that of the AlMgSi alloy layer, i.e. for example less than 180 MPa. However other aluminium alloys are conceivable for the external aluminium alloy layers, for example other low-alloyed aluminium alloys such as alloy types AA1XXX, for example AA1200.
[0105] The rolling ingot 1 with the applied aluminium alloy layers or cladding layers is hot rolled, in the embodiment example according to the invention shown in FIG. 1 c ), by reversing through a hot-roll mill 3 , wherein the rolling ingot 1 has a temperature of 400 to 550° C. during hot rolling. In this embodiment example after exiting the hot-roll mill 3 and before the penultimate hot-roll pass, the hot strip 4 preferably has a temperature of at least 400° C., preferably 470 to 490° C. Preferably at this hot-strip temperature, the hot strip 4 is quenched using a plate cooler 5 and the working rolls of the working roll mill 3 . For example the hot strip is here cooled to a temperature of 290 to 310° C. before the last hot-roll pass, so that this can be carried out safely and without difficulty and the hot strip can be cooled further. For this the plate cooler 5 , indicated merely diagrammatically, sprays cooling rolling emulsion onto the hot strip and ensures an accelerated cooling of the hot strip to the said temperatures. The working rolls of the hot-roll mill are also loaded with emulsion and cool the hot strip 4 further in the last hot-roll pass. After the last roll pass, the hot strip 4 has a temperature of 230 to 200° C. at the exit from the plate cooler 5 ′ in the present embodiment example and is then coiled via the recoiler 6 at this temperature.
[0106] Because the hot strip 4 immediately at the exit from the last hot-roll pass has a temperature of over 135° C. to 250° C., preferably 200 to 330° C., or optionally is brought to said temperatures in the last two hot-roll passes using the plate cooler and working rolls of the hot-roll mill 3 , the hot strip 4 , despite the increased coiling temperature, has a crystalline microstructural state which leads to very good uniform elongation values A g in state T4 of more than 23%, preferably more than 25%. Despite the frozen microstructural state, the hot strip can be processed and coiled with relatively high speed at said temperatures. The hot strip is coiled via the recoiler 6 with a thickness of 3 to 12 mm, preferably 3 to 5 mm. Since no coarse Mg 2 Si precipitations can form at the relatively low coiling temperatures, the core alloy layer has a particularly advantageous crystalline state and can therefore be cold rolled very well, for example using a cold-rolling mill 9 , and recoiled onto the recoiler 8 , FIG. 1 d ).
[0107] The resulting cold-rolled strip 11 is coiled. Then it undergoes solution annealing at a temperature of typically 500 to 570° C. and quenching 10 , FIG. 1 e ). For this it is again decoiled from the coil 12 , solution-treated and quenched in a furnace 10 , and recoiled into a coil 13 . After natural ageing at room temperature, the aluminium strip can then be delivered in state T4 with maximum formability.
[0108] With greater aluminium strip thicknesses, for example for chassis applications or components such as for example brake anchor plates, alternatively piece annealing can be carried out and the sheets quenched afterwards.
[0109] In state T6, which is achieved by artificial ageing at 100° C. to 220° C., the strip according to the invention shows a further rise in yield point value so that particularly high strengths are achieved. The artificial ageing can take place for example at 205° C. for 30 minutes. The strips produced according to the embodiment shown here, from an aluminium alloy composite material, after cold rolling for example have a thickness of 0.5 to 4.5 mm. Strip thicknesses of 0.5 to 2 mm are normally used for bodywork applications and strip thicknesses of 2.0 mm to 4.5 mm for chassis components in motor vehicle construction. In both application fields, the improved uniform elongation values are a decisive advantage in the production of components since usually very strong forming of the sheets is carried out and nonetheless high strengths are required in usage state T6 of the end product. The improved bendability of the strips according to the invention, which as already stated above allow particularly small bend angles, is added on top of this.
[0110] To achieve the improved bending behaviour, it is advantageous if the external aluminium alloy layers have grain sizes of less than 50 μm, preferably less than 25 μm. A longitudinal ground section according to Barker through an embodiment example of a strip 1 produced according to the invention is shown in FIG. 2 in greatly magnified view. It is clear that the external aluminium alloy layer 1 a, which is here formed by an aluminium alloy type AA8079, has a much smaller grain size than the core alloy layer. In this embodiment example average grain sizes of around 20 μm were measured.
[0111] FIG. 3 shows in a perspective view the test arrangement for performance of bending tests to determine the maximum bend angle. The tests are based on the specification 238-100 of the Association of the German Automotive Industry (VDA). The test arrangement consists of a bending punch 14 , which in the present case has a punch radius of 0.4 mm. The specimen 15 was previously cut to size 270 mm×60 mm transverse to the rolling direction. The specimen 15 was then expanded with pre-elongation of 10% transverse to the rolling direction, with a pre-elongation speed of 25 mm/min and a free clamping length of 150 mm. Then from this the specimen 15 was cut to a size 60×60 mm and placed in the bending jig. The bending punch 14 , which, as shown in FIG. 4 , runs parallel to the rolling direction so that the bending line 18 also runs parallel to the rolling direction, now presses the specimen with force F b between two rollers 16 , 17 with roll diameter of 30 mm which are arranged spaced apart by twice the specimen thickness (table 2) or twice specimen thickness plus 0.5 mm (table 3). The bending force F b is measured while the bending punch 14 bends the specimen 15 . When the bending force F b reaches the maximum and then falls by 30 N, the maximum achievable bend angle is reached. Specimen 15 is then taken from the bending jig and the bend angle measured as shown in FIG. 5 .
[0112] As representative of a typical AlMgSi alloy, the alloy Core 1 was used as a core alloy layer, the alloy constituents of which are shown in table 1. In addition two different external aluminium alloy layers Clad 1 , Clad 2 were used, the composition of which is also shown in table 1.
[0000]
TABLE 1
Si
Fe
Cu
Mn
Mg
Cr
Zn
Ti
Alloy
w. %
w. %
w. %
w. %
w. %
w . %
w. %
w. %
Core1
1.3
0.20
—
0.06
0.3
—
—
0.03
Clad1
0.125
1.11
0.0002
—
—
—
0.0029
—
Clad2
0.14
0.25
0.03
0.02
0.9
—
—
—
[0113] Taking into account the method described in FIGS. 1 a )- e ), strips were produced and solution annealed. In the test series shown in table 2, the solution annealing took place in the laboratory using a salt bath on sheets cut from correspondingly roll-hardened strips with final thickness. The specimens were then quenched in the water basin and aged for 7 days. This corresponds approximately to state T4 as also achieved in mass production by the use of a continuous strip furnace.
[0000]
TABLE 2
Test
Annealing in
Thickness
R p0.2
Rm
A g
A 80 mm
Bend
No.
Alloy
salt bath
mm
N/mm 2
N/mm 2
%
%
angle
VLG1
T4
Core1
60 sec
1.58
108
222
24.0
29.2
49.3
520°
VGL2
T4
Core1
20 sec
1.58
111
224
24.4
29.4
47.5
540°
VGL3
T4
Core1
60 sec
1.58
110
225
24.7
30.4
48.5
540°
Inv 1
T4
Core1 +
60 sec
1.58
94
196
24.3
29.8
36.9
Clad1
540°
Inv 2
T4
Core1 +
20 sec
1.58
93
199
25.3
30.9
37.3
Clad1
540°
Inv 3
T4
Core1 +
60 sec
1.58
93
199
24.6
30.3
36.0
Clad1
540°
VGL4
T4
Core1
60 sec
1.50
103
213
24.4
28.6
50.2
520°
VGL5
T4
Core1
20 sec
1.50
102
216
25.5
31.0
47.5
540°
VGL6
T4
Core1
60 sec
1.50
102
216
24.7
29.5
44.3
540°
[0114] It is evident from table 2 that the embodiments Inv 1 , Inv 2 , Inv 3 according to the invention, in comparison with the comparative examples VLG1-VLG6, achieve significantly smaller bend angles i.e. the opening angle of the bent specimens were significantly smaller than in the comparison strips. The bend angles amounted to 36° to 37.3° in the alloy strips clad according to the invention. The unclad comparative examples however only showed minimum bend angles of more than 44°. The uniformity elongation A g of the embodiments according to the invention, despite the cladding layer arranged on both sides, was still very high at over 24%.
[0000]
TABLE 3
Bend
Test
Position
Thickness
R p0.2
Rm
A g
A 80
angle *
No.
Alloy
in strip
mm
N/mm 2
N/mm 2
%
%
°
Inv5
T4
Core1 +
Strip
1.50
85
187
25.7
29.9
31.4
Clad1
start
Inv6
T4
Core1 +
Strip
1.50
84
186
26.0
29.9
31.5
Clad1
centre
Inv7
T4
Core1 +
Strip
1.50
92
198
23.3
27.5
36.4
Clad2
start
Inv 8
T4
Core1 +
Strip
1.50
93
196
23.2
27.4
36.3
Clad2
end
VGL7
Soft
AA5182
Strip
1.50
138
278
23.4
26.0
68.7
start
* Bend angle measured with modified roll spacing
[0115] Table 3 shows the measurement results of embodiments according to the invention which were produced totally industrially, i.e. here too, the solution annealing step to achieve state T4 in tests Inv 5 to Inv 8 was carried out in a continuous strip furnace. All measurements given in table 3 were taken on strips with thickness 1.50 mm and hence on slightly thinner strips in comparison with the measurements in table 2. Strips Inv 5 to Inv 8 were also aged for 19 days at room temperature. For comparison, table 3 shows an aluminium alloy AA5182 typically used for automotive engineering. In the bending tests, in contrast to table 2, a modified roll spacing was selected which corresponded to twice the thickness of the specimen to be measured plus 0.5 mm. This test arrangement, conventional in the automotive industry, gives very reproducible measurement results for the minimum bend angle. For the comparison example VGL7, only a minimum bend angle of 68.7° could be achieved. The embodiment examples according to the invention, however, achieved bend angles of minimum 31.4° and hence are particularly suitable for example for the production of flanged folds, as occur frequently in automotive engineering. The improved bending behaviour is reflected in particular in the improved appearance of the bend edge, which has a very homogenous appearance because of the fine-grained recrystallised external aluminium alloy layer.
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The invention relates to a strip consisting of an aluminum material for producing components with improved bending behavior and exacting shaping requirements, a method for producing the strip and the use of sheets produced from the strip according to the invention. The strip has a core layer of an AlMgSi alloy and at least one outer aluminum alloy layer arranged on one or both sides, made from a non-hardenable aluminum alloy, wherein the at least one outer aluminum layer has a lower tensile strength in the (T4) state than the AlMgSi layer, wherein the strip has a uniform strain (A g ) in the (T4) state of more than 23% transverse to the rolling direction and, at a thickness of 1.5 mm-1.6 mm, achieves a bending angle of less than 40° in a bending test.
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CROSS REFERENCE
This application is a continuation of U.S. application Ser. No. 09/966,630, filed on Sep. 28, 2001 now U.S. Pat. No. 6,725,933.
BACKGROUND
This disclosure relates to a method and apparatus for treating a subterranean well formation to stimulate the production of hydrocarbons and, more particularly, such a method and apparatus utilizing foam diversion in the well formation.
Several techniques have evolved for treating a subterranean well formation to stimulate hydrocarbon production. For example, hydraulic fracture acidizing methods have often been used according to which a portion of a formation to be stimulated is isolated using conventional packers, or the like, and a stimulation fluid containing gels, acids, sand slurry, and the like, is pumped through the well bore into the isolated portion of the formation. The pressurized stimulation fluid pushes against the formation at a very high force to establish and extend cracks on the formation.
Also, squeezing methods have been used which involve introducing stimulation fluids containing acids to formations at a pressure that is higher than the formation pressure (but not as high as the fluid pressure in the fracturing methods), causing the fluid to infiltrate the pores in the formation and react with the formation to enlarge the pores.
In these methods, foam diversion is often used according to which foam is created and used to plug pores in the formation and thus promote the spreading of the fluids over a relatively large surface area of the formation. To this end, conventional foaming equipment is provided on the ground surface that creates a foam, which is then pumped downhole. Foams, however, have much larger friction coefficients and reduced hydrostatic effects, both of which severely increase the required pressures to treat the well. Moreover, using conventional procedures, a foam generated at the surface is sent through the same conduit as the other liquids. Therefore, if a foam is needed, it cannot be introduced into the formation until all the liquids used previously are cleared from the wellbore. The gas into the foam generator could be changed, but this change will not occur until all previously delivered foam clears the wellbore. This, of course, is very time-consuming.
SUMMARY
According to an embodiment of the present invention a method for acid treatment of a subterranean well formation is provided to stimulate the production of hydrocarbons which utilizes foam diversion which can be initiated substantially instantaneously in situ.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a fracturing system according to an embodiment of the present invention, shown in a vertical wellbore.
FIG. 2 is an exploded elevational view of two components of the systems of FIG. 1 .
FIG. 3 is a cross-sectional view of the components of FIG. 2 .
FIG. 4 is a sectional view of a fracturing system according to an embodiment of the present invention, shown in a wellbore having a horizontal deviation.
FIG. 5 is a view similar to that of FIG. 1 but depicting an alternate embodiment of the fracturing system of the present invention shown in a vertical wellbore.
FIG. 6 is a view similar to that of FIG. 5, but depicting the fracturing system of the embodiment of FIG. 5 in a wellbore having a horizontal deviation.
DETAILED DESCRIPTION
Referring to FIG. 1, a stimulation system according to an embodiment of the present invention is shown installed in an underground, substantially vertically-extending, wellbore 10 that penetrates a hydrocarbon producing subterranean formation 12 . A casing 14 extends from the ground surface (not shown) into the wellbore 10 and terminates above the formation. The stimulation system includes a work string 16 , in the form of piping or coiled tubing, that also extends from the ground surface and through the casing 14 . The work string 16 could be placed just above the lower end of the casing 14 or could extend beyond, or below, the end of the casing 14 as viewed in FIG. 1 . One end of the work string 16 is connected to one end of a tubular jet sub 20 in a manner to be described. The jet sub has a plurality of through openings 22 machined through its wall that form discharge jets which will be described in detail later.
A valve sub 26 is connected to the other end of the jet sub 20 , also in a manner to be described. The end of the work string 16 at the ground surface is adapted to receive a gas, such as nitrogen or carbon dioxide.
The valve sub 26 is normally closed to cause flow of the gas to discharge from the jet sub 22 . The valve sub 26 is optional and is generally required for allowing emergency reverse circulation processes, such as during screenouts, equipment failures, etc. An annulus 28 is formed between the inner surface of the wellbore 10 and the outer surfaces of the workstring 16 and the subs 20 and 26 . Several different types of fluids are pumped into the annulus 28 from the ground, for reasons to be described.
The respective axes of the jet sub 20 and the valve sub 26 extend substantially vertically in the wellbore 10 . When the gas is pumped through the work string 16 , it enters the interior of the jet sub 20 and discharges through the openings 22 , into the wellbore 10 , and against the formation 12 .
Details of the jet sub 20 and the ball valve sub 26 are shown in FIGS. 2 and 3. The jet sub 20 is formed by a tubular housing 30 that includes a longitudinal flow passage 32 extending through the length of the housing. The openings 22 extend through the wall of the casing in one plane and can extend perpendicular to the axis of the casing as shown in FIG. 2, and/or at an acute angle to the axis of the casing as shown in FIG. 3, and/or aligned with the axis (not shown). Thus, the gas from the work string 16 enters the housing 30 , passes through the passage 32 and is discharged from the openings 22 , with the discharge pattern being in the form of a disc extending around the housing 30 .
If the gas is introduced into the work string 16 , and discharges through the openings 22 , at a relatively high pressure, under conditions to be described, a jetting effect is achieved. This creates a relatively high differential discharge pressure, which accelerates the stimulation fluid in the annulus 28 to a relatively high velocity. Thus a relatively high shear occurs between the jetted gas and the fluid in the annulus 28 . This high shear causes the development of a high quality foam in situ for reasons to be explained.
Two tubular nipples 34 and 36 are formed at the respective ends of the housing 30 and preferably are formed integrally with the housing. The nipples 34 and 36 have a smaller diameter than that of the housing 30 and are externally threaded, and the corresponding end portion of the work string 16 (FIG. 1) is internally threaded to secure the work string to the housing 30 via the nipple 34 .
The valve sub 26 is formed by a tubular housing 40 that includes a first longitudinal flow passage 42 extending from one end of the housing and a second longitudinal flow passage 44 extending from the passage 42 to the other end of the housing. The diameter of the passage 42 is greater than that of the passage 44 to form a shoulder between the passages, and a ball 46 extends in the passage 42 and normally seats against the shoulder.
An externally threaded nipple 48 extends from one end of the casing 40 for connection to other components (not shown) that may be used in the stimulation process, such as sensors, recorders, centralizers and the like. The other end of the housing 40 is internally threaded to receive the externally threaded nipple 36 of the jet sub 20 to connect the housing 40 of the valve sub 26 to the housing 30 of the jet sub.
It is understood that other conventional components, such as centering devices, BOPs, strippers, tubing valves, anchors, seals etc. can be associated with the system of FIG. 1 . Since these components are conventional and do not form any part of the present invention, they have been omitted from FIG. 1 in the interest of clarity.
In operation, the ball 46 is dropped into the work string 16 , passes through the passage 42 , and seats on the shoulder between the passages 42 and 44 . A gas, such as nitrogen or carbon dioxide is pumped down the work string 16 and the fluid pressure thus builds up in the subs 20 and 26 . This pumping of the gas is continued until the system is fully charged at which time it is discontinued.
A preflush fluid is then pumped down the annulus 28 at pressures between the pressure of the pores of the formation and the fracture pressure. This preflush fluid removes carbonates and/or sweeps away harmful minerals from the wellbore 10 which would otherwise cause precipitates when contacting hydrofluoric acid at a later stage. The preflush fluid can be non-acidic, acidic, or both.
A stimulation fluid is then pumped down the annulus 28 at pressures at the reservoir 12 between the pore pressure and the fracture pressure. The stimulation fluid, can be in the form of a conventional acid that is used in squeezing or matrix acidizing, along with various additives that are well known in the art. Typical acids include mineral or organic acids, such as hydrochloric acid, hydroflouric acid, formic acid, or acetic acid, or a blend thereof. The stimulation fluid reacts with the formation to cause fracturing and squeezing, in a conventional manner.
An afterflush fluid is then pumped down the annulus 28 to sweep the hydrofluoric acid out of the wellbore. This afterflush fluid is generally non-acidic and can contain foaming agents for reasons to be described. It is noted that, during the above, some of the above gas may be present in the workstring 16 near or at its end, and some of the gas may have leaked into the annulus 28 as a result of the charging of the system, as described above. This gas is at a concentration, or pressure, to prevent the above fluids from rising up into the workstring 16 , but is not high enough in concentration to create a viscous foam when it mixes with the fluid at the openings 22 in the jet sub 20 .
After a predetermined pumping of the afterflush fluid, a diversion stage is initiated to insure that the fluid is spread over a relative large surface area of the formation. To this end, the pumping rate of the gas into the workstring 16 and through the openings 22 is initiated at an increased rate compared to the initial charging of the system, as discussed above. One of the following steps are taken to insure that foam is created in the annulus 28 at or below the jet sub 20 when the gas discharging from the openings 22 mixes with the afterflush fluid in the annulus 28 :
1) the differential pressure of the gas across the openings 22 will be high enough to create a homogeneous foam;
2) a foaming agent is added to the fluid; and/or
3) the gas-to-liquid ratio will be high enough to create a viscous foam.
The foam thus formed is directed to the formation and is forced into the pores thereof, creating a barrier so that the fluids of the next stage, or cycle, to be described are redirected to other untreated portions of the formation.
During this diversion stage, pressure increases or decreases occurring at the reservoir face 12 are monitored at the surface. Changes at the surface can be made with respect to either the fluid or gas rate to change the downhole foam's viscosity for fluid loss effects and stage sizes.
Once the desired diversion is accomplished, the above steps are repeated in another cycle and the above-mentioned barriers created by the foam caused by the diversion enables the fluid, and particularly, the stimulation fluid, to be spread over a relatively large surface area of the formation. Thus, in accordance with the foregoing, the foam is generated in situ on demand and substantially instantaneously.
The accelerated gas flow can be computed as follows:
Assuming Q is quality, V g is the volumetric flow rate of gas at a certain pressure (in this example, pressure effects and gas expansion effects are ignored for clarity purposes; and it can be included in the future using common engineering know how) and V l is the liquid rate; V g1 is the gas rate at Q 1 , and V g2 at Q 2 ; and dV is equal to (Vg2−Vg1), then, knowing that V g =(Q*V l )/(1−Q), the eventual gas flow can be computed at Q 2 ; which is V g2 =(Q 2 *V l )/(1−Q 2 ). In order to create the downhole step change and deliver the volume relatively quickly, this volume is V ADD =dV*V PIPE /V g2 ; where V PIPE is the total volume of the conduit carrying gas. V ADD must be delivered in addition to V g2 as quickly as possible.
After the above operations, if it is desired to clean out spent acid or foreign material such as debris, pipe dope, etc. from the wellbore 10 , the work string 16 , and the subs 20 and 26 , the pressure of the stimulation fluid in the work string 16 is reduced and a cleaning fluid, such as water, at a relatively high pressure, is introduced into the annulus 28 . After reaching a depth in the wellbore 10 below the subs 20 and 26 , this high pressure cleaning fluid flows in an opposite direction to the direction of the stimulation fluid discussed above and enters the discharge end of the flow passage 44 of the valve sub 26 . The pressure of the cleaning fluid forces the ball valve 46 out of engagement with the shoulders between the passages 42 and 44 of the sub 26 . The ball valve 46 and the cleaning fluid pass through the passage 42 , the jet sub 20 , and the work string 16 to the ground surface. This circulation of the cleaning fluid cleans out the foreign material inside the work string 16 , the subs 20 and 26 , and the well bore 10 .
FIG. 4 depicts a stimulation system, including some of the components of the system of FIGS. 1-3 which are given the same reference numerals. The system of FIG. 4 is installed in an underground wellbore 50 having a substantially vertical section 50 a extending from the ground surface and a deviated, substantially horizontal section 50 b that extends from the section 50 a into a hydrocarbon producing subterranean formation 52 . As in the previous embodiment, the casing 14 extends from the ground surface into the wellbore section 50 a.
The stimulation system of FIG. 4 includes a work string 56 , in the form of piping or coiled tubing, that extends from the ground surface, positioned at the lower portion of casing 14 . As in the previous embodiment, gas, such as nitrogen, is introduced into the end of the work string 56 at the ground surface (not shown); while a stimulation fluid, described above, is pumped into the annulus of wellbore 50 . One end of the tubular jet sub 20 is connected to the other end of the work string 56 in the manner described above for receiving and discharging the gas into the wellbore section 50 b and into the formation 52 in the manner described above. The valve sub 26 is connected to the other end of the jet sub 20 and controls the flow of the gas through the jet sub in the manner described above. The respective axes of the jet sub 20 and the valve sub 26 extend substantially horizontally in the wellbore section 50 b so that when the gas is pumped through the work string 56 , it enters the interior of the jet sub 20 and is discharged, in a substantially radial or angular direction, through the wellbore section 50 b and against the formation 52 to create a foam with the gas in the wellbore 50 . The horizontal or deviated section of the wellbore is completed openhole and the operation of this embodiment is identical to that of FIG. 1 . It is understood that, although the wellbore section 50 b is shown extending substantially horizontally in FIG. 4, the above embodiment is equally applicable to wellbores that extend at an angle to the horizontal.
In connection with formations in which the wellbores extend for relatively long distances, either vertically, horizontally, or angularly, the jet sub 20 , the valve sub 26 and workstring 56 can be initially placed at the toe section (i.e., the farthest section from the ground surface) of the well. The acid spotting and squeezing process discussed above can then be repeated numerous times throughout the horizontal wellbore section, such as every 100 to 200 feet.
The embodiment of FIG. 5 is similar to that of FIG. 1 and utilizes many of the same components of the latter embodiments, which components are given the same reference numerals. In the embodiment of FIG. 5, a casing 60 is provided which extends from the ground surface (not shown) into the wellbore 10 formed in the formation 12 . The casing 60 extends for the entire length of that portion of the wellbore in which the workstring 16 and the subs 20 and 26 extend. Thus, the casing 60 , as well as the axes of the subs 20 and 26 extend substantially vertically. The casing 60 must be either preperforated or perforated using conventional means; or it could be hydrajetted with sand using the jet sub 20 . Optionally, inside the casing 60 wire screens could be installed and packed with gravel in a manner well known in the art. Then the operation described in connection with the embodiments of FIGS. 1-3 above, is initiated and the mixture of stimulation fluid and foamed gas discharge, at a relatively high velocity, through the openings 22 , through the above openings in the casing 60 , and against the casing 60 to generate foam and squeeze it in the manner discussed above. Otherwise the operation of the embodiment of FIG. 5 is identical to those of FIGS. 1-4.
The embodiment of FIG. 6 is similar to that of FIG. 4 and utilizes many of the same components of the latter embodiments, which components are given the same reference numerals. In the embodiment of FIG. 6, a casing 62 is provided which extends from the ground surface (not shown) into the wellbore 50 formed in the formation 52 . The casing 62 extends for the entire length of that portion of the wellbore in which the workstring 56 and the subs 20 and 22 are located. Thus, the casing 62 has a substantially vertical section 62 a and a substantially horizontal section 60 b that extend in the wellbore sections 50 a and 50 b , respectively. The subs 20 and 26 are located in the casing section 62 b and their respective axes extend substantially horizontally. The casing section 62 b must be either preperforated or perforated using conventional means; or it could be hydrajetted with sand using the jet sub 20 . Optionally, inside the casing section 62 b wire screens could be installed and packed with gravel in a manner well known in the art. Then the stimulation operation described in connection with the embodiments of FIGS. 1-3, above, is initiated with the mixture of stimulation fluid and gas discharging, at a relatively high velocity, through the above openings in the casing 62 , and against the formation 12 to fracture squeeze it in the manner discussed above. Otherwise the operation of the embodiment of FIG. 6 is identical to those of FIGS. 1-3.
Equivalents and Alternatives
It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, although the above technique was described in connection with a process to matrix acidize sandstone reservoirs, it is understood that it is not exclusive to matrix sandstone acidizing with hydrofluoric acid, and can be used in carbonate matrix acidizing with other type acids which are compatible with carbonate reservoirs. Also, a variety of other fluids can be used in the annulus 28 , including clean stimulation fluids, liquids that chemically control clay stability, and plain, low-cost fluids. Further, the liquids may be injected through the workstring 16 , while the gas is pumped into the annulus 28 . Moreover, it may be decided that the dispensing of the reactive fluids, such as the acids, be spotted at different positions of the well. To do this, position of the jet sub 20 may be far below the casing 14 as shown in FIG. 1 . Still further, the above preflushes and afterflushes can be acidic or not acidic.
Also, the gas can be premixed with some liquids prior to entering the work string 16 for many reasons such as cost reduction and increasing hydrostatic pressure. Moreover the makeup of the stimulation fluid can be varied within the scope of the invention. Further, the particular orientation of the wellbores can vary from completely vertical to completely horizontal. Still further, the openings 22 in the sub 20 could be replaced by separately installed jet nozzles that are made of exotic materials such as carbide mixtures for increased durability.
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many other modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
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A method and apparatus or treating a subterranean well formation to stimulate the production of hydrocarbons utilizing foam diversion in the well formation.
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TECHNICAL FIELD
[0001] The present invention relates generally to stains and coatings and, more particularly, to oleoresinous compositions that can be applied as stains and coatings to materials for use in building various types of products.
BACKGROUND OF THE INVENTION
[0002] Concerns for both the environment and worker health and safety have prompted almost every industry to explore novel and innovative technologies to reduce or eliminate volatile organic compounds (VOC) from their applications. Volatile organic compounds are organic chemicals that have sufficient vapor pressures under ambient conditions to significantly vaporize and enter the atmosphere. Common sources of VOC include compounds such as those used in dry cleaning and other cleaning processes, in painting and staining applications, and in the processing and use of materials for construction. Other sources of VOC can be found in the processing, dispensing, and use of petroleum fuels.
[0003] Although the specific definition can vary, a VOC is generally taken to be any volatile compound of carbon with the exception of carbon monoxide, carbon dioxide, carbonic acid, metal carbides, metal carbonates, and certain other carbon-containing compounds that have no or negligible photoreactivity under ambient atmospheric conditions. Some VOC having more than negligible photoreactivity react with nitrogen dioxides in the air to form ozone, which has been deemed to pose a health threat by causing or exacerbating respiratory problems. Some VOC emitted from paints, stains, varnishes, shellacs, other coating materials as well as plastics, carpets, and other building materials can pose a threat to persons in an indoor environment. Indoor VOC emission is often considered to be a factor in “sick building syndrome.”
[0004] Commercial finishing operations typically apply large volumes of coating materials to various types of products. These products include, but are not limited to, furniture, raw and finished lumber, and architectural building materials (e.g., trims, moldings, cabinetry, flooring, and the like). These coating materials may be either water- or solvent-based, and VOC can be emitted from either.
[0005] The coating materials that are applied include paints, stains, varnishes, and the like. Each of these materials generally includes a solvent in which pigments (paints), dyes (paints and stains), and resin (varnish) are dissolved or suspended. These solvents are typically carbon compounds having considerable volatility (thus putting them into the VOC category), thereby making them subject to regulation or targets for elimination.
[0006] The paints, stains, varnishes, etc. as described above may also include VOC-containing binders. One particular type of VOC-containing binder commonly used is an alkyd-based material. Alkyds are typically manufactured from acid anhydrides (e.g., phthalic, maleic anhydride, and the like) and polyols (e.g., glycerol, pentaerythritol, and the like) and are modified with unsaturated vegetable oil. The unsaturated sites in the oil molecules oxidize, thereby causing polymerization or cross-linking. In the processing of alkyd-based compositions, specifically those in which alkyds are incorporated into paints, stains, varnishes, and the like, the alkyds are undesirably released into the atmosphere.
[0007] What is needed is a composition that can be applied to architectural building materials, such a composition having no VOC emissions but that exhibits suitable and desirable properties relating to covering, curing, hardness, and durability.
SUMMARY OF THE INVENTION
[0008] In one aspect, the present invention resides in a composition for coating a building material such as an article of architectural lumber or the like. The composition includes dicyclopentadiene modified oil and an oleoresinous component having a high solids content mixed therewith. This component can include a dye or a pigment to impart a color to the composition. The oleoresinous component mixed with the dicyclopentadiene modified oil is free of volatile organic compounds (VOC).
[0009] In another aspect, the present invention resides in an article of architectural lumber. An article of architectural lumber includes a substrate (e.g., wood, fiberboard, paper, or the like) and a coating disposed on the substrate. The coating is a dicyclopentadiene modified oil and an oleoresinous component having a high solids content mixed therewith. The oleoresinous component has a high solids content and is free of VOC.
[0010] In another aspect, the present invention resides in a method of coating a building material. This method includes the steps of preparing a composition of dicyclopentadiene modified linseed oil and an oleoresinous component having a high solids content that is free of VOC, applying the composition to the building material, and allowing the composition to dry into a hardened film on the building material.
[0011] Preferably, the dicyclopentadiene modified oil in any of the embodiments described herein is made with linseed oil.
[0012] One advantage of the present invention is that no VOC is released from the composition into the atmosphere. Both the dicyclopentadiene modified oil and the oleoresinous component mixed therewith are free of VOC so that upon application of the composition to a substrate (e.g., architectural lumber), the oil hardens into a film without the release of chemicals deemed harmful to the environment or humans.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] As used herein, the term “building material” refers to wood in all its forms (e.g., raw lumber, hardwood, softwood, plywood, fiberboard, engineered wood, and the like).
[0014] As used herein, the term “copolymer” refers to a material produced by the simultaneous polymerization of two or more dissimilar monomers.
[0015] As used herein, the term “oleoresinous” is used to describe a mixture of a resin and an oil extracted from a plant or a tree.
[0016] As used herein, the term “dicyclopentadiene” is used to describe the dimer of cyclopentadiene, which is derived from petroleum products such as coal tar and various oils. Cyclopentadiene dimerizes via a Diels-Alder reaction to produce the dicyclopentadiene dimer.
[0017] As used herein, the term “linseed oil” refers to a hydrocarbon material derived from vegetable sources and including glycerides of linolenic, linoleic, oleic, and saturated fatty acids. Linseed oil is a drying oil, which is an oil that, when applied as a thin film, readily absorbs oxygen from the air and polymerizes to form a relatively tough, elastic film.
[0018] As used herein, the term “iodine value” refers to the mass of iodine in grams that is consumed by 100 grams of a chemical substance. Because double bonds in fatty acids react with iodine, the iodine number is a determination of saturation of fatty acid.
[0019] As used herein, “volatile organic compound” and “VOC” refer to carbon-containing chemicals that have sufficient vapor pressures under ambient conditions to significantly vaporize and enter the atmosphere.
[0020] The present invention includes copolymers that are applied to various types of building materials. These copolymers generally comprise oleoresinous dicyclopentadiene modified linseed oil and are used to provide vehicles for formulations (compositions) of coating materials. The compositions can be applied to the various types of building materials as stains, varnishes, paints, and the like. Because the copolymers are oleoresinous oils, no volatile organic compounds (VOC) are emitted therefrom. Although the compositions are typically applied in factory settings, the present invention is not limited in this regard and as such the compositions may be applied by an end user outside of a factory setting (e.g., by a builder installing architectural trim during construction of a building).
[0021] In formulating the copolymer, dicyclopentadiene modified linseed oil is prepared by reacting dicyclopentadiene with linseed oil having an iodine value of greater than about 150. The dicyclopentadiene is added in increments to the oil with agitation and at a temperature of about 250 degrees C. to about 270 degrees C. The dicyclopentadiene de-dimerizes (cleaves into separate cyclopentadiene monomers) and reacts with the unsaturated sites of the linseed oil. The extent of the unsaturation of the linseed oil is determined by the iodine value. The reaction of the cyclopentadiene with the unsaturated sites of the linseed oil proceeds by the Diels-Alder reaction. Although the oil is described herein as being linseed oil, the present invention is not limited in this regard as other drying oils (such as tung, perilla, soya, otitica, sunflower, safflower, castor, and fish oils) may be used in place of or in combination with the linseed oil. In particular, other drying oils can be used to modify the rheological properties of the linseed oil-based compositions of the present invention.
[0022] Once the dicyclopentadiene modified linseed oil is prepared, a high solids content oleoresin is incorporated therein to form an oleoresinous dicyclopentadiene modified linseed oil copolymer that serves as the vehicle for the stain, varnish, or paint. A high solids content oleoresin is one in which the total amount of solids is about 50 wt. % to about 100 wt. %, preferably about 75 wt. % to about 100 wt. %, and more preferably about 90 wt. % to about 100 wt. %. When the high solids content oleoresin is less than 100 wt. % solids, the solids portion may be diluted in a non-VOC solvent such as tert-butyl acetate, a cyclic siloxane, 2-chlorobenzotrifluoride, or the like, or any other solvent that is photochemically non-reactive. When the oleoresin is less than 100% solids and diluted in a solvent, the viscosity of the oleoresin may cause it to be heated to facilitate its addition to the dicyclopentadiene modified linseed oil. When the resin is 100% solids (e.g., in the form of a powder, flake, chip, or the like), it is melted directly into the dicyclopentadiene modified linseed oil.
[0023] The oleoresin itself can be cumarone (also known as benzofuran), which is a heterocyclic aromatic organic compound having the formula C 8 H 6 O. Other materials that may be used in addition to or in place of the cumarone include, but are not limited to, 100% solids resin modifiers such as hydrocarbons, shellacs, maleic anhydride and/or maleic acid, polymers, vegetable oils, and the like. The present invention is not limited in this regard, however, as other materials may be used.
[0024] In one composition of the present invention, a stain is formulated by solublizing or suspending a dye in the oleoresinous dicyclopentadiene modified linseed oil without additional binder or solvent so that the oleoresinous dicyclopentadiene modified linseed oil functions both as the binder and the solvent. Upon drying, the dye imparts color to a hardened film formed by the oleoresinous dicyclopentadiene modified linseed oil.
[0025] In another composition of the present invention, a paint may be formulated with the oleoresinous dicyclopentadiene modified linseed oil. Such a paint includes the oleoresinous dicyclopentadiene modified linseed oil as the vehicle with pigments and/or dyes incorporated there. In paint, the preferred additive is pigment, which is generally in the form of a powder that is insoluble in the oleoresinous dicyclopentadiene modified linseed oil but is dispersed therein to form a suspension. When the composition of the present invention is a paint, a dispersant is typically included to facilitate the dispersion and the wetting of the pigment in the oleoresinous dicyclopentadiene modified linseed oil.
[0026] The amount of pigment in the oleoresinous dicyclopentadiene modified linseed oil to form a paint is about 10 wt. % to about 90 wt. %, preferably about 10 wt. % to about 50 wt. %, and more preferably about 10 wt. % to about 40 wt. %. Upon drying, the pigment imparts color (and likely an opaque quality) to a hardened film of oleoresinous dicyclopentadiene modified linseed oil.
[0027] In any embodiment, the oleoresinous dicyclopentadiene modified linseed oil may include materials in addition to the dyes, resins, or pigments. Such materials include, but are not limited to, leveling agents, drying agents (e.g., naphthenates, rare earth oxides and/or other rare earth materials, and the like), fillers, film forming agents, agents that absorb, block, or filter ultraviolet radiation (to protect from fade), stabilizers, preservatives, surfactants, thickening agents, combinations of the foregoing, and the like. Preferably, a rare earth material is included in the composition to effect the oxidation of the composition.
[0028] Whether the composition of the present invention is a stain, varnish, paint, or some other type of material, it may be applied to a substrate using any suitable means to form a film. The substrate is preferably wood-based, although the present invention is not limited in this regard as materials other than wood may be used as substrates. Suitable methods for applying the composition include, but are not limited to, brushing, rolling, spraying, roller coating, curtain coating, dipping, combinations of any of the foregoing, and the like. Preferably, the composition is sprayed onto the substrate. If the composition is a stain, excess composition may be removed from the substrate. Also, if the composition is a stain or a paint, a composition of the present invention in which varnish is incorporated into the oleoresinous dicyclopentadiene modified linseed oil may be applied as a topcoat.
[0029] In the present invention, the compositions are preferably applied to architectural lumber in a factory setting using suitable pumping and atomizing equipment. The present invention is not limited to application of the compositions in a factory setting, however, as the compositions may be applied at the points at which articles into which the compositions are incorporated are assembled or used. Architectural lumber includes, but is not limited to, trim, molding, cabinetry, flooring, siding, doors, decking materials, and the like. Other things that the coating compositions may be applied to include, but are not limited to, indoor furniture, outdoor furniture, artwork, framing material, fencing, tool handles, musical instruments, paper products, and the like.
[0030] Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those of skill 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, 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 embodiments disclosed in the above detailed description, but that the invention will include all embodiments falling within the scope of the appended claims.
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A composition for coating a building material such as an article of architectural lumber or the like includes dicyclopentadiene modified oil and an oleoresinous component having a high solids content mixed therewith. The oleoresinous component is free of volatile organic compounds (VOC). An article of architectural lumber includes a substrate (e.g., wood, fiberboard, paper, or the like) and a coating disposed thereon, the coating being a dicyclopentadiene modified oil and an oleoresinous component having a high solids content mixed therewith. The oleoresinous component has a high solids content and is free of VOC. A method of coating a building material includes the steps of preparing a composition of dicyclopentadiene modified linseed oil and an oleoresinous component having a high solids content that is free of VOC, applying the composition to the building material, and allowing the composition to dry into a hardened film on the building material.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a cryostat for an MR magnet for medical magnetic resonance (MR) imaging.
2. Description of the Prior Art
Superconducting magnetic coils are used in medical imaging in magnetic resonance tomography (MRT) apparatuses. The superconducting magnetic coils are cooled with liquid helium. If the superconducting magnet coils are suddenly transitioned into the normally-conducting state (“quench”), the energy of the magnetic field is transduced into heat. The liquid helium is thereby vaporized and large quantities of cold helium gas must be safely conducted to the atmosphere. For this purpose, an opening is provided on the top of the tank in which the magnet is located. A structure known as the tower (or turret) extends above the opening, with a tower pipe that serves for filling the tank with liquid helium. The tower pipe transitions into the quench pipe. The diameter of the quench pipe depends on its length and its radius of curvature and is on the order to 20 to 40 cm. The diameter of the tower pipe can be smaller because the helium gas given a quench is still very cold at this point and therefore does not occupy much volume.
A particular danger is that the tower pipe of the magnet is completely sealed by air-ice droplets. Such a sealing can occur due to operating error upon refilling with liquid helium or due to leaks in the system. The seal forms from frozen air that is located in the lower, cold region of the tower. The seal withstands pressures up to several bars, such that the danger exists that the helium tank bursts. Upon a quench of an iced magnet the danger exists of the magnet exploding.
It is therefore vital for a seal in the tower pipe or quench pipe to be immediately remedied. This can ensue by radiant heat or by careful injection of warm helium gas onto the seal, but the magnet must not be caused to quench by the supplied heat. A de-energizing of the magnet is not possible if the pipe is sealed since increased helium is vaporized upon de-energizing, which would increase the pressure in the helium tank.
Detection of a seal in one of the pipes is possible in the prior art only by optical, visual monitoring, i.e. via cameras or other such sensors in the tower pipe as is described in DE 10 2005 058 650 B3, for example. A device for monitoring a tower pipe in a cryomagnet is known from this document, which has at least one monitoring unit that has a functional interaction with a state of the inside of the tower pipe of a cryomagnet to monitor the continuity of the inside of the tower pipe.
A monitoring system for a superconducting magnet as well as a corresponding monitoring method is known from U.S. Patent Application Publication No. 2006/0230769. In this system and method the quantity of liquid helium that is still present and in which the superconducting coil is located is detected. The output unit outputs the monitoring information depending on the detected remaining volume.
The solutions known in the prior art are in need of improvement.
SUMMARY OF THE INVENTION
An object of the present invention to provide a cryostat in which the sealing of filling pipes and exhaust pipes with ice (for example) is immediately communicated.
The invention is essentially based on providing the cryostat with an additional, thin pipe. This auxiliary pipe advantageously runs from the tower of the cryostat over the winding or, respectively, the winding body of the magnet and into the helium tank, wherein it describes a gentle arc around the winding body. In that the auxiliary pipe extends far into the helium tank, the probability is reduced that the pipe ices over since the air ice forms first at the cold points in the system, and that is the lower part of the tower pipe. A pressure sensor is arranged in the auxiliary pipe, which pressure sensor is thus engaged in a communication connection with the inside of the helium tank so that the pressure inside the helium tank can be monitored in this manner with the pressure sensor in the auxiliary pipe.
The cryostat according to the invention, with a tank to accommodate a coolant and at least one superconducting magnet coil to generate a magnetic field—wherein the tank possesses at least one tower pipe on a top side for the filling of the coolant and/or for discharging vaporized coolant—is accordingly characterized by a pressure sensor that is engaged in a communication connection with the inside of the tank via a pressure sensor pipe.
The cryostat advantageously has one or more of the following features:
The pressure sensor pipe and the tower pipe are mutually directed through a tower at the top side of the tank. This has the advantage that the necessary number of openings in the tank is limited to a minimum, and thus the surface across which a heat exchange of the tank with the environment can occur is kept as small as possible.
The pressure sensor pipe extends beyond the tower pipe and into the tank. In particular, the pressure sensor pipe extends beyond the superconducting magnet coil and into the tank and is thereby curved around the superconducting magnet coil. With these embodiments the fact is utilized that the probability that an ice seal forms under the pressure sensor pipe, and therefore that the pressure in the pressure sensor pipe no longer corresponds to the pressure inside the tank, is lower the deeper that the pressure sensor pipe projects into the tank.
A second pressure sensor is provided to detect a pressure difference between the tower and the pressure sensor pipe, wherein the second pressure sensor is arranged in the tower. Both the absolute pressure in the tower and the difference pressure between tower and first pressure sensor can therefore be established.
The pressure sensor pipe is terminated with a pressure sensor pipe seal that breaks upon exceeding a predetermined pressure value, such that the tank can be vented via the pressure sensor pipe and the overpressure can be dissipated. The safety of the cryostat can be additionally improved with this device.
An advantage (among others) of the present invention is apparent in that the most dangerous state of an MR magnet is immediately detected, namely the obstruction of the tower pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross section through a cryostat according to the prior art for a superconducting magnet.
FIG. 2 is a schematic cross section through a cryostat according to the invention for a superconducting magnet.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawings are not to scale. Identical or identically operating elements are provided with the same reference characters insofar as it is not noted otherwise.
The invention assumes a bath cryostat. In a bath cryostat, the magnet coil to be cooled is surrounded by coolant. Liquid helium with a boiling point of −268.93° C. or 4.2 Kelvin serves as a coolant. The tank with the magnet coil is normally surrounded with two thermal shields for better thermal insulation.
A schematic cross section through a cryostat for a superconducting magnet is shown in FIG. 1 . The cryostat comprises a magnet housing with an outer surface 1 and an inner surface 2 . Such a cryostat with superconducting magnet is used, for example, in an MRT apparatus for the generation of the basic magnetic field; the patient (not shown) then lies in the inner chamber that is defined by the inner surface 2 of the housing.
The conductor coils 9 generating the magnetic field are merely schematically indicated and consist of a superconducting material. In order to keep their temperature at a required, low value, they are located in a helium tank filled with liquid helium 8 , the outside 5 and inside 6 of which are indicated in FIG. 1 . Moreover, an outer radiation shield 3 and an inner radiation shield 4 are provided around the magnet 9 . These serve for additional thermal shielding.
The liquid helium 8 is filled into the cryostat via a tower pipe 7 that is directed via a tower 10 into the inside of the cryostat. The tower pipe 7 simultaneously serves for the venting of the cryostat. The tower 10 is arranged on an upward-facing side of the cryostat. The liquid helium 8 essentially entirely fills the helium tank 5 , 6 ; only helium that is located directly at the top side of the helium tank 5 , 6 is in the gaseous state. (The vaporized coolant 13 is indicated by a few circles over the liquid surface; the boundary surface between vaporized coolant 13 and liquid coolant 8 is indicated by a wavy line.) The conductor coils 9 inside the helium tank 5 , 6 are cooled by the liquid helium 8 to a temperature of 4.2 K. In contrast to this, a temperature that approaches the room temperature prevails in the upper part of the filling nozzle or tower pipe 7 .
A quench pipe 11 is connected with the tower pipe 7 , which quench pipe 11 establishes a connection between the helium tank 5 , 6 and the outside world given a quench of the superconducting magnet 9 so that gaseous helium can escape and an overpressure inside the cryostat does not build. For this it is necessary that both the tower pipe 7 and the quench pipe 11 remain passable. Moreover, the quench pipe 11 is sealed with a burst disc 11 a so that the helium cannot escape during the normal, disruption-free operation of the superconducting magnet, which burst disc 11 a breaks in the event of a quench so that the gaseous helium 13 can escape.
Air can get into the tower 10 upon filling the cryostat 1 with liquid helium due to leaks of the quench pipe 11 or the tower 10 and due to inattention. This air can freeze in the lower region of the tower pipe 7 —thus in a region where temperatures around 4.2 K predominate—since the melting points of, for example, oxygen or nitrogen are well above 4.2 K. This region is designated with the reference character 12 in FIG. 1 . The icing 12 can constrict or entirely seal the free diameter of the tower pipe 7 , which under the circumstances represents a great danger, as is briefly explained in the following.
At 4.2 Kelvin liquid helium has a specific weight of 125 kg/m 3 . Gaseous helium at this temperature has a specific weight of 17 kg/m 3 . The volume increases by a factor of 7 upon vaporization of the helium, which means a pressure increase to 7 bar given a completely filled and closed vessel. At room temperature, gaseous helium has 700 times the volume of liquid helium. Theoretically, a maximum pressure of a few hundred bar can build in a sealed helium tank at room temperature. In reality, the system follows the complicated laws of thermodynamics: the temperature and the pressure rise only slowly, and the boiling point of the helium increases with the rising temperature and rising pressure up to the maximum temperature of liquid helium (critical point) of 5.2 K. At this point the helium remains gaseous at any pressure.
So that the continuity of the quench pipe 11 as well as of the tower pipe 7 can be monitored quickly and without problems in a simple manner, according to the invention a pressure monitoring unit is provided that interacts with a functional state inside the tower 10 and therefore can monitor the state of the tower pipe 7 . The pressure monitoring unit is advantageously arranged at the tower pipe 7 . One possible embodiment of the pressure monitoring unit is shown in FIG. 2 and explained in the following.
In the embodiment of the invention according to FIG. 2 , the pressure monitoring unit comprises a pressure sensor 14 that is connected via a pressure sensor tube 15 with the inside of the tank 5 , 6 in which the superconducting magnet is located. In this way it is ensured that the pressure sensor 14 always indicates the pressure in the chamber of the superconducting magnet, and no falsifications of the measurement values should result. This naturally assumes that the pressure sensor tube 15 is free so that a pressure equalization with the region of the cryostat around the superconducting magnet can actually occur.
The extent that the pressure sensor tube 15 extends into the cryostat depends on, among other things, the probability that the pressure sensor tube 15 is also sealed by air ice or the like. The pressure sensor pipe 15 should therefore advantageously extend beyond the tower pipe 7 into the tank 5 , 6 . in particular, the pressure sensor pipe 15 should extend beyond the superconducting magnet coil 9 into the tank 5 , 6 . This is indicated in FIG. 2 , where the pressure sensor pip 15 ends with its lower end approximately at the level of the center point of the magnet coil 9 wound in a circle. The pressure sensor pipe 15 must thereby be adapted to the curvature of the superconducting magnet coil 9 around its center point and be curved for its own part. In this way the pressure sensor pipe 15 comes to lie between the coil 9 and the outer surface 5 of the helium tank 5 , 6 .
In order to keep the number and size of the openings of the cryostat as low as possible, the pressure sensor pipe 15 and the tower pipe 7 advantageously run together through the pipe 10 of the cryostat and penetrate its outer skin 1 on its top side.
In order to detect the pressure differential between the tower pipe 7 and the pressure sensor pipe 15 , a second pressure sensor 16 is advantageously provided in the tower pipe 7 . The pressure differential between pressure sensor pipe 15 and tower pipe 7 is continually measured with these two pressure sensors 14 and 16 . If the pressure differential is different [sic] for a longer period of time, it can be directly concluded that a seal has formed either in the tower pipe 7 or in the pressure sensor pipe 15 .
In an additional embodiment of the invention (not shown), it is monitored as to whether a negative pressure relative to atmospheric pressure predominates in the tower pipe 7 or the pressure sensor pipe 15 . In this case the danger exists that air is sucked into the tower pipe 7 and that the tower pipe 7 ices over. A slight overpressure should consequently always predominate in the tower. The maintenance of this overpressure can be ensured with a monitoring measurement by the pressure sensors 14 and 16 .
If the pressure sensor pipe 15 nevertheless ices over, an opening of the pressure sensor pipe 15 by means of heat is normally only possible if the pressure build-up in the tank has not yet progressed too far. The opening ensues with an electric heater (not shown) that is inserted into the pressure sensor pipe 15 , or with warm helium gas (advantageously with a de-energized magnet). The danger thereby exists that a great deal of helium is released, which would increase the pressure in the magnet. A quench could also be triggered. Given a greater pressure build-up in the tank, the pressure sensor pipe 15 can be opened in any state of the magnet with a cutter that is attached to a flexible shaft. If the magnet is energized, the cutter is advantageously anti-magnetic.
Moreover, given a cryostat according to the invention according to a further embodiment (not shown), the pressure sensor pipe 15 is sealed with a pressure sensor pipe seal 17 that breaks upon exceeding a predetermined pressure value so that the tank 5 , 6 can be vented via the pressure sensor pipe 15 .
Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventor to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of his contribution to the art.
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A cryostat has a tank for accommodation of a coolant and at least one superconducting magnet coil to generate a magnetic field. The tank has on a top side at least one tower pipe for filling the coolant and/or for venting vaporized coolant. In order to immediately indicate if and when sealing of filling pipes and discharging pipes with (for example) ice has occurred, a pressure sensor is connected via a pressure sensor pipe with the inside of the tank.
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CLAIM OF PRIORITY
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/136,422, filed on Sep. 4, 2008, the entire contents of which are hereby incorporated by reference.
DESCRIPTION
[0002] FIG. 1 shows the magnet sphere, known as magnet sphere 1 . Which consist of a sphere shape metal framing ( FIG. 1 a ) around a light weight sphere shaped material, connected by a support rod, that provide the external force needed to rotate the magnet sphere 1 . FIG. 1 shows gear 1 and gear 2 connected to the support rod at both ends. The external force moves the magnet sphere 1 to a clockwise rotation. FIG. 1 also shows the placement of the magnets, which are arranged in a north, south order, within the given roll.
[0000] FIG. 2 shows a ceramic sphere framing ( FIG. 2 a ), which supports the copper wiring. Which is placed around the magnet sphere 1 . Each copper wire coil, is connected to the opposite corresponding copper wire coil and or will remain independent. Positioning will be determined during testing, either at the opposite end of the corresponding top or bottom, left or right hemisphere or within the same hemisphere. Each section of coils may also be independent. (Positive to one rod 1 and negative to the other rod 2 . The next coil connected to the rods, negative to rod 1 and positive to rod 2 .) The positive and negative, will be determined by the inter sphere. And as long as there is a draw from the Rod 1 and Rod 2 , with less resistance, the electron will not flow to the next coil. Without using a commutator. Which ever generates the highest power output. To be determined during testing. Rods tubes 1 and 2 are fixed on top of the top hemisphere, with gear 1 and gears 2 connected. Within rod tubes 1 and 2 , are rods 1 and 2 , which is the output for the corresponding hemisphere. Rods tubes 3 and 4 are fixed on the bottom of the bottom hemisphere, with gear 3 and gear 4 connected. Within rod tubes 3 and 4 , are rods 3 and 4 , which is the output for the corresponding hemisphere. Gears 1 , 2 , 3 , and 4 rotate freely without movement of the coil sphere. Gears 1 and 2 are connected to magnet sphere gear 1 , and gear 3 and 4 are connected to magnet cylinder gear 2 . This will cause ceramic gears 1 and 2 to rotate counterclockwise to magnet sphere gear 1 , which rotates clockwise and cylinder gear 3 and 4 also rotates counterclockwise to magnet sphere 2 , which rotates clockwise, as the ceramic coil sphere remains still. (shown on Page 12)
FIG. 3 shows the magnet sphere, known as magnet sphere 2 . Which also consist of a sphere shape metal framing ( FIG. 3 a ), fixed around the wire coil. Fixed on the top and bottom of the magnet sphere 2 , are gear 1 and gear 2 , which rotates the magnet sphere 2 counterclockwise. The placement of the magnets arranged to the corresponding magnetic field of the magnet sphere 1 , all within the inside of magnet sphere 2 . If needed, magnets can be placed on the outside of the sphere to create multiple layers.
FIG. 4 shows another coil sphere, known as sphere coil 2 . This is to increase power output. Components are similar to the FIG. 2 , with it's corresponding gear as shown page 8 .
FIG. 5 shows another magnet sphere 3 , fixed around the sphere coil 2 . With its similar gears as magnet sphere 2 . As shown on page 10.
[0003] Page 12 shows the rotation of the gears as stated with gear FIG. 1 , gears FIG. 2 , and gear FIG. 3 . Also shows the rotation of the gears as stated with gear FIG. 1 , gears FIG. 4 , and FIG. 5 . This rotation of the gears will rotate the corresponding sphere.
[0004] Function:
[0005] The rotation of the magnet sphere 1 and the rotation of magnet sphere 2 , creates the electricity when it passes the corresponding copper wire coil.
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New design of generator and or generators, which creates electricity. Using a sphere shape design compared to the traditional generator designs already in use today. Using a sphere shape design for the placements of the magnets and coils. The gears will allow for multiple layers to be used for rotation, dependent on power needs.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/389,328 filed Oct. 4, 2010 entitled “Gasless Pilot Accumulator” and claims priority to U.S. Provisional Application No. 61/349,313 filed May 28, 2010 entitled Gasless Pilot Accumulator and each are incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to accumulators and regulators. In particular, the present invention relates to accumulators and regulators that may be implemented in pressurized fluidic conditions or where remote hydraulic control of a regulator is required.
[0004] 2. Description of Related Art
[0005] This invention preferably may be used for deepwater accumulators that supply pressurized fluid to control and operate equipment disposed below fluid levels. Accumulators are typically associated with blowout preventers (BOP) in order to temporarily cease well bore operations, gate valves in order to control fluid flow and to divert various fluids to surfaces or other subsea locations, as well as hydraulically actuated connectors and similarly associated devices. Pressurized fluid is typically an oil or water based fluid with increased lubricity and corrosion protection.
[0006] Currently accumulators come in various styles, but most share the same underlying operative principle. This principle involves pre-charging each accumulator with pressurized gas to a pressure which closely approximates the minimally anticipated operative pressure, which often approaches the ambient temperature of the environment in which the accumulator will be used. By pre-charging an accumulator fluid may be optionally added to the accumulator, increasing the pressure of the pressurized gas and the fluid. Fluid introduced into the accumulator is therefore stored at a pressure at least as high as the pre-charged pressure and is capable of doing hydraulic work.
[0007] Accumulators are often styled to operate in a bladder, piston, or float type fashion. Bladder types open employ an expandable bladder which separates gasses from fluids. Piston types use a piston which translates along an axis to separate fluids from gasses. Float types use a float to provide a partial separation of fluid from gas and closing of a valve when the float approaches the bottom. This in turn prevents the escape of gas.
[0008] Pilot Accumulators are typically pre-charged with gas at approximately ambient pressure plus the minimum working pressure of the circuit. As accumulators are used in deeper water, the efficiency of conventional accumulators is decreased. In 1000 feet of seawater ambient pressure approximates 465 pounds per square inch. Thus, in order for an accumulator to provide a 500 psi differential at 1000 ft. depth, it is required to be pre-charged at 732.5 pounds per square inch. At about 4000 feet of depth, ambient pressure is approximates 930 pounds per square inch, requiring an initial pre-charge of 1430 pounds per square inch, when only 500 pounds per square inch is required for operations. And at 10,000 ft, these numbers are 4,650 plus 500 psi. This is problematic because cylindrical design often requires thicker walls, stronger end caps, tighter welds, and stronger materials merely to accomplish an operative working environment. When higher working pressures are employed, larger deviations in translational pressure shifts occur. This requires stronger sealing mechanisms and more accurate gauges. When pressure variants are introduced into the environment, often being cold water, even more extraneous pressure is required to get an accumulator to operational status. For example subsea accumulators are often exposed to very cold temperatures after being pre-charged which causes them to lose pressure.
[0009] As the BOP is deployed, the ambient pressure increases, thus decreasing the efficiency of the gas accumulators and can render them useless and cause the system to lose functionality. To alleviate this problem, the current approach is to fit multiple parallel accumulators into the circuit with multiple pre-charge pressures to allow added control at different depths.
[0010] The use of these multiple accumulators adds another problem, as the rates of increase and decrease vary with the volume of gas contained in the system, thus making control erratic and changing dependent on the depth. Also as deployment takes place, the isolated fluid in the system loses pressure equal to the increase of the ambient pressure, requiring frequent adjustments to the internal pressure to keep the system within the control range required to operate the functions.
[0011] Due to the properties of the gas systems, increasing the pressure is not linear and follows a parabolic arc, thus limiting control at higher pressures.
[0012] Although these systems represent great strides in the area of accumulator technology, many shortcomings remain.
[0013] Thus there exists a need for an accumulator that is capable of operating at a higher pressure and not required to be overly pre-charged with pressure, not require multiple pre-charge pressures and not require frequent pressure increases during deployment and conversely, not require frequent decreases during recovery. Without decreases during recovery, due to error or equipment failure, the internal pressure at the surface can be as high as 3,000 psi plus the ambient pressure due to water depth. At 10,000 feet this could be 7,650 psi.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The novel features believed to be characteristic of the invention are set forth in the appended claims. However, the invention itself, as well as a preferred mode of use and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:
[0015] FIG. 1 illustrates a cross sectional view of a gasless pilot accumulator according to a preferred embodiment of the invention.
[0016] FIG. 2 illustrates a perspective view of a gasless pilot accumulator with T bar control arm according to a preferred embodiment of the invention.
[0017] FIG. 2A illustrates a cross sectional view of a gasless pilot accumulator with T-bar control arm according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Referring now to FIG. 1 , there is shown a cross sectional view of gasless pilot accumulator 5 . Gasless pilot accumulator 5 includes a first stage 12 and second stage 14 and a translational member 9 therebetween defining two chambers. First stage 12 has two primary load disbursing members 3 and 6 , and second stage 14 has two secondary load disbursing members 10 and 15 , with translational member 9 therebetween the two stages. Second stage 14 is communicatively associated with first chamber 12 via translational member 9 . A regulator, not shown, is operatively associated with entry chamber 46 and is controlled by the pressure of fluid input and dispensed from gasless pilot accumulator 5 through port 47 . Primary load disbursing member 3 can be capable of overcoming secondary load disbursing member 6 or load disbursing member 6 may be capable of overcoming load disbursing member 3 in order for translational member 9 to translate. Load disbursing members 3 and 6 may be of any of a variety of pre-determined springs well known in the art. Other biasing mechanism may also be employed that are well known in the art.
[0019] Gasless pilot accumulator 5 may or may not also include a bladder member 19 or use an external configuration for storing fluid. Bladder member 19 is operatively associated with second stage 14 in order to manipulate fluid into and out of second stage 14 through ports 26 a and 26 b . Bladder member 19 is positioned to translate in a substantially longitudinal direction relative to second stage 14 . Bladder member 19 may substantially collapse and expand as fluid is input and dispelled. Another member (not pictured) may dispose or release force about an outer surface of bladder member 19 in order to dispose fluid into and out of second stage 14 . In this particular embodiment, bladder member 19 is of a two chamber type in order to provide sufficient space for fluid. In other embodiments, bladder member 19 may be of a single chamber type or balloon type. In yet other embodiments bladder member 19 may be of three or more chambers and allow for sufficient amounts of fluid so that the ambient pressure may be imparted to the displacement piston 34 and also allow for compression of the fluid due to pressure or temperature.
[0020] In certain embodiments, second stage load disbursing member 15 may act in combination with second stage load disbursing member 10 to function as a load disbursing-damper combination. In certain embodiments, load disbursing member 6 and load disbursing member 3 may act in combination to function as a load disbursing-damper combination. Second stage load disbursing member 15 and second stage load disbursing member 10 supply opposing forces against load disbursing member 6 and load disbursing member 3 via translational member 9 . Translational member 9 is capable of impacting longitudinal member 34 .
[0021] Longitudinal member 34 protrudes through an annulus in plated member 32 . Plated member 32 allows longitudinal member 34 to translate along a longitudinal direction while supplying a substantially equal load disbursement from load disbursing member 3 and primary load disbursing member 6 . Plated member 32 substantially conforms to the diameter of chamber 28 . Longitudinal member 34 translates along second chamber 35 while providing a void 46 to allow for movement of pilot control fluid. Pilot control fluid is connected to the regulator pilot piston through port 47 . Longitudinal member 34 contains a seal 42 and ports 43 a and 43 b which allow for fluidic communication with an pilot control circuit via port 44 . The pilot control circuit is configured to allow the increase or decrease of the pilot control circuit pressure and volume. Port 44 permits introduction of fluid to chamber 35 . Ports 43 a and 43 b can be configured by the introduction of an orifice and a check valve which will control the opening speed of the regulator without changing the closing rate. This leads to a reduction of water hammer in the connected function circuits.
[0022] In operation, a member (not pictured) acts to exert and release force about bladder member 19 . Bladder member 19 communicates fluid with channels 26 a , 26 b , and 26 c . Second stage load disbursing member 15 and second stage load disbursing member 10 communicate force to translational member 9 which in turn makes contact with longitudinal member 34 . In the event that ambient fluid begins to exert sufficient pressure on longitudinal member 34 and convey force towards translational member 9 , second stage load disbursing member 15 and second stage load disbursing member 10 can act in combination to provide sufficient resistance and overcome primary load disbursing member 6 and secondary load disbursing member 3 .
[0023] Various components of gasless pilot accumulator 5 may be made from a wide variety of materials. These materials may include metallic or non-metallic, magnetic or non-magnetic, elastomeric or non-elastomeric, malleable or non-malleable materials. Non-limiting examples of suitable materials include metals, plastics, polymers, wood, alloys, composites and the like. The metals may be selected from one or more metals, such as steel, stainless steel, aluminum, titanium, nickel, magnesium, or any other structural metal. Examples of plastics or polymers may include, but are not limited to, nylon, polyethylene (PE), polypropylene (PP), polyester (PE), polytetraflouroethylene (PTFE), acrylonitrile butadiene styrene (ABS), polyvinylchloride (PVC), or polycarbonate and combinations thereof, among other plastics. Gasless pilot accumulator 5 and its various components may be molded, sintered, machined and/or combinations thereof to form the required pieces for assembly. Furthermore gasless pilot accumulator 5 and its various components may be manufactured using injection molding, sintering, die casting, or machining.
[0024] Referring now to FIG. 2 , an embodiment of gasless pilot accumulator 5 illustrated in FIG. 1 , is shown including a manual override mechanism 50 . Manual override mechanism 50 , includes a handle portion 52 which connects to a shaft portion 54 . Shaft portion contains and end which opposes handle portion 52 and includes threads for mating with a component disposed within gasless pilot accumulator 5 . Manual override mechanism 50 can be inserted into gasless pilot accumulator 5 by turning override mechanism 50 into threading to engage stage 14 and apply opposing force to load dispersing members 10 and 15 as shown and can be employed to override a shutoff mechanism. Manual override mechanism 50 can be operated by a remote operated vehicle in order to restore functionality to gasless pilot accumulator when it is directly mechanically connected to a regulator.
[0025] Referring now to FIG. 2A , there is shown a cross sectional view of an embodiment of gasless pilot accumulator 5 illustrated in FIG. 2 . Manual override mechanism 50 may have threading disposed along its shaft at first threading 60 second threading 65 , or both to facilitate variable movement of the override mechanism to engage load disbursing members in second stage 14 upon rotation of shaft 54 . Mateable threading on shaft 54 at either points 60 or 65 with threading on the inside diameter of female apertures 62 and 67 may be employed to permit rotational movement of shaft 54 inward or outward to variably engage load disbursing members in second stage 14 .
[0026] It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
[0027] All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of various embodiments, it will be apparent to those of skill in the art that other variations can be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.
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A gasless subsea accumulator having a series of opposing springs in two separate chambers defined by a central cross shaped member for translating force on a piston in the accumulator to dampen the movement of the piston. The body of the accumulator may be operably engaged to a bladder in fluid communication with one of the two chambers to provide additional dampening. The body may be vented through a port and have a port for controlling pressure on body through a pilot control circuit. The accumulator may be manually controlled by an ROV and operatively connected to a regulator.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The invention relates to a disposable cassette that is configured as a replaceable component of an analysis instrument.
2. Description of the Prior Art
Disposable plastic articles with fluid carrying passages are frequently used in medical equipment. Corresponding cassette systems have proven their worth here as alternatives to conventional hose systems. The corresponding fluid paths are formed in these cassette systems. The fluid flowing through the fluid paths is introduced by means of corresponding actuators. For instance, valves are, for example, used via which the fluid paths are switched open or are closed. On the other hand, pumps for the transport of the fluid are integrated in such cassette systems. In the field of medical application, disposable cassettes are already known in which a rigid part is provided in which passages and chambers are let in. This rigid part is covered by a continuously flexible film. In accordance with DE 102 39 597, this flexible film is formed by flexibly formed regions in the rigid part, with the rigid and flexible regions being able to be manufactured in one piece using a two-component injection molding technology.
The aforesaid cassette systems can also be used to advantage in the field of analysis technology.
SUMMARY OF THE INVENTION
It is the object of the invention to make available a disposable cassette for analysis purposes in which, for example, gases or electrolytes in whole blood, serum or urine can be measured. All liquids, i.e. the sample to be analyzed and also calibration solutions to be used correspondingly for the analysis, should remain in the disposable cassette in this process.
This object is solved in accordance with the invention as described herein. Accordingly, a sample inlet is provided in the disposable cassette which serves as a replaceable component of an analysis instrument. At least one container, preferably designed as a pouch, is integrated in the disposable cassette and has a liquid, preferably a calibration fluid, as well as at least one waste container, preferably a waste pouch, with the sample inlet and the different pouches being able to be connected to one another via fluid paths integrated in the disposable cassette.
It is the particular advantage of the blood analysis instrument using this disposable cassette in accordance with the invention that all fluid paths are located in the disposable cassette without direct contact to the analysis instrument. A further advantage consists of the fact that a plurality of measurements can be carried out with one disposable cassette. The waste pouch integrated into the cassette ensures that no liquid can leave the disposable cassette and that the disposable cassette with the liquids can be disposed of hygienically after the measurement series. It is therefore possible using the disposable cassette in accordance with the invention to fill in and to measure a sample, with the fluid located in the lines, in particular the calibration fluid, being displaced during the filling in of the sample. After the measurement of the sample, the cassette is flushed with calibration fluid so that the sample is flushed into the waste pouch with the calibration fluid. The sensors are subsequently recalibrated. The cassette is thus ready to receive a new sample. This cycle can be repeated approximately 30 times and even more frequently. The flushing capability of the port, as is preferably claimed, is of great importance in this process.
Preferred aspects of the invention result from the other embodiments of the disposable cassette as described herein.
For instance, at least one pouch is present in addition to the obligatorily provided waste pouch, for example, and contains a corresponding calibration fluid. Multiple measurements are hereby possible which, as previously recited, is also due to the fact that all fluid paths lie in a flushable manner inside the cassette and that there is admittedly a sample inlet in the cassette, but no liquid outlet. The consumed liquid is collected in the corresponding waste pouch. To the extent that two pouches provided with calibration fluid are provided, a two-point calibration is possible. Such a two-point calibration is substantially more precise than a one-point calibration.
The sample inlet made in the form of a port is advantageously closable by means of a slider. The slider can be adjustable in an automated manner by the analysis instrument into which the disposable cassette can be inserted, for example via a driver provided at the machine side. After the corresponding introduction of the sample, the disposable cassette can be closed by closing the slider to such an extent that a closed circuit is present inside the disposable cassette. At the end of the service life, the closure of the sample inlet serves to close the contaminated disposable cassette hermetically to allow it to be disposed of without risk.
In accordance with a further preferred aspect, the port is closable via a plastic flap hinged via a film hinge and sealingly pressable with the rim of the port via the aforesaid slider. A liquid-tight closure is ensured by the plastic flap.
The sample port can be lined on the interior with a flexible plastic material. This flexible plastic material is preferably the flexible plastic material which is provided for the limitation of the fluid paths and of the recesses for the actuators and which corresponds to the embodiment in accordance with the prior application DE 102 39 597. The sample port itself can have a passage which broadens slightly conically, adjoins a first fluid path leading into the cassette in the form of a passage with a narrow lumen and is adjoined by a cylindrical connection for the connection of a luer connector. It is possible on the basis of this aspect to permit a filling of the disposable cassette through a blood capillary (diameter 1.26 to 2.7 mm) or through a needle, for example a syringe needle or a cannula and also through a luer connector. The sample can be input in various manners due to this design of the sample port. First, the sample can be introduced via a syringe in that the luer cone is inserted and the sample is injected manually into the disposable cassette. The syringe is then removed and the plastic flap closed by means of the blocking slider.
An alternative filling possibility results via a blood capillary which is inserted into the lower, smaller cone. Since the capillary is upwardly open, the user can activate a disposable pump which interacts with the disposable cassette and which transports the desired sample into the sample passage. The capillary can then be removed and the plastic flap can be closed by means of the blocking slider.
There is a further option for the event that the sample should be removed from the interior of the syringe. A suction capillary is placed onto the luer cone of the syringe. This system is inserted into the luer cone of the sample port. Since the suction capillary is open to the side, air can follow into the syringe from the front. The user can therefore activate the disposable pump which transports the sample into the sample passage inside the disposable cassette. He can then remove the system and he can close the plastic flap by means of the blocking slider.
In accordance with an advantageous embodiment variant, a flushing passage in communication with the pouches via the fluid paths of the disposable cassette opens at the proximal end of the sample port. This permits a complete flushing of the fluid paths of the cassette. The opening region of the flushing passage is in communication with the cylindrical connection for the connection of the luer connector which is provided in the sample port. During flushing, which takes place with the port closed in a liquid-tight manner, flushing liquid therefore flows through the total port region and the flushing liquid is led into the first passage having a narrow lumen and is transported via the fluid paths integrated into the disposable cassette up to the waste pouch.
Actuators such as valves or a membrane pump are advantageously arranged in the region of the fluid paths.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the invention will be explained in more detail with reference to an embodiment shown in the drawing. There are shown:
FIG. 1 : the plan view of a disposable cassette in accordance with a first embodiment of the present invention, partly sectioned;
FIG. 2 : a section corresponding to the section line II-II through FIG. 1 ; and
FIG. 3 : an enlarged section through the sample port of the disposable cassette in accordance with FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
In the disposable cassette 10 shown in FIGS. 1 and 2 , a passage structure 14 is formed in a first part 12 , which is made as an injection molded plastic part, for the purpose of the fluid guidance and is covered in a known manner by means of flexible elastomer material in accordance with DE 102 39 597 of the same applicant. The injection molded plastic part 12 has a shell-like recessed region 16 in which there lie 3 pouches with calibration fluid 18 and one waste pouch 20 . The pouches 18 which are provided with calibration fluid and which are closed in the unused state of the disposable cassette 10 are connected to passages 14 via input regions which are to be opened directly. The waste pouch 20 is likewise connected to the passages 14 at 28 . A series of actuators is present in the passage system 14 in the form of valves 30 or of a pump 32 . Respective flexible plastic layers, which can be actuated via pushers on the machine side not shown in more detail here, are provided in the valves 30 or in the pump 32 . Reference can be made to DE 102 39 597 for the more detailed function. Liquid can be directly transported in the passage system 14 by a corresponding control of the valves 30 or of the pump 32 . The measurement path is designated by 60 in FIG. 1 .
A sample port 34 , such as is shown in enlarged form in FIG. 3 , is present for the inlet of a sample liquid, for example whole blood, serum or urine. The sample port 34 is closable in a liquid-tight manner via a plastic flap 38 hinged by means of a film hinge 36 . The flap 38 is sealingly pressed onto the surface of the port 34 by pushing a slider 40 in the direction of the arrow a. The slider 40 is pushed in the opposite direction to the direction of the arrow a for the release. The slider 40 has a driver 42 via which the slider is displaceable at the machine side in or counter to the direction of the arrow. The sample port 34 is in communication with the passage system 14 via a first passage 44 . A slightly conically broadening passage region 46 adjoins the passage 44 having the narrow lumen and broadens to become a cylindrical connection 48 which is made as the connection of a luer connector. The wall of this cylindrical region and of the slightly conically broadening passage 46 can be lined with flexible plastic, preferably with the same material as the passage covering. A second passage 50 having a narrow lumen extends parallel to the first passage 44 , however, up to the proximal end of the sample port 34 where it is in communication with the cylindrical region 48 of the sample port 34 . After closing the plastic flap 38 , the whole sample port 48 can be flushed by introducing flushing liquid via the passage 50 , with the consumed liquid being pumpable into the waste pouch 20 via the passage 44 , the passages 14 due to the pumping effect of the pump 32 .
An old blood sample or an old calibration solution can be replaced by fresh calibration solution by this flushing. The disposable cassette 10 shown in its design and its function is placed into the analysis instrument not shown in more detail here and is tightly pressed. The disposable cassettes are usually designed for a service life of 24 hours or of approximately 10 to 30 measurements. After corresponding use, the contaminated disposable cassette can be hermetically closed via closure of the slider 40 and of the plastic flap 38 and can be disposed of without risk after removal from the analysis instrument.
A cost-favorable system is provided by means of the disposable cassette in accordance with the invention in which the inlet port is suitable for samples of blood, urine or serum. The sample volume can be kept very small, with a sample volume of a maximum of 150 μl, including the volume up to the end of the sample passage, being able to be realized in the embodiment shown here. The sample port can therefore be used both for syringes and for capillaries. A favorable course of flow can be realized by means of the disposable cassette such that only a low tendency to hemolysis exists. Dead spaces are avoided in the system of the inlet port. After inputting the sample, the whole system can be flushed using an internal flushing solution. It is thereby possible to dispense with a maintenance effort for the disposable cassette. Latch positions (not shown in any more detail herein) for the port can also be realized by means of the slider 40 and here indicate a clear opened or closed state.
The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be recognized by one skilled in the art are intended to be included within the scope of the following claims.
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A disposable cassette that is configured as a replaceable component of an analysis instrument has integrated therein a sample inlet and fluid paths. At least one container with a liquid, for example a calibration fluid, and at least one waste container are integrated in the disposable cassette.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to supplying hydraulic fluid, such as lubricant, to a component and, in particular, to a fluid flow path in a rotating hub of clutch for a motor vehicle transmission.
2. Description of the Prior Art
The hub of a friction clutch or an overrunning clutch in an automatic transmission assembly transfers torque between an element of the clutch element and a shaft or another component that transmits torque in the assembly. In addition, such hubs carry hydraulic fluid, such as automatic transmission fluid (ATF), to lubricate and cool surfaces of the clutch, especially those surfaces that are subject to friction, fretting or chafing during in-service use. To provide fluid passageways, the hub is usually formed with a series of angularly spaced holes drilled radially through the hub thickness, through which holes fluid passes to the critical surfaces of the component. ATF fluid is continually deposited by being thrown radially outward against the inner surface of the component as the assembly operates.
Typically, hubs that are machined from a solid metal blank or forging, or by another forming method other than sheet metal forming, require machining an oil dam on the inner diameter of the hub to direct oil through radial drilled holes in order to cool the clutch and to prevent oil flow from the ends of the hub. Oil dams are, however, expensive to machine in such hubs.
Axially directed slots located at each radial hole are ineffective toward directing a sufficient volume of oil from the inside diameter of the hub to the radial holes because oil delivered to the hub inner diameter along the circumferential length of the hub between the slots will run off the end of the hub instead of flowing into the axial slots and radial holes.
There is a need in the industry, therefore, for a low cost technique that efficiently and effectively gathers and transports oil from the inner circumference of a hub to and through holes that pass through the wall thickness of a hub to facilitate lubrication and cooling of the critical surface of the component.
SUMMARY OF THE INVENTION
The hub is formed with a series of fluid channels, each having a base located at the inner radial surface of the hub where ATF, or another hydraulic fluid, is continually deposited by being thrown radially outward as the assembly rotates. Each channel has a base, whose contour collects oil along substantially the entire angular length of the inner surface between adjacent channels. The channels are formed such that they eliminate or reduce the need for machining the inner surface of the hub or race of an overrunning clutch.
Rather than using axial slots, the profile of each channel's base has the appearance of a cam, similar to that of a ratcheting, mechanical one-way clutch. The channel base directs oil to the major diameter of the channel, where a radial lube hole is located such that all oil delivered to the hub inner diameter is directed through the radial oil holes instead of only that portion of the oil contained in axial slots having a narrow angular length.
The contour of the channel's base is uniquely formed to operate with hubs that rotate in one direction only so that the end of the channel terminates at a radial hole and the depth of the channel is a maximum at the hole. Alternately, the contour of the channel's base extends is opposite angular direction from its respective hole to accommodate hubs that rotate in opposite directions. Similarly in this instance, the end of the channel terminates at a radial hole and the depth of the channel is a maximum at the hole.
A component, surrounding an axis for directing fluid along a flow path in a transmission for a motor vehicle, includes a first wall having a thickness formed with an inner surface facing the axis, and a hole spaced about the axis and extending through the thickness of the wall. A channel formed in the wall, communicates with the hole and the inner surface. The channel includes a base having a length that extends angularly about the axis, and a depth that increases along the length as distance from the hole decreases.
The scope of applicability of the preferred embodiment will become apparent from the following detailed description, claims and drawings. It should be understood, that the description and specific examples, although indicating preferred embodiments of the invention, are given by way of illustration only. Various changes and modifications to the described embodiments and examples will become apparent to those skilled in the art.
DESCRIPTION OF THE DRAWINGS
These and other advantages will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
FIG. 1 is a side view showing a hydraulically actuated clutch and servo in an automatic transmission assembly;
FIG. 2 is an isometric view of a clutch ring illustrating its hub and inner surfaces;
FIG. 3 is an end view of a clutch component showing a fluid channel;
FIG. 4 is a cross section taken at plane 4 - 4 of FIG. 3 ;
FIG. 5 is an end view of a component showing an alternate fluid channel;
FIG. 6 is a cross section taken at plane 6 - 6 of FIG. 5 ;
FIG. 7 is a partial isometric view illustrating the fluid channel of FIG. 3 formed on the inner surfaces of a clutch ring; and
FIG. 8 is a partial isometric view illustrating the fluid channel of FIG. 4 formed on the inner surfaces of a clutch ring.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1 , a clutch 10 for alternately opening and closing a drive connection between a hub 12 and a drum member (also called a clutch cylinder) 14 in a hydraulically-actuated automatic transmission includes clutch plates 16 , mutually spaced axially along the drum 14 . The radial outer periphery of the plates 16 are connected to the drum by a spline 17 formed on the inner surface of drum 14 , such that the plates and drum rotate as a unit. Located between each of the plates 16 is a friction disc 18 , which is connected to the hub 12 by a spline 19 formed on the radial outer surface of the hub, such that the discs and hub rotate as a unit. The hub 12 is supported on a bearing 20 and is formed with a series of angularly-spaced radial holes 22 , through which hydraulic fluid passes radially outward to the friction discs 18 and plates 16 . The clutch is substantially symmetric about a longitudinal axis 23
The clutch plates 16 and friction discs 18 are forced into mutual frictional content by movement of a servo piston 24 , located in a cylinder defined by drum 14 . Chamber 26 is supplied with a pressurized hydraulic fluid through a passage 28 and check valve 30 . When cylinder 26 is pressurized, piston 24 moves rightward forcing plates 16 and discs 18 against a pressure plate 32 , which is engaged with spline 17 and is secured by a snap ring 34 to the drum 14 . In this way, plates 16 and discs 18 produce a drive connection between hub 12 and drum 14 . A return spring 36 continually applies to piston 24 a force that resists its movement rightward and causes the piston to move leftward to the position shown in FIG. 1 , when pressure in cylinder 26 is low. The position of compression return spring 36 is fixed by a plate 38 , which is secured by a snap ring 40 to a hub 42 . A check valve 30 allows oil to exit the chamber 26 when pressure is low to reduce centrifugal forces from the residual oil in the chamber and ensure leftward movement of the piston 24 when intended.
FIG. 2 is an isometric view of a ring for a one-way clutch. The ring 50 includes a hub 52 , which extends angularly about axis 23 , the hub being formed with angularly-spaced axial holes 56 and a large central hole 57 . A portion of the outer surface of ring 50 is formed with axially directed spline teeth 58 , similar to the spline teeth 17 , 19 , which driveably connect the plates 16 and discs 18 of clutch 10 to the drum 14 and hub 10 . Another portion of the outer surface of ring 50 is formed with cam surfaces 60 , which can be engaged by rockers of a one-way clutch, such as those described and illustrated in U.S. Pat. No. 7,100,756. Extending axially parallel to axis 23 and located on the radial inner surface opposite spline 58 is a surface 60 formed with profiles, which are described in detail with reference to FIGS. 3-6 . A series of angularly spaced radial holes 80 pass through the axial wall 74 , 94 .
Referring next to FIGS. 3 and 4 , a clutch ring component 70 arranged about the central axis 23 , includes a wall 74 , which extends radially with respect to the axis between an inner surface 76 , which faces the axis, and an outer surface 78 . A series of radial holes 80 , mutually angularly spaced about axis 72 , extend through the wall 74 .
Fluid channels 82 , formed in the wall 74 , are mutually spaced about axis 23 . Each channel 82 includes a base 84 , which extends angularly toward a respective hole 80 . The depth of each channel 82 , as measured by the radial distance between the inner surface 76 and the base 84 , increases as the angular distance along the base from the respective hole 80 decreases. The depth of each channel 82 is a maximum at the respective hole 80 .
The base 84 of each channel 82 terminates at a surface 86 , which intersects both the base and the inner surface 76 . Each channel 82 communicates with the respective hole 80 . As FIG. 4 illustrates, at one end face 87 of wall 74 , each channel 82 is closed by the radial hub 52 . At the opposite axial end of face 88 , each channel 82 is open to permit tool extraction so that these features can be formed by the initial manufacturing process.
In operation, preferably component 70 rotates counterclockwise about axis 23 . Hydraulic fluid, thrown radially outward against inner surface 76 as the component 70 rotates, enters each channel 82 along its entire angular length between adjacent holes 80 , flows in the channel toward and through the respective hole at the end of the channel 82 .
Referring to FIGS. 5 and 6 , a clutch ring component 90 arranged about the central axis 23 , includes a wall 94 , which extends radially with respect to the axis between an inner surface 96 , which faces the axis, and an outer surface 98 . A series of holes 80 , mutually angularly spaced about axis 23 , extend radially through the wall 94 .
Fluid channels 102 , formed in the wall 94 , are mutually spaced about axis 23 . Each channel 102 includes a base 104 , which extends angularly toward a respective hole 80 . The base 104 of each channel 82 extends angularly on both sides of a radial line, which extends from axis 23 through the center of each hole 80 , from the base of an adjacent channel to the hole of the subject channel. The depth of each channel 102 , as measured by the radial distance between inner surface 96 and the base 104 , increases as the angular distance along the base from the respective hole 80 decreases. The depth of each channel 102 is a maximum at the respective hole 80 .
Each channel 102 communicates with its respective hole 80 . As FIG. 6 illustrates, at one end face 108 of wall 94 , each channel 102 is closed by radial hub 52 . At the opposite axial end face 112 , each channel 102 is open to permit fluid to flow into the channel along its length toward the hole 80 and though the hole to the outer surface 98 .
In operation, component 90 rotates in either direction about axis 72 . Hydraulic fluid, thrown radially outward against inner surface 96 as component 90 rotates, enters each channel 102 along its entire angular length between adjacent holes 80 , flows in the channel in both angular directions toward and through the respective hole 80 at the end of the channel 82 .
In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that the alternate embodiments can be practiced otherwise than as specifically illustrated and described.
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A component surrounding an axis for directing fluid along a flow path in a transmission for a motor vehicle. The component includes a first wall having a thickness formed with an inner surface facing the axis, and a hole spaced about the axis and extending through the thickness of the wall, and a channel formed in the wall, communicating with the hole and the inner surface, including a base having a length that extends angularly about the axis, and having a depth that increases along the length as distance from the hole decreases.
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[0001] This application is a continuation-in-part of Provisional Application S. No. 60/390,453, filed Jun. 21, 2002 entitled INSULATED JACKETS FOR HOT AND COLD PIPING SYSTEMS AND METHODS OF USE.
BACKGROUND OF THE INVENTION
[0002] The air gap technology, as described in U.S. Pat. Nos. 5,797,415 and 6,000,420, which are owned by the Horizon Resources Corporation also and which is hereby incorporated by reference, discloses the significant advantages of using entrapped air as a thermal insulating barrier in the insulation of piping systems. The entrapped or “still” air technology may be accomplished in several ways that provide the multiple layers of “still” air enclosed in an opaque, clear or translucent material such as plastic. When using a clear or translucent material, the insulation system provides the added advantage of being able to evaluate the condition of the pipe or insulating system without removal of the insulation.
[0003] The first generation of the inventive insulation comprised a series of ridged multi-lumen extrusions that would be “clipped”, “locked” or “snapped” together, then placed over the pipe and installed by a final “snap” to complete the installation.
BRIEF SUMMARY OF THE INVENTION
[0004] The invention incorporates a design that provides the same or similar insulation characteristics as that achieved in our previous patents. The jacket uses a core that could be extruded, thermoformed or pressed, just to name a few methods. The geometry of the inner core is constructed such that different pipe diameters can be handled with one or two designs rather than needing a separate core for each pipe size. One core design uses a relatively thin (0.010/0.020 inches) plastic “film” to form the core rather than the typical profile extrusion which is three to four times thicker, as shown in FIG. 6. The thinner core design reduces the material needed in the manufacturing process and makes the core more flexible. A plastic sheet or cover is used with the core to form the jacket. The cover also can be made thinner (0.020-0.025 inches) than the corresponding element of the previous designs. This smaller thickness allows this design to more easily meet the low smoke requirements for a fire situation in the industry. The cover and the core can be made from fire retardant polycarbonate plastic. The cover could be made of fire retatdant polycarbonate and the core could be made of polyvinlychloride.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 shows a top view of the core.
[0006] [0006]FIG. 2 shows a side view of the core.
[0007] [0007]FIG. 3 shows a longitudinal cross-section of the core.
[0008] [0008]FIG. 4 shows a magnification of a portion of the cross-section of the core shown in a circle in FIG. 3 and named DETAIL “A”.
[0009] [0009]FIG. 5 is an end view of the core installed on a pipe.
[0010] [0010]FIG. 5A is a partial cross-sectional view of an alternate embodiment of the core installed on a pipe.
[0011] [0011]FIG. 5B is a partial cross-sectional view of the alternate embodiment of the jacket of FIG. 5A installed on a pipe using a double wrapping of the core and cover.
[0012] [0012]FIG. 6 is an end view of further embodiments of the core with four different shapes shown on one portion.
[0013] [0013]FIG. 6A is an end view of four different shapes of the core of FIG. 6 used in an alternate embodiment.
[0014] [0014]FIG. 7 is a chart showing some examples of dimensions that can be used in carrying out the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] [0015]FIG. 1 shows a top view of the plastic corrugated core 2 . The length AB of the core relates to the chart shown in FIG. 7. The width of the core is shown as 35⅝ inches but it can be any length. When positioned on a pipe, the width of the core 2 is oriented so as to be along the length of the pipe to be insulated. As an example, the length AB of the core 2 can be manufactured in 72 inch lengths. The length AB of the core is then cut to the length shown in the AB column for the pipe size or OD shown in the chart.
[0016] [0016]FIG. 1 shows from a top view the formations created in the flat plastic sheet from which it is formed. The core is formed to create “trapped air” spaces, to strengthen the core and to minimize contact between the core, the fluid system element and the cover for the core. The core 2 has feet or protuberances 11 which contact the element and the cover to space the rest of the core from the element and the core. Rectangular portions 12 which provide areas which stiffen the core. Rectangular portions 12 are lower than the portions immediately around them and feet 11 so that they form a depressed area. Curved portions 13 , 14 are spaced from the fluid system element by feet 11 which extend form the curved portions 13 , 14 . The curved portions add strength to the core. Flat portions 15 are spaced from the cover by feet 11 which extent from the flat portions 15 . Flat portions 15 and rectangular portions 12 can be formed in the same plane.
[0017] [0017]FIG. 2 shows a side view of the core 2 of FIG. 1 with some typical dimensions. The legend TYP. stands for typical dimension. Portions of the core 2 are formed into different planes to create an undulating or corrugated form.
[0018] [0018]FIG. 3 shows a longitudinal cross-section of the core 2 taken along the dotted line referenced by arrows showing the direction of viewing and the number 3 . The IPS legends stand for Iron Pipe Size. The legend 2″ IPS shows the point at which the core length AB is cut to produce the proper wrap length for a 2 inch pipe. The same applies to 3″, 4″, etc. Flat portions 15 and curved portions 13 , 14 are joined by connecting walls 16 .
[0019] [0019]FIG. 4 shows the DETAIL “A” in FIG. 3 with some typical dimensions. The air spaces are created by the volumes delineated by flat portions 15 , curved portions 13 , 14 and connecting walls 16 . Feet or protuberances 11 extend from portions 13 , 14 and 15 to minimize the contact of the core 2 with the cover and the fluid system element. The feet 11 and the space that they create allow for scale on the element and other irregularities of the element.
[0020] [0020]FIG. 5 shows an end view of the insulated jacket 10 loosely fitted on the pipe or fluid system element 1 to be insulated (shown in cross-section). In the actual installation, the core 2 would be more tightly fit around the pipe 1 . That is, the feet or protuberances 11 of the core 2 will normally be touching the outer surface/diameter of the pipe 1 at many if not all of their adjacent points. FIGS. 5A and 5B show a much tighter wrapping of the jacket 10 .
[0021] [0021]FIG. 5 shows the formed core bonded at a point 9 to one end A to a smooth, flat “exterior” sheet, shell or covering 3 which is also thinner (0.020/0.025 inches) than the typical profile extrusion shown in FIGS. 6,6A. This design allows for the simple “wrapping” of the pipe 1 where the inner end 5 of the sheet 3 is overlapped by the outer end 4 of the sheet creating a longitudinally extending seam and attached to the sheet 3 with tape 6 or other simple bonding process. The tape 6 can be applied between the sheet ends as shown. Tape 6 is a double stick tape that is it has adhesive on both sides of the film carrier. Alternately, an adhesive can be laid on the sheet 3 with a cover film that can be removed during installation. Alternately, a one-sided tape 6 ′, having adhesive on only one side of the film carrier, can be applied to the exterior sheet surfaces to overlapped end portion 4 and the adjacent sheet portion as shown by the dotted line and exploded in FIG. 5.
[0022] This application process is faster than the current “snap” together process. The multiple “still” or “trapped” air spaces are accomplished in much the same way in either design but with the new design the wrap around the pipe could be two revolutions rather than one. The two revolutions could be accomplished by adding a separate core 2 and a separate sheet 3 to form a second jacket 10 ′ on an already installed core and sheet jacket 10 as shown in FIG. 5A. Alternatively, a second wrap and jacket 10 ′ could be accomplished merely by applying a longer core 2 and sheet or covering 3 and wrapping twice and sealing the outer end 4 once by the use of a fastener such as tape 6 ′ shown in dotted lines and exploded in FIG. 5B. The tape 6 ′ can be applied to the exterior sheet surfaces to overlapped end portion 4 and the adjacent sheet portion as shown. This double jacket will provide a greater level of insulation in those areas where extra insulation is required. Of course, more jackets 10 , 10 ′ can be provided than the two disclosed to build more insulation by the use of either design, FIG. 5A or 5 B, or a combination of the designs. That is, three or more jackets can be built by wrapping more times or making three or more separate jackets or a combination of multiple wraps and separate jackets.
[0023] In FIG. 6, an alternate core design is shown in which the “still” air space is designed so that it will automatically compensate for different pipe sizes by having an integral core and sheet element or jacket 20 with flexible hinges 22 and flexible standoffs 24 which flex as necessary to allow for “wrapping” different size piping. In this design, the core is bonded to the smooth outer shell/sheet at every contact point thereby forming the jacket 20 . This figure shows different core configurations in the same figure; however only one configuration need be used. FIG. 6A shows that the jacket 20 can be reversed with the smooth shell/sheet facing inwards. The figure also shows separately some of the core configurations that could be used. Hinges 22 and stand-offs 24 would be added where needed.
[0024] The chart of FIG. 7 gives examples of dimensions of the jacket of FIGS. 1 - 5 for various pipe sizes. The section of the chart under the Insulair TM section refers to the jacket dimensions. AB refers to the length of the core. The length of the sheet or cover 3 is AB plus three inches, for example to allow the sheet to overlap the core. Actual OD is the jacket OD.
[0025] The concepts shown in FIGS. 1 - 5 have the core bonded to the outer sheet/cover ONLY at a first contact point 9 ; all other contact points are not bonded thereby allowing the inner core and outer sheet to slide with respect to each other and thereby compensate for any pipe diameter or even unusual shape such as a water tank or jacketed tank.
[0026] The core geometry as shown in FIG. 4 is only one of many patterns that would be acceptable to accomplish all the desired attributes of the system. As only one example of the many core shapes that are acceptable, FIGS. 5A and 5B show the use of a simple undulating core having the corrugations extending longitudinally along the element or pipe 1 . The corrugations can extend at an angle to the length of the element. The corrugations can even be perpendicular to the length of the element by providing areas which allow portions of the corrugations to flex or to move relative to each other.
[0027] It has been proven that there does not need to be a continuous seal between individual chambers within the core, reduced clearances between core chambers are sufficient to greatly reduce airflow between them and therefore still provide ample insulation. Additionally the size of the “entrapped” air gap or “still” air gap although optimum at approximately ⅜″ is only minimally affected by being formed larger or smaller.
[0028] A “donut” gasket having a cut portion is installed, as disclosed in U.S. Pat. No. 6,000,420, between the jacket ends. The core can be made shorter than the cover by the dimension of the gasket or less so that the gasket will be fully or partially within the cover during installation. For example, the core would be 35⅝ inches and the cover would be 36 inches. The adjacent jackets are sealed to each other by tape which is applied around the ends of the adjacent jackets and over the gasket if it is not full contained within the jacket cover. The gasket can be wholly outside the jackets.
[0029] In another embodiment of the invention, the insulative jacket is used to cover, contain or further insulate an existing insulation system. This embodiment would allow the inventive insulation system to be used on existing systems that may need containment of the materials of the insulation (fibers, etc.), resealing or replacement either now or in the future. The advantage of this design is that it would allow the fibers in the existing insulation to be contained in a very cost effective manner. The cost of removing the fibers of a fiberglass installation would be eliminated. Also, extra insulation would be added to the present/existing insulation. Further, the condition of the system would be visible through any transparent or translucent plastic making up the system or parts thereof. Further each portion of the insulation system can be easily accessed by removing the fastening means, such as tape, at the longitudinal joint formed by the overlap of the sheet outer end 4 and the adjacent sheet portion.
[0030] When using tape 6 as the fastening means, a further seal is not needed at the joint/overlap because the tape can perform both functions. If another non-sealing type of fastener is used at the overlap of end 4 , then a separate seal could be added to overlap area such as by adding an elastomeric material to end 4 on the inside surface. If the tape is provided only to hold an area together which is less than the total area to be sealed then a seal would be needed at least on the non-taped portions of the joint. U.S. Pat. Nos. 5,797,415 and 6,000,240 discuss some of the possible seals.
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The disclosure relates to a plastic jacket having air spaces formed by a core and a cover used to insulate hot and cold piping systems and the fittings for those systems. The jacket is made by providing a core that has portions that extends away from the element and a cover surrounding the core. The insulation value of the jacket is created by the air spaces created by the jacket. The plastic of the cover alone or the cover and core can be transparent or translucent so that the condition of the piping element and the jacketed space can be checked without removing the jacket.
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FIELD OF THE INVENTION
The invention relates to the stable human therapeutic composition for injectable, i.e., intravenous or oral administration, or for topical administration, comprising intact unmodified immunoglobulin A and process of making the same.
BACKGROUND OF THE INVENTION
Of the five major classes of immunoglobulin found in humans, immunoglobulin A (IgA) or secretory immunoglobulin generally is found in serous or mucus fluids Levels of IgA in serum are lower than that of IgG and about twice that of IgM. IgA levels are considerable in the sero-mucous secretion such as saliva, tears, nasal fluids, sweat, colostrum and secretions of the lungs and gastrointestinal tract. It is believed that IgA plays a major role in protecting the exposed epithelium.
It is not uncommon to find IgA in the form of a dimer, joined by a secretory protein which is synthesized by local epithelial cells. Dimers generally comprise antibodies with the same specificity. There are at least two IgA subclasses.
As with the other classes of antibodies, deficiency of IgA can occur transiently, for example in infants when maternal IgA levels wane when breast feeding is discontinued, or permanently, as in the not uncommon occurrence of patients with congenital IgA deficiency. Secretory IgA is known to have a beneficial protective effect on the intestinal mucosa in infants. Stoliar et al., Lancet 1976; i:1258; Williams & Gibbons, Science 1972; 177:697.
Eibl et al. (NEJM 1988; 319:1) found that oral feeding of an IgA-IgG preparation minimized the risk of infants not fed breast milk of contracting necrotizing enterocolitis. The immunoglobulin preparation was made from human serum, Cohn's Fraction II, by ion exchange chromatography. The preparations contained anywhere from 66% to 85% IgA, 15% to 34% IgG and 0.1% to 2% IgM.
Because of the various immunoglobulin deficiencies and the perceived benefits of passively immunizing patients with immunoglobulin deficiency, it is desirable to obtain preparations rich in immunoglobulin, and in particular IgA, for therapeutic uses.
U.S. Pat. No. 4,396,608 teaches a method of preparing an immune serum globulin (IgG) preparation suitable for injection. The method relates generally to preparing IgG rich compositions. A suitable starting material for the process of preparing the IgG rich composition is Cohn's Fraction II or Fraction II plus III. The starting wet paste or powder dissolved in water or physiologic solution is subjected to an acid treatment of about pH 3.5 to 5.0 and thereafter its ionic strength is reduced. All steps are performed at a temperature of 0°-20° C. Protein concentration is adjusted by conventional techniques such as ultrafiltration.
U.S. Pat. No. 4,477,432 relates to an immunoglobulin preparation containing not less than 70% IgG, suitable for oral administration. The immunoglobulin preparation has a pH of about 4-8, is sterile filtered and has a protein concentration of between 5-20%.
U.S. Pat. No. 4,499,073 relates to an immunoglobulin (IgG) preparation prepared by acid treatment wherein the monomer content is greater than about 90%. The starting paste or powder is dissolved in water or physiologic equivalent, the solution is adjusted to a pH of 3.5-5 and the ionic strength is adjusted to a low value.
In view of the apparent advantages of IgA rich preparations for therapeutic purposes it is desirable to have a procedure for obtaining IgA in sufficient quantity, of sufficient purity and suitable for human therapeutic purposes. The above patent references teach methods to obtain immunoglobulin rich preparations in general and those preparations are not necessarily rich in IgA.
Eibl et al., supra, relates to a chromatographic method for preparing an IgA rich preparation.
Skvaril & Brummelova (Coll. Czech. Chem. Comm. 1965; 30:2886) described a method of purifying IgA from the ethanol fraction III of placental serum using zinc salt in combination with ammonium sulphate and gel filtration. Thus, Cohn's Fraction III suspended in cold water was exposed to alumina gel and the eluted protein then was exposed to ammonium sulphate at 40-60% saturation. That cut was removed and dialyzed against water. The remaining proteins were dissolved in acetate buffer. The pass-through from a DEAE-Sephadex separation was obtained and zinc acetate was added to the solution. The precipitate that formed at 4° C. was separated and the supernatant was treated with ammonium sulfate to a concentration of 2.05M. The precipitate was dissolved in water and upon passage through a Sephadex G200 column, fractions containing essentially pure IgA were identified. In vivo studies revealed that the IgA preparations contained trace amounts of IgG but no IgM was noted.
Anderson et al. (J Imm. 1970; 105:146) relates to a one-step isolation of IgA from small volumes of human serum using a bromoacetyl cellulose anti-IgA immunoabsorbent in a batch process. IgA was dissociated from the matrix with acetic acid and then dialyzed against phosphate buffer. The immunoabsorbent, however, is difficult to prepare. The preparations contained from 86% to 98.5% IgA, 0.7% to 11.2% IgG and 0.7% to 5.6% IgM.
Pejaudier et al., (Vox Sang. 1972; 23:165) obtained IgA from Cohn's Fraction III. Several purification schemes were tested. The preferred method comprised extraction of Fraction III with water at pH 5.6, precipitation with caprylic acid in acetate buffer and passage of the supernatant over a DEAE-cellulose matrix with an acetate buffer for elution. The preparations contained trace amounts of IgG and no IgM.
Kondoh et al. (Mol. Imm. 1987; 24:1219) described a procedure for the isolation of human secretory IgA using jacalin lectin. The jacalin was coupled with Sepharose 4B to produce an affinity column. Secreted IgA was obtained from human colostrum. The preparations contained trace amounts of IgM and no IgG.
Thus, it remains desirable to provide a simple procedure for purifying immunoglobulin A in sufficient quantities to produce compositions suitable for therapeutic uses.
SUMMARY OF THE INVENTION
A first object of the invention is to provide a process for producing a human IgA rich preparation.
A second object of the invention is to provide a human IgA rich preparation.
A third object of the invention is to provide a process for producing an IgA rich preparation.
A fourth object of the invention is to provide an IgA rich preparation, preferably at least 50% IgA and of low conductivity.
Those and other objects have been achieved by using an IgA containing composition such as Cohn's Fraction III or Fraction II plus III as a starting material and extracting that starting material with low ionic strength salt solutions such as sodium caprylate or zinc caprylate.
Optionally, the supernatant is passed over an anion exchange matrix, treated to inactivate virus and sterile filtered.
DESCRIPTION OF THE DRAWING
The figure of the Drawing is a flow chart of a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Suitable starting materials are any fluids or fluid concentrates known to contain IgA. A preferred starting material is serum because despite the modest IgA concentration in serum, large quantities of serum can be obtained. The Cohn's Fraction II plus III, and III, pastes of serum are preferred. Preferably, the resultant product of this invention has a plasminogen content testing as less than 0.001 casein unit.
Generally, the Cohn's fractions are obtained as a solid or a paste. The proteins are suspended in a suitable buffer, for example, sodium phosphate (Na 2 HPO 4 ) or a sodium chloride solution. A suitable dilution ratio is 1:9 to 1:20 (w/v). The pH is adjusted to about 7.
The suspension can be clarified by low speed centrifugation.
The solution then is extracted with an amino acid, organic salt or inorganic salt at reduced temperature, for example, from about 2° C. to about 20° C., preferably about 2° to 10° C.
Suitable amino acids include phenylalanine, acetyl tryptophan, histidine, glycine, lysine, tryptophan and arginine.
Suitable inorganic salts include NaCl, KH 2 PO 4 , K 2 HPO 6 , Na 2 HPO 4 , NaH 2 PO 4 , (NH 4 ) 2 SO 4 , Na 2 SO 6 , ZnSO 6 and borate.
Suitable organic salts include sodium acetate, sodium citrate, sodium caprylate and zinc caprylate.
The amino acid, organic or inorganic salt is added to a final concentration of about 0.001 to about 0.020M.
The preferred extractant is a caprylate salt, not caprylic acid, such as the aforementioned sodium caprylate and zinc caprylate.
The precipitate formed is separated from the solution, for example by centrifugation or filtration, yielding an IgA rich supernatant. This precipitation step separates unwanted protein including fibrinogen from IgA.
Optionally, the preparation can be treated to inactivate virus, for example, using a solvent or solvent/detergent process. Preferably, the viral inactivation includes contact with a di- or trialkyl phosphate such as tri-n-butyl phosphate (TNBP) with or without a wetting agent such as a non-ionic surfactant. For example, the solution can be treated with about 0.1 to about 0.5% TNBP and about 1 to about 4% TWEEN or about 1 to about 4% TRITON. The solution generally is incubated at about 10°-30° C. for about 1-6 hours at about pH 5-9. See U.S. Pat. No. 4,540,573 and U.S. Pat. No. 4,481,189.
The detergent where needed can be removed by art-recognized procedures such as by ethanol precipitation (using about a 15-30% concentration of ethanol), polyethyleneglycol (at a concentration of about 4% to about 15%) or absorption onto anion exchangers.
Also, optionally, the supernatant can be passed over an anion exchange matrix. Suitable anion exchangers include DEAE and QAE attached to various matrices. For example, DEAE-Cellulose, DEAE-Sephadex (Pharmacia Co.), DEAE-Sepharose (Pharmacia Co.), DEAE-Cellulofine (Chisso Co.), DEAE-Toyopearl (Toyoroshi Co.), QAE-Sephadex (Pharmacia Co.) and QAE-Sepharose (Pharmacia Co.) are preferred.
The absorption onto an anion exchanger is optional and when used, standard chromatography procedures known in the art are practiced. When both the solvent or solvent/detergent process and the anion exchange treatment are employed, it is preferred that the solvent or solvent/detergent process be carried out prior to the anion exchange treatment.
After removing detergent, the resulting solution can be sterilized by filtration and used (with proper dilution as appropriate) as a liquid IgA product for oral and/or IV administration. Where needed, the liquid product can be lyophilized to provide a dry product for later reconstitution.
The product provided herein, in water, has a conductivity of below 100 Mho, preferably below 50 Mho, that is 20 to 40 Mho, and pH of 5.5 to 10.0, preferably 6 to 9. Also, a topical form can be prepared from the solution or lyophilized IgA products as described hereinbelow.
In another embodiment, immunoglobulins can be obtained from a host that is sensitized to a specific pathogen. Thus, the host can be a patient exposed to the pathogen of interest and who exhibits a suitable immunoglobulin response or a non-human animal that is immunized with the pathogen of interest. In the latter case, the artisan can practice a known method for obtaining immunoglobulins from the animal species or suitably modify the claimed method to maximize the recovery of non-human immunoglobulins and suitably modify the non-human immunoglobulins to minimize immunogenicity of the same in the patient, for example remove the F c portion of the antibodies.
For example, an individual carrying a herpesvirus can serve as a source of herpes-specific IgA. The IgA is purified as described herein and prepared in the form of a topical preparation for direct application to herpes lesions.
The preparation can be suitably diluted with a pharmacologically acceptable diluent to obtain a pharmaceutical composition containing a therapeutically effective amount of IgA that can be administered intravenously, intramuscularly, orally, topically and the like.
The artisan can configure appropriate pharmaceutic compositions containing the IgA rich solution described herein using any of a variety of art-recognized techniques and reagents. For example, to produce a composition suitable for intravenous administration, the IgA rich solution can be mixed with a pharmaceutically acceptable aqueous carrier such as physiologic saline or Ringer's solution. The IgA solution is diluted to a physiologically acceptable level, for example, about a 5% solution.
In another example, the IgA preparation can be administered in a topical form, such as a 1 to 20% IgA (w/w) solution, emulsion, ointment, paste, cream, gel, foam, jelly and the like. Appropriate pharmaceutically acceptable diluents and fillers, binders, lubricants, buffers, preservatives, surfactants, emulsifiers and the like can be incorporated into the final formulation according to art-recognized methods using known materials. Such topical products can be used to treat various infections in humans and other mammals, such as vaginal herpes.
The IgA solution can be made physiologic in pH, approximately 7.2-7.4, and rendered isotonic, approximately 280 milliosmolar immediately prior to use. Pharmaceutically acceptable carriers and excipients can be used in the adjustments and also to provide preservative, handling and other desired features to the solution.
Suitable dosages are derived empirically from, for example, animal studies, clinical trials and other art-recognized foundational experiments. The dosages also will depend on disease severity, patient age, sex and body weight and the like.
Certain aspects of the invention are described in further detail in the following non-limiting examples. Unless noted otherwise, all weight ratios are on a weight/volume ratio.
Example illustrates a preferred sequence employing in order caprylate salt, solvent/detergent treatment and absorption onto an anion exchanger, without the need for removal of detergent by ethanol precipitation, polyethylene glycol precipitation, etc.
EXAMPLE 1
Cohn's fraction III (Fr. III) paste (100 g) was suspended in a Na 2 HPO 4 solution (0.002M, 900 ml). The pH was adjusted to 7.2 ±0.1 with normal (1N) HCl or NaOH and the solution was stirred for 2 hrs. at 4° C. The suspension was centrifuged (5000 rpm, 30 min.) to obtain a clear supernatant. The IgA recovery in the supernatant was 95% of the amount of IgA contained in the original Fr. III paste.
Sodium caprylate (20 g) was added to the supernatant and the mixture was stirred for 20 minutes at 4° C. The pH was adjusted to 6.0 ±0.2 by 0.5N HCl and incubated at 4° to 15° C. for 30 to 60 minutes. The precipitate, which appears after pH adjustment, was removed by centrifugation and the supernatant was collected.
The IgA-rich supernatant was concentrated ten times by ultrafiltration. The resulting concentrate was treated with 1% w/v TWEEN-80 and 0.3% w/v TNBP at 25° C. for 6 hrs. to inactivate viruses which might have remained in the source paste. After the viral inactivation, the solution was treated with DEAE-Sepharose to absorb IgA. The DEAE-Sepharose was washed with 0.005M NaCl solution, pH 7.0, before use. The absorption and subsequent washing and elution were performed in a column. The resin was washed with 0.002M NaCl pH 7.0 and the IgA was eluted from the Sepharose using 2% NaCl. For larger scale production, a batch-wise method for absorption, washing and elution would be useful.
The eluted IgA fraction was dialyzed against 0.2% NaCl solution for 20 hours at 4° C. (the NaCl solution was changed three times during dialysis) to adjust salt concentration, pH adjusted to 6 to 8, and lyophilized under sterile conditions. The recovery of IgA was 60% as determined by single radial immunodiffusion method. The percentages of IgA, IgG and other proteins in the final preparation, having a pH of 6 to 8 and low conductivity provided by a 0.2% NaCl content, were 55, 40 and 5%, respectively.
Instead of the dialysis method, salt concentration can be adjusted by employing other conventional techniques such as an ultrafiltration (UF) membrane (available from Amicon, Millipore, etc.)
EXAMPLE 2
Fraction II plus III (Fr. II+III) paste (1 kg) was suspended in a cold (4°-10° C.) NaCl solution (0.001M, 9 l) and stirred to obtain complete dissolution. Sodium caprylate (250 g) was added to the suspension and the pH was adjusted to 6.0 with 1N NaOH or HCl. Following incubation at 10° C., the resulting precipitate was removed by centrifugation (5000 rpm×30 min.).
The IgA recovery of the centrifuged supernatant was 90% of that contained in the original paste.
TWEEN-80 (1%) and TNBP (0.3%) were added to the supernatant. The pH was adjusted to 7.0-8.0 with 1N NaOH or HCL and the solution was incubated at 25° C. for 6 hrs.
After the incubation, polyethylene glycol #4000 (PEG) was added to the solution (final concentration of 6% w/v) and the clear supernatant was collected following centrifugation (5000 rpm×30 min.). PEG was added to the supernatant (final concentration of 15%) and the precipitate (IgA-rich fraction) was collected. The precipitate was washed with the 15% PEG solution several times to assure complete removal of the detergents.
The IgA rich fraction was dissolved in sterile water and lyophilized under sterile conditions.
The final-recovery of IgA was 65%. The percentages of IgA, IgG and other proteins in the final preparation, having a pH of 6 to 7, were 65, 30 and 5%, respectively.
EXAMPLE 3
Fr. II+III paste (1 kg) was suspended in cold NaCl as in Example 2. The pH was adjusted to 7.0-7.2 with N-NaCl or HCl and insoluble particles were removed by filtration using CTX10C filter pad available from KUNO.
Sodium caprylate (150 g) was added to the filtrate, the pH was adjusted to 6.0 with N-HCl and the precipitate was removed by filtration.
The protein concentration was adjusted to 3-5% and then TWEEN-80 (1% w/v) and TNBP (0.3% w/v) were added to the solution. The pH was adjusted to 7.0 with N-NaOH and the solution was incubated at 25° C. for 6 hrs.
DEAE-Sephadex, conditioned with 0.005 mM NaCl, pH 7.0, was added to the solution. More than 80% of IgA was absorbed to the Sephadex resin. The resin was washed several times with 0.005M NaCl buffer to remove TWEEN-80, TNBP and impurity proteins. The IgA was eluted using 100 mM NaCl. The eluate (IgA-rich solution) was concentrated to a 5% solution by UF membrane and the ionic strength also adjusted to lower than 100 mM NaCl.
After sterile filtration and lyophilization, the IgA product, having a pH of about 6.0, was found to be non-pyrogenic in the rabbit (100 mg/Kg rabbit).
The IgA-rich products of the above examples can be used to formulate compositions in aqueous medium containing human IgA 40-90% w/v, human IgG 0-60% w/v and human IgM 0-5% w/v, with conductivity and pH ranges as above disclosed of less than 100 mM, and pH of 5.5 to 10.0.
The Figure of the Drawing depicts a schematic flow chart of a preferred method of the present invention. The Cohn's Fr. II plus III or Fr. III paste is suspended in 0.005M NaCl at 1 Kg paste per 14 Kg of salt solution. pH is adjusted to 6.9 to 7.1 and the suspension stirred for about 2 hours at 4° C. Then, the suspension is centrifuged to obtain a clean supernatant. Sodium caprylate is added to the supernatant in a concentration of 2% (w/v) with stirring for 1 hour at 10° C. pH is adjusted to 6.0 with HCl, while the solution is held at 4° to 15° C. A precipitate appears which is removed by centrifugation. The supernatant is treated for virus inactivation using a solvent/detergent process at 25° C. for 6 hours. Next, the IgA is absorbed on DEAE-Sephadex A50 previously washed with 0.005M NaCl solution of pH 7.0. The Sephadex is washed with additional 0.005M NaCl solution of pH 7.0. Thereafter, the IgA is eluted by 0.10M NaCl solution of pH 6 to 7, and is concentrated and desalted by ultrafiltration followed by adjustment of protein content to 5% w/v and NaCl content to 0.5% w/v. After sterile filtration, the resultant solution can be used as a liquid product, lyophilized to a dry powder or employed in the preparation of a topical medicament.
EXAMPLE 4
To determine the efficacy of virus inactivation and elimination, the following was conducted. Five viruses were added individually prior to the following noted steps of the IgA purification procedure and virus potency was tested before and after each step.
The five viruses were, Vesicular stomatitis (VSV), chikungunya (CHV), sindbis (SV), Echo and human immunodeficiency-1 (HIV-1). The viruses were added at 10 5 -10 7 units prior to the following steps and testing carried out as described in Uemura, et al., Vox Sano 56:155 (1989).
______________________________________1st step: Fr. II plus III suspension in 0.005M NaCl2nd step: Extract before caprylate treatment3rd step: TWEEN-80 and TNBP treatment4th step: PEG 6% fractionation5th step: Lyophilization______________________________________
Before and after the purification steps, virus potencies (remaining virus antigen or remaining infectious potency) were tested. The inactivation (or elimination) rates were >10 5 at each step for each tested virus.
______________________________________Virus inactivation and elimination during the purification process.Purification Step HIV-1 VSV CHV SV Echo______________________________________1st Fr. II + III >10.sup.5 >10.sup.5 >10.sup.5 >10.sup.5 >10.sup.5extraction2nd Caprylate >10.sup.5 >10.sup.5 >10.sup.5 >10.sup.5 >10.sup.5precipitation3rd SD treatment >10.sup.5 >10.sup.5 >10.sup.5 >10.sup.5 NT4th PEG 6% >10.sup.5 >10.sup.5 >10.sup.5 >10.sup.5 >10.sup.55th Lyphilization NT NT NT NT >10.sup.5Accumulated >10.sup.20 >10.sup.20 >10.sup.20 >10.sup.20 >10.sup.20inactivation rate______________________________________ NT: Not tested.
The artisan will appreciate that the methods and compositions of the instant invention are capable of being incorporated in the form of a variety of embodiments, only a few of which have been illustrated and described herein. The artisan will appreciate that various changes can be made to the invention without departing from the spirit and essential characteristics thereof. The scope of the invention is to be determined by the claims attached hereto.
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A method of preparing an IgA rich preparation comprising exposing a plasma fraction to an amino acid, organic salt or inorganic salt with optional chromatographic treatment yielding a product suitable for use in medical conditions treatable with IgA.
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BACKGROUND
In recent years, much effort has been applied to developing the structure and application of nanogenerators. Nanogenerators, of which there are several categories, harvest mechanical energy in the environment, and accordingly have provided new power sources for devices. However, current nanogenerators tend to be small scale (less than XXXX inches squared per unit), even though fabricating large scale units should theoretically reduce costs and increase overall output. Accordingly, this invention seeks to provide a method of fabricating larger scale nanogenerators.
SUMMARY
Aspects of the present invention include: a method of fabricating a large-scale triboelectric nano-generator, a method of fabricating a large scale piezoelectric nanogenerator, and a method of placing either or both kinds of nano-generators in a single housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 features a graphic flowchart of one or more embodiments.
FIG. 2 features illustrations of one or more steps.
DETAILED DESCRIPTION
In one embodiment, the device comprises a triboelectric nano-generator or TENG. An exemplary fabrication of a large-scale TENG is as follows.
See FIG. 1 . Provide a first tile 2 of any size, preferably one foot by one foot, made of any smooth, hard, insulating material, preferably ceramic or rubber. A first sheet of foil 1 , made of any suitable conductive material, preferably aluminum, is placed on top of the first tile. Gold and copper sheets may also suffice. While any suitable technique of attaching or adhering 4 the tile to the foil are acceptable, the ideal is to provide as much contact area between the substrates while permitting a degree of vertical motion, perhaps 1 mm-cm, between them. Also, the smooth contour of the foil should be preserved. Accordingly, the use of double-sided tape 3 , laid out in an “X” formation from corner to corner, serves as an exceedingly inexpensive, simple technique. Another technique involves the application of KAPTON tape, preferably 400 microns thick, to the outer edges.
Ideally, air bubbles between the first tile and first sheet of foil should be removed. This can be done by pressing out the air bubbles, although this must be done gently so as not to tear the first sheet of foil. Placing the first tile and first sheet of foil in a vacuum chamber or using a vacuum pump may be a superior technique because it does not apply a contact force. 2 CFM pumps are preferable, although 1 CFM pumps may also suffice. A reasonable vacuum time frame ranges from ten to fourty minutes, with thirty minutes being ideal, and pressed so as to remove any air bubbles. A 200-300 micron thick adhesive layer 4 , preferably KAPTON Tape, a polyimide tape or any suitable insulating material having a tolerance for high temperatures, is placed along the edges of the first sheet of foil such that it forms a ⅓ inch border.
A first amount of polymer, preferably polydimethylsiloxane (PDMS), is cured with a curing agent in a ratio preferably between ten to one and five to one, mixed for ten minutes continuously, although longer mixing times may be appropriate if more than ten grams of polymer is used. A good rule of thumb is to continue mixing until the polymer resists mixing. The polymer is then set aside for five minutes or until it is clear, although setting it aside for a longer time, even up to an hour, will permit the polymer to more fully harden.
The cured polymer is placed into a vacuum chamber for at least forty five minutes, preferably an hour, up to two hours. Then the cured polymer 5 is added to the first sheet of foil using a pipette or similar instrument. The cured polymer is spread across the surface of the first sheet of foil 1 thoroughly, and in between the border made by the adhesive layer, such that the thickness of the polymer approximates the thickness of the adhesive layer. A rod or similar instrument, even a razor blade, may be helpful in both spreading the polymer and removing excess polymer, using the adhesive layer thickness as a guide.
Spreading the polymer onto the foil likely results in air bubbles 6 disposed between them. These air bubbles should be removed 7 . For a less than four inches in width, the tile should be placed in a vacuum chamber for at least half an hour, although 45 minutes is ideal. For a tile of four to eight inches in width, the tile should be placed in a vacuum chamber for at least 45 minutes, although an hour is ideal. For a tile larger than eight inches, the minimum time spent in the vacuum chamber should be an hour and a half, although two hours is ideal.
After the air bubbles are substantially removed, the tile should be cooked 8 at 120 degrees for sixteen hours. It is left to cool for an hour at room temperature.
A second sheet of foil 9 is applied to a second tile 10 , by means of an adhesive 11 , as described above. Then a 1 cm by 1 cm square 12 is removed from the first amount of cured polymer on the first tile. A wire 13 , preferably a single core magnetic wire, is connected to the exposed end of the first sheet foil, and insulated using any suitable adhesive material. An identical wire is then attached to the second sheet of foil on the second tile and again insulated using any suitable material.
In one embodiment, the device comprises a piezoelectric nano-generator or PENG. An exemplary fabrication of a large-scale PENG is similar to the exemplary fabrication of TENG, above, except instead of a layer of cured polymer, a layer of ZnO crystals is applied in the following manner:
ZnO crystals, preferably a half a gram to a gram, is mixed with deionized water, preferably a Liter, for at least five minutes or until the ZnO crystals are dissolved. A layer of ZnO, between one and one hundred microns thick, but preferably five microns, is applied 5 to the surface of the first sheet of foil 1 , in a PVD setting. The first tile 3 is cooled for an hour, and then placed on the surface of the mixture of deionized water and dissolved ZnO crystals. The first tile should not be permitted to sink. The first tile and mixture should then be covered and sealed, and heated at 95 degrees C. for approximately 12 hours. Then the first tile should be washed with deionized water without it being submerged. Afterwards, the first tile should be left to cool for an hour under a hood. Then it should be heated at 100 degrees C. A layer of PMMA, preferably 50-100 microns thick, should be applied to the first sheet of foil. Again, a border of Kapton or polyimide tape provides a useful guide.
In one embodiment, one or more NGs 26 27 (TENGs and/or PENGs) can be utilized concurrently in the same device provided that they are adequately insulated from one another. Any suitable insulating material 28 will work, although a layer of rubber of a ¼ inch thickness is preferable. The one or more NGs can be placed in parallel or in series.
In one embodiment, the device comprises a Housing 20 . An exemplary housing comprises a first article of durable material 21 , such as plywood, cut to preferably one foot by one foot and possessing a half inch thickness. The first article of durable material comprises a recess 22 in the center, preferably eight inches by eight inches by a quarter of an inch, so as to receive either a TENG 26 and/or a PENG 27 . A second article 23 of durable material is disposed on top so that the TENG or PENG is situated between the first and second article of durable material. A platform 24 , or third article of durable material, preferably carpet, asphalt, or any such material appropriate for foot traffic, is placed on top of the second article of durable material opposite the first article of durable material. In one embodiment, the third article of durable material may be embedded with LEDs 25 . In this embodiment, when a person steps on the third article of durable material, the LEDs light up.
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A method of fabricating a large-scale triboelectric nano-generator by adhering foil to two separate plates, laying polymer to the foil, heating the plates, and then electrically coupling one of the plates.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to telephone switching equipment and, more partiucularly, to equipment for protecting against inadvertent interruption of a circuit line at a telephone switching station.
2. Description of the Prior Art
In a telephone switching station, a plurality of panels (sometimes referred to as a DSX panel) are employed for providing access to each circuit routed through the station. Each such panel includes a status light, a monitor jack, a line out jack and a line in jack for each circuit routed to it. These components are vertically aligned in the panel. The light provides a visual indication of the status of the circuit. The monitor jack permits monitoring a transmission in progress on the circuit without interruption of the transmission. The line in jack and line out jack permit rerouting of the circuit and necessarily interrupt any transmission ongoing upon insertion of a plug into one of these two jacks.
Presently, computers and various other electronic signal handling devices communicate via telephone lines. An interruption during such transmission will usually garble the information transmitted and the informational content of the transmission will be lost with a potential serious detriment to the user. When only a telephone conversation is ongoing, the momentary interruption is usually, at worst, a minor irritation. Because of the potential consequences attendant loss of data as a result of an interruption, telephone maintenance and service personnel at telephone switching stations must be very careful not to cause an interruption of communications by inadvertent or mistaken insertion of a plug into a live out jack or live in jack. Despite careful attention, errors do occur and transmissions are lost during the normal course of performing maintenance and service functions.
To prevent access to a circuit at a DSX panel, a piece of tape or other barrier has been placed across the three jacks and light or at least the two critical jacks of a circuit in service. Such barrier would require removal thereof to perform maintenance or service functions upon the circuit. Once the barrier is removed, it may be inadvertently misplaced or simply not replaced due to forgetfulness. Further, if the light is covered, the informational content provided thereby is lost and if the monitor jack is covered, normal monitoring functions would require removal of the barrier.
SUMMARY OF THE INVENTION
The present invention is directed to a protection device usable at a DSX type panel for preventing inadvertent or mistaken line interruption of an active circuit while accommodating line monitoring and visual determination of the status of the line. A pivotable plate of the device requires positive manipulation to provide access before interruption of the line can be effected which positive act will reduce inadvertent interruption. The pivotable plate remains attached to the panel to preclude loss or misplacement.
It is therefore a primary object of the present invention to provide a protection device for preventing inadvertent interruption of a circuit routed to a DSX panel or the like.
Another object of the present invention is to provide a detachably attachable protection device for securing a circuit which is not to interrupted.
Yet another object of the present invention is to provide a protection device for accommodating visual review of the status of a circuit and monitoring of the circuit without interrupting the circuit.
Still another object of the present invention is to provide a protection device for simultaneously protecting each of a plurality of circuits against inadvertent interruption while accommodating access to any one of the protected circuits.
A further object of the present invention is to provide an inexpensive protection device for preventing interruption of a circuit routed to a DSX panel or the like.
A yet further object of the present invention is to provide a method for providing protected access to a circuit routed to a DSX panel.
A still further object of the present invention is to provide a method for accommodating non-invasive telephone line monitoring line functions while precluding interruption of a circuit routed to a DSX panel or the like.
These and other objects of the present invention will become apparent to those skilled in the art as the description thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with greater specificity and clarity with reference to the followign figures, in which:
FIG. 1 illustrates a partial view of a conventional DSX panel used in many telephone switching stations having the present invention mounted thereon;
FIG. 2 is a front view of the present invention;
FIG. 3 is a side view of the present invention;
FIG. 4 is a rear view of the present invention;
FIG. 5 illustrates a variant of a conventional DSX panel having a variant of the present invention mounted thereon;
FIG. 6 is a rear view of the variant of the present invention;
FIG. 7 illustrates an alternative means for attaching the present invention or the variant thereof;
FIG. 8 illustrates a functional variation of the present invention; and
FIG. 9 is a side view taken along lines 9--9, as shown in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A typical DSX panel 10 is illustrated in FIG. 1. Such panels are employed by the hundreds in a telephone switching station. Previously and presently widely used DSX panels have 25 to 50 circuits routed to each and each circuit may include 24 telephone lines. Recently developed variants of such panels are of smaller size in both width and length with 10 circuits routed thereto. Typically, for each circuit routed to a DSX panel or the like, four functions are available. A light 12 provides a visually perceivable indication of the status of the associated circuit. A monitor jack 14 permits, through insertion of a plug, monitoring of the communication being transmitted through a telephone line without interrupting the flow of communication or data. An output jack 16 and an input jack 18 accommodate, through insertion of plugs, rerouting of the circuit through or to other equipment; furthermore, signal generating and test equipment may be connected for testing and other purposes. Any insertion of a plug into either of jacks 16 or 18 usually results in interruption of the circuit. Variations in the size and/or configuration of the various jacks exist.
Presently, substantial data is transmitted through telephone lines between signal transmitting and signal receiving equipment. Moreover, emergency telephone systems, such as the 911 calls, include automated data transmissions. Generally, any interruption of a telephone line during transmission of data, will include either a loss of data or a garbling of subsequently transmitted data due to an out of syn condition between the source and recipient of the data transmission. Where a data loss occurs due to interruption of a 911 telephone call, substantial loss of property or loss of life may result. It is therefore evident that protection against inadvertent interruption of a circuit through insertion of a plug into either of jacks 16 or 18 must be guarded against.
This problem is not new and various crude solutions have been entertained and used. These solutions include the placing of adhesive tape across at least jacks 16 and 18 of critical circuits. Often, technicians may place the tape in a column across the light and monitor, output and input jacks of each circuit of critical interest. This latter procedure will preclude monitoring of the line through insertion of a plug in jack 14 and visually inspecting light 12. If access to jack 16 and 18 are needed, the tape is usually ripped off; after such removal, an operator may inadvertently or mistakenly place a plug in a jack adjacent to the circuit of interest. A less crude shield in the form of a strip of plastic, wood, cardboard, or the like has been taped across circuits which are critical. Again, protection is provided by such shields but problems may arise on removal of the shield.
Referring jointly to FIGS. 1, 2, 3 and 4, a protection device or protector 30 for use in conjunction with a circuit routed to a DSX panel 10, or the like, will be described in detail. The protector is configured in plan form to be superimposed upon the light and jacks associated with a circuit routed to a DSX panel or the like; in the presently known configurations of DSX type panels, these lights and jacks are vertically aligned. Furthermore, protector 30 is of a narrow enough width to permit the use of other protectors with adjacent circuits without creating functional interference therebetween, as illustrated in FIG. 1.
A first plate 32 is secured to a DSX panel 10, or the like, by a layer of adhesive 34. This adhesive may be of the type known as an acrylic film manufactured by the 3M Company, Product No. 950; which particular adhesive has a thickness of 5 mils. The first plate includes aperture 36 cooperates with light 12 on the DSX panel to accommodate continuous visual access to the light. A second aperture 38 is aligned with jack 14 to accommodate insertion of a plug into the monitoring jack. From the abvoe description, it becomes evident that first plate 32 is adhesively attached to the DSX panel about light 12 and jack 14 without impeding or interfering with access thereto by service or maintenance personnel.
A second plate 40 is pivotally attached to the first plate by a hinge 42. A dummy plug 44 of dielectric material extends from side 46 of the second plate for frictional engagement with one of jacks 16 or 18. In the presently considered preferred embodiment, dummy plug 44 is pentrably associated with jack 18. The dummy plug serves a function of maintaining second plate 40 adjacent to and parallel with the DSX panel. The second plate serves as a shield or guard to preclude access to either of output jack 16 or input jack 18 and thereby precludes inadvertent interruption of any ongoing transmission on the associated circuit.
Because access to output jack 16 and input jack 18 must be provided from time to time for service, maintenance or rerouting purposes, a pull tab 48 extends from side 50 of second plate 40. By pulling upon this tab, after installation of protector 30, the second plate will pivot about hinge 42 to disengage dummy plug 44 from the associated jack. Thereafter, access to either of the output or input jacks becomes available. Depending upon the nature of hinge 42, the second plate may tend to stay at or close to the position to which it was pivoted or it may tend to pivot downwardly in response to the force of gravity. After the work associated with either or both of the output and input jacks is completed, second plate 40 is manually pivoted downwardly to bring about engagement of dummy plug 44 with the associated jack to secure the second plate in a position adjacent the surface of the DSX panel.
From the above description several features of the present invention will be readily apparent. First, continous visual access to light 12 and physical access to monitor jack 14 is provided. Second, a deliberate physical manipulation must be performed to uncover the output and input jacks before interruption of the associated circuit can occur. Third, the output and input jacks are effectively electrically shielded when the second plate of protector 30 is in place. Fourth, uncovering of the output and input jacks will result in pivotal movement of the second plate which repositioning provides a clear indication to personnel of the identity of the circuit upon which work is being performed. Fifth, the protector will not be lost or misplaced during work performed on the associated circuit.
By adding a label 52 to side 50, symbology or indicia identifying the particular circuit can be added. Moreover, such label can contain information vital to the circuit or work to be performed thereon. By having label 52 removable or the surface thereof erasable, the symbology or indicia can be changed at will. Referring to FIG. 5, there is illustrated a recently developed configuration for a panel 60 of the DSX type. For each circuit routed thereto, it includes a light 62, a monitor jack 64, an output jack 66 and an input jack 68. All three jacks, as illustrated, are T-shaped in cross section rather than the more widely used circular cross section jacks.
Referring jointly to FIGS. 5 and 6, there is illustrated a protector 80 for use in conjunction with panel 60 to prevent inadvertent electrical contact with output jack 66 or input jack 68. Protector 80 is very similar to protector 30 illustrated in FIG. 1 and with respect to common features therebetween, similar reference numerals will be used. First plate 32 includes an aperture 36 for providing continuous visual access to light 62. Aperture 82 is T-shaped to accommodate a plug associated with monitor jack 64 in order to permit insertion of the plug into the jack without removal of protector 80. Second plate 40 is attached to the first plate through hinge 42. A tab 48 permits ready pivotal manipulation of the second plate about the hinge line. A dummy plug 84 is in the nature of a flange or tab configured to fictionally engage the base portion of T-shaped jack 68. Dummy plug 84 serves the same purpose of dummy plug 44 which is that of retaining second plate 40 adjacent panel 60 when the output and input jacks are to remain shielded. It also accommodates access to these jacks by readily disengaging and subsequently reengaging with jack 68.
In FIG. 7 there is illustrated a variant 90 of protector 80. In variant 90 hinge 42 has been eliminated. This variant includes a further plate 92 pivotally connected to the upper end of shield 94 through a hinge 96 to permit pivotal movement in one, the other or both directions; the direction of pivotal movement is a function of the location of the surface to which plate 92 is attached. Double stick foam tape or a layer of adhesive 98 secures side 100 of plate 92 to a horizonatal or other surface of panel 60. Variant 90 includes aperture 102 for maintaining visual access to light 62 and aperture 104 for maintaining continuous access to monitor jack 64. Dummy plug 106, which may be tab like in configuration, frictionally engages input jack 68 to retain protector 90 in place. A pull tab 48 is included to facilitate deliberate pivotal movement of the shield. It is to be understood that hinge 96 and plate 92 could be adapted for use with protector 30.
Referring to FIGS. 8 and 9, there is shown a protector 110 for use in conjunction with a full DSX type panel while still providing individual access to each line routed to the DSX type panel. The protector includes a first plate 112 having a plurality of apertures 114 sized and spaced to accommodate each of the lights associated with each telephone line at the DSX panel. A further plurality of apertures 116 are formed in first plate 112 to cooperate with and accommodate in configuration the monitor jacks of the associated DSX type panel. A plurality of slits 118 delineate adjacent parallel second plates 120 where each second plate shields an associated pair of output and input jacks corresponding with the vertically aligned ones of the light and monitor jack. Each of second plates 120 is pivotally connected to first plate 112 by a hinge 122, which hinge may be of the type illustrated in FIGS. 1, 2, 3 and 4. A pull tab 124, like pull tab 48, extends outwardly from each of the second plates to permit individual pivotal movement of the associated second plate. Each second plate 120 includes a dummy plug 126 for frictional engagement with one of the underlying output or input jacks of the associated DSX panel. A label 128 for having indicia placed thereupon to identify the underlying circuit may be incorporated in or affixed to one or more of second plates 120.
Protector 110 is particularly useful where most or all of the circuits associated with a DSX type panel must be protected against interruption. To accommodate such permanent or semi-permanent installation, protector 110 may be attached, via first plate 112, by a film of adhesive 130, as described above, or by more permanent attachment means, such as machine screws, rivets or the like.
The configuration of any one of protectors 30, 80, 90, 110 is readily formable from any one of many well known man made plastics by conventional well known techniques. Depending upon the plastic material selected, the hinge interconnecting the first and second plate of each protector may be of the type known in the plastics art as a living hinge. By using such a hinge, the complete protector can be manufactured as a one piece unit at substantial savings in manufacturing and assembly costs. Because most man made plastics suitable for fabrication of the protector are relatively inexpensive and as the manufacturing techniques permit mass production at a low per unit cost, every one of the protectors described above is relatively inexpensive to manufacture. This cost aspect becomes of substantial significance when one considers that at each telephone switching station, there may be hundreds or thousands of circuits with which a protector could and should be used. Thus, the costs for providing an essentially fool proof protection against inadvertent or mistaken interruption of a transmission is very low.
It is to be understood that the adhesive (34,130) associated with plates 32 and 112 could be replaced by a dummy plug extending from the plate into engagement with the monitor jack (38, 82, 116). In such event, plates 32 and 112 would be pivoted downwardly to permit and retain access to the monitor jack while the respective remaining plate 40, 120 would retain the protector (30, 80, 100) attached to the DSX type panel through its dummy plug. Moreover, in certain applications, plates 32 and 112 would be configured so as not to surround or otherwise be associated with the respective light of the DSX type panel.
While the principles of the invention have now been made clear in an illustrative embodiment, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, elements, materials, and components, used in the practice of the invention which are particularly adapted for specific environments and operating requirements without departing from those principles.
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A detachably attachable protection device for use with a circuit routed to a DSX panel or the like in a telephone switching station includes a fixed plate having apertures for visual access to a light associated with the circuit, an aperture for access to a monitor jack and a pivotable plate connected to the fixed plate for selectively providing access to jacks for rerouting the circuit. The lift tab may be incorporated to assist in positioning the pivotable plate. In a variant protection device, a plurality of pivotable plates secured to a common fixed plate may be employed to individually protect all circuits routed to a DSX panel.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from German Application DE 198 33 853.8, filed Jul. 28, 1998, which disclosure is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of producing enantiomer-enriched amino acids and amino-acid derivatives of the general formula (I) or acid addition salts thereof ##STR3## in which *=center of asymmetry
X=O or NH
R 1 =H, (C 1 -C 6 ) alkyl, benzyl or (C 3 -C 6 ) alkoxycarbonylmethyl and
R 2 =H or (C 1 -C 6 ) alkyl, which can be interrupted or substituted with heteroatoms such as N, P, O, S or Si, which heteroatoms can be substituted themselves singly or multiply with linear or branched (C 1 -C 3 ) alkyl, (C 2 -C 6 ) alkenyl, (C 1 -C 6 ) haloalkyl, halogen, aryl, such as naphthyl or phenyl, which can be substituted singly or multiply with (C 1 -C 3 ) alkyl, hydroxy, halogen or (C 1 -C 3 ) alkoxy, aralkyl such as 2-naphthylmethyl or benzyl or 1,1- or 1,2-phenethyl, which for its part can be substituted singly or multiply with (C 1 -C 3 ) alkyl, hydroxy, halogen or (C 1 -C 3 ) alkoxy, heteroaralkyl such as N-protected 3-indolylmethyl, and
R 3 signifies H or OH,
from enantiomer-enriched nitrons of the general formula (II) ##STR4## in which * and R 1 have the significance indicated above.
2. Background Information
Enantiomer-enriched amino acids and amino-acid derivatives are important substances in the organic synthesis of peptides and peptide-mimetic substances which are used in drugs and biologically active substances. Thus, the optically active tert.-leucine methylamide which can be produced according to the method of the invention is required in the synthesis for producing a matrix metalloproteinase inhibitor which is currently being investigated in the clinical phase for the combating of tumors (J. Med. Chem. 1998, 41, 1209-1217).
WO 97/10203 teaches a method for the addition of nucleophiles onto nitrons of the general formula (II). However, the known method is based on the use of strong bases such as alkyl metal compounds. One is therefore limited to the use of dehydrated solvents and working under inert atmosphere protective gas as well as the exclusion of any traces of water during the reaction. Such methods are difficult to carry out on an industrial scale.
A method for the addition of radical compounds to derivatives of the general formula (II) is likewise mentioned in WO 97/10203. The reaction of the derivatives (II) with a carboxylic acid in the presence of a radical starter in various solvents under the exclusion of oxygen was described there. However, under the selected conditions α-substituted nitrons are recovered after the reaction without the actually desired asymmetry on the α-C atom of the amino-acid structural element.
According to Iwamura et al. (Bull. Chem. Soc. Jpn. 1970, 43, 856-860) 1,3 addition products or nitroxides or substituted nitrons are obtained in the reaction of nitrons with radicals. In certain instances the substituted nitroxide disproportionates in nitron and hydroxylamine (Iwamura et al., Bull. Chem. Soc. Jpn. 1967, 40, 703). The products were not isolated; however, this mechanism permits a yield of only a maximum of 50% of the desired compound. 50% of the product compounds accumulate as waste, which is considered from the industrial standpoint as a not very logical product variant.
All previously described method variants for the addition of compounds to nitrons of the formulas (II) (see WO 97/10203) have the disadvantages that they supply only moderate yields, especially in the case of bulky amino acids, and in some instances require a complicated conduction of the reaction (metallo-organic reagents, exclusion of water,e purification, etc.).
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of producing enantiomer-enriched amino acids and amino-acid derivatives under radical conditions starting with the nitrons (II) with the obtention of a stereogenic center located on the α-C atom of the amino-acid structural element.
The term "under radical conditions" denotes in the framework of the invention a reaction in which at least one of the reactants has a radical nature.
This and other problems not cited in detail but which result nevertheless from the state of the art in an obvious manner are solved by a method wherein a nitron of the general formula (II) is reacted with a hydrazine derivative of the general formula (III) ##STR5## in which R 2 has the meaning indicated above, in a solvent in the presence of a radical starter or under electrochemical conditions to diastereomer-enriched compounds of the general formula (IV) ##STR6## in which R 1 and R 2 have the meanings indicated above and R 3 =OH, the product is subsequently hydrolyzed or first reduced to compounds of the general formula (IV), in which R 1 and R 2 have the meanings indicated above and R 3 =H, and then hydrolyzed.
As a result of the fact that for the production of enantiomer-enriched amino acids and amino-acid derivatives of the general formula (I) or acid addition salts thereof ##STR7## in which *=center of asymmetry
X=O or NH
R 1 =H, (C 1 -C 6 ) alkyl, benzyl or (C 3 -C 6 ) alkoxycarbonylmethyl and
R=H or (C 1 -C 6 ) alkyl, which can be interrupted or substituted with heteroatoms such as N, P, O, S or Si, which heteroatoms can be substituted themselves singly or multiply with (C 1 -C 3 ) alkyl, (C 2 -C 6 ) alkenyl, (C 1 -C 6 ) haloalkyl, halogen, aryl, such as naphthyl or phenyl, which can be substituted singly or multiply with (C 1 -C 3 ) alkyl, hydroxy, halogen or (C 1 -C 3 ) alkoxy, aralkyl such as 2-naphthylmethyl or benzyl or 1,1- or 1,2- phenethyl, which for its part can be substituted singly or multiply with (C 1 -C 3 ) alkyl, hydroxy, halogen or (C 1 -C 3 ) alkoxy, heteroaralkyl such as N-protected 3-indolylmethyl, and R 3 signifies H or OH,
diastereomer-enriched nitrons of the general formula (II) ##STR8## in which * and R 1 have the meanings indicated above are reacted in such a manner that the nitron of the general formula (II) is reacted with a hydrazine derivative of the general formula (III) ##STR9## in which R 2 has the meaning indicated above, in a solvent in the presence of a radical starter or under electrochemical conditions to compounds of the general formula (IV) ##STR10## in which R 1 and R 2 have the meanings indicated above and R 3 =OH, the product is subsequently hydrolyzed or first reduced to compounds of the general formula (IV), in which R 1 and R 2 have the meanings indicated above and R 3 =H, and then hydrolyzed, the desired compounds are obtained in a quite extraordinarily simple and elegant manner.
The electrochemical generation of radicals from compounds of type III can take place according to methods known to the expert in the art (e.g.: F. Beck, Electroorg. [-anische] Chemie 1974, VCH-Verlag; T. Shono, Electroorganic Synthesis, 1991, Academic Press; T. Shono, Electroorganic Chemistry as a New Tool in Organic Synthesis 1984, Springer Verlag). Carbon as well as metals such as silver and platinum can be considered as electrode material. Carboxylic acid esters and alcohols, preferably acetic ester and methanol, as well as mixtures of these can be used as solvent.
The radical addition can take place at temperatures between -78° C. and 150° C., preferably -20° C. to 100° C., and especially preferably at -10° C. to 50° C. The reaction is monitored by thin-layer or gas chromatography. The end of the reaction can also be observed from the subsiding development of gas.
This reaction can be carried out in an organic solvent such as a halogenated hydrocarbon like methylene chloride, trichloromethane or dichloroethane, in esters such as acetic ester, ethers such as diethylether, MtBE, THF, dioxane, or alcohols such as methanol, ethanol, propanol, isopropanol, n-, sec-, iso-, tert.-butanol as well as in an inert, aromatic hydrocarbon such as benzene, toluene, xylene, chlorobenzene, nitrobenzene, optionally in the presence of water.
The use of a two-phase system of toluene and water is especially preferred.
In principle, all derivatives which can be considered as radical starters and are known to the expert in the art can be used for that purpose. Common radical starters are, e.g., lead dioxide, sodium- or potassium peroxodisulfate, iron(III) salts, sodium nitrite, hydrogen peroxide, sodium periodate, sodium hypochlorite, sodium perborate, sodium percarbonate or meta-chloroperbenzoic acid (see also Houben-Weyl, "Methoden der Organischen Chemie" ["Methods of Organic Chemistry"], vol. E19a, part 1, pp. 140ff, as well as part 2, e.g., pp. 1201ff; vol. E16a, pp. 805ff; vol. X/2, pp. 68ff, E. J. Corey; A. W. Gross, J. Org. Chem. 1985, 50 5391).
The use of oxidizing agents such as sodium- or potassium peroxodisulfate, sodium percarbonate or sodium perborate is especially preferred.
The reduction of the hydroxylamines (IV) with R 3 =OH to the corresponding amines with R 3 =H can take place in a known manner (Houben-Weyl, vol. 11/1, pp. 341ff). Organic acids such as, for example, acetic acids, inorganic acids such as, for example, HCl, or organic solvents such as acetonitrile, alcohols, ethers, esters, hydrocarbons, CS 2 can be used as solvents as a function of the reduction method used. The reaction temperature is between -20° C. and +120° C., preferably between +20° C. and +60° C. The addition of the reducing agent can take place in hyperstoichiometric amounts (1 equivalent relative to IV) and in catalytic amounts.
Commercial catalysts such as, for example, Pd/C, Rh/Al 2 O 3 , Pt/C, Raney nickel, Raney cobalt, copper chromite, platinum oxide, palladium hydroxide can be used for the catalytic reduction. The hydrogenolytic reduction can take place at normal pressure or pressures up to 50 atm.
The reduction preferably takes place in the presence of CS 2 , zinc or hydrogenolytically with Pd/C, Pt/C or Ra Ni. The catalytic hydrogenation of IV with R 3 =OH with Pd/C is especially preferred, which can optionally be carried out in hydrochloric-acid solution at normal pressure and room temperature, if necessary under the addition of ethanol.
The hydrolysis of compounds of the general formula (IV) with R 3 =H to the L- and/or D-amine-acid derivatives with R 3 =H can take place analogously to WO 97/10203 in an acidic reaction environment such as, for example, in the presence of an inorganic acid such as HCl, HBr or H 2 SO 4 , and/or an acidic cation exchanger and/or an organic acid such as para-TsOH, camphor sulfonic acid, bromocamphor sulfonic acid or acetic acid, and/or an organic solvent such as toluene or methanol. The reaction can take place at temperatures between 0° C. and 140° C. at normal pressure or in an autoclave. The workup and isolation take place in a customary manner and analogously to D. Seebach, R. Fitzi, Tetrahedron 44 (1988) 5277. The variant in which the hydrolysis is carried out in aqueous hydrochloric acid is quite especially preferred.
Either optically active α-amino-acid amides or the corresponding α-amino acids can be obtained by suitably carrying out the reaction as a function of temperature and concentration of acid (cf. D. Seebach, E. Juaristi, D. Muller, Ch. Schickli and Th. Weber, Helv. Chim. Acta, 70 (1987), 237).
The hydrolysis of the compounds of general formula IV with R 3 =OH to the L- and/or D-hydroxylamino-acid derivatives of formula I with R 3 =OH and X=NH takes place analogously to WO 97/10203 but can be carried out much more simply in a reaction step with an alcoholic solution of a mineral acid, especially preferably with HCl in ethanol under mild conditions, especially preferably at room temperature.
The compounds of general formula I can also accumulate, depending on the conditions of hydrolysis selected, in the form of an acid addition salt such as, for example, HCl salt, HBr salt, H 2 SO 4 salt, part-TsOH salt, camphor sulfonic-acid salt, bromocamphor sulfonic-acid salt or acetic-acid salt.
The compounds of general formula (IV), in which R 1 and R 2 have the meanings indicated above and R 3 =OH, can be optionally eliminated to compounds of the general formula V ##STR11## in which R 1 and R 2 have the meanings indicated above, and subsequently reduced and hydrolyzed to the compounds of general formula (I) with R 3 =H.
The dehydration of compounds IV can take place in a known manner (Houben-Weyl, "Methoden der Organischen Chemie", vol. 10/1, p. 1247, vol. E16a, p. 211ff). Thus, for example, the hydroxylamine compound of type IV is agitated in an organic solvent such as methylene chloride, pyridine, or ether in the presence of a dehydrating agent such as N,N'-carbonyldiimidazole, DCC or P 2 O 5 under the exclusion of air (e.g., N 2 atmosphere or argon atmosphere) at temperatures between 0° C. and 120° C., preferably between 20° C. and 30° C. and worked up after the end of the reaction.
The elimination products V can then be converted as mentioned under reducing conditions and inversion of configuration into the optical antipodes of the original type IV with R 3 =H. The reduction can be carried out analogously to the already described reduction of compounds of type IV with R 3 =OH to IV with R 3 =H. The catalytic hydrogenation with Pd(OH) 2 /C in ethanol at 25° C. and normal pressure is preferred (cf. also B. Trost, I. Fleming, Compr. Org. Syn., vol. 8, "Reductions", Pergamon Press, Oxford 1991).
The following hydrolysis of the optical antipodes of IV with R 3 =H to compounds of type I with R 3 =H takes place in analogy with what was described above.
In addition, it is possible, as described in WO 97/10203, to oxidize the compounds of type IV ##STR12##
R 3 =OH to nitrons again and to make them accessible again to a further reaction with nucleophiles. In this manner, optically active α,α-disubstituted amino-acid derivatives of general formula IV are obtained in a further reaction step.
The further reactions of the α,α-dialkyl derivatives take place analogously to the steps cited above.
The production of the compound of general formula (II) is described in WO 97/10203 but can be carried out in a more advantageous manner avoiding solvents containing chlorinated hydrocarbons and avoiding halogen-containing aromatic peracids such as 3-chloroperoxobenzoic acid in alcohols using MMPP (monoperoxyphthalic-acid magnesium salt) or by means of hydrogen peroxide in the presence of catalytic amounts of methyltrioxorhenium (MeReO 3 ).
The hydrazine (III) can be produced according to the method known to the expert in the art (Houben-Weyl, vol. E16a, p. 425 ff, editor D. Klamann and X/2, p. 1ff, editor E. Muller).
The reaction of compounds of structural type II to compounds of general formula IV takes place with the addition of monosubstituted hydrazine III, e.g., in the presence of an oxidizing agent. The diastereomerically pure compounds IV accumulate after purification by crystallization, distillation or column chromatography in yields up to 96%.
For this, the compounds of structural type II are dissolved in an organic solvent, e.g., toluene, acetic ester, ether, alcohols, etc. and compounded preferably at room temperature with 3-6 equivalents of a monosubstituted hydrazine III and 3-6 equivalents of an oxidizing agent.
Alternatively, the hydrazine III can be released in situ out of the hydrazine acid compounds by a base, e.g., sodium hydroxide, potassium hydroxide or triethylamine.
After the end of the reaction, readily recognizable from the decreasing production of nitrogen, the solid residue is simply filtered off or worked up in an aqueous manner, according to the oxidizing agents used, (separation and extraction of the aqueous phase with an appropriate organic solvent and drying of the collected organic phases). The purification of the raw products takes place by recrystallization, distillation or column chromatography.
A significant advantage of the method is the fact that the initial substances (+)-menthol as well as (-)-menthol are readily available commercially at favorable and similar prices.
In comparison to the known methods, the method of the invention permits a novel conduction of the reaction which makes possible a simpler and more rapid production of the compounds of general type I. Thus, L-α-hydroxylamino-acid derivatives or L-α-amino-acid derivatives or D-α-hydroxylamino-acid derivatives or D-α-amino-acid derivatives can be obtained in a purposeful manner, depending on the initial material selected.
Starting from (-)-menthol the corresponding L-α-hydroxylamino acids/L-α-amino acids and their derivatives can be obtained in an advantageous manner and starting from the optical antipode (+)-menthol the corresponding D-α-hydroxylamino acids/D-α-amino acids and their derivatives. The characterization of the asymmetric carbons in the cyclohexane fragment of the compounds of general formulas II and IV with * is intended to make it clear that this is a stereocenter of the configuration 6S,9R or 6R,9S, according to the initial material selected--(-)-menthol or (+)-menthol. The unambiguous and absolute configuration of the other center of asymmetry in IV results from the selection of the initial materials. Thus, the center is clearly fixed on the α-C atom of the amino-acid structural element in IV by the configuration on the cyclohexane ring.
(-)-Menthol and (+)-menthol are converted thereby in a manner known in the literature (Houben-Weyl, "Methoden der Organischen Chemie", vol. 7/2a, p. 724) by oxidation into the corresponding (-)-menthone and (+)-menthone.
The radical addition to the nitron (II) suggested here makes possible, in comparison to the previously known radical addition with subsequent hydrogenation, a more efficient synthesis of, e.g., optically active tert. leucine. Along with the shortening of the reaction sequence by one reaction stage, compared with the radical addition of WO 97/10203, the reaction takes place here with significantly higher yields. Furthermore, no cooling is necessary for monitoring the reaction temperature as in the reduction of the substituted nitron (II) with lithium aluminum hydride in WO 97/10203. As a result of the broad variability of the oxidizing agent for producing the radicals, heavy metals can be eliminated in an advantageous manner in contrast to the known methods.
In comparison to the described ionic methods, the increased yields of the radical addition, especially in the case of sterically demanding groups, are noted. In the case of the tert. butyl group an increase of the yield from 40% to above 96% results, with a diastereoselectivity which is likewise equally high.
Complicated reaction techniques, such as the exclusion of water, low reaction temperatures and metallo-organic reagents which are difficult to manage, can be completely eliminated.
Instead, the reaction conditions, the solvent and the oxidizing agent used can be freely selected within broad ranges. In the case of an electrochemical oxidation of the hydrazine even the formation of salt can be minimized. All known byproducts, e.g., nitrogen, alkanes, potassium sulfate, etc. are reaction products which can be safely managed on an industrial scale.
The educts used are commercially available or can be synthesized in a simple manner.
The term "alkyl" denotes both "straight-chain" and "branched" alkyl groups. The term "straight-chain alkyl group" denotes, e.g., groups such as methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl and the term "branched alkyl group" denotes groups such as, e.g., isopropyl, neopentyl or tert. butyl. The designation halogen stands for fluorine, chlorine, bromine or iodine. The term "alkoxy group" represents groups such as, e.g., methoxy, ethoxy, propoxy, butoxy, isopropoxy, isobutoxy or pentoxy along with their possible bonding isomers.
Publications and patents cited herein are hereby incorporated by reference.
DETAILED DESCRIPTION OF THE INVENTION
The following examples are intended to explain the invention:
A) Oxidation to the Compound of General Formula II Using magnesium monoperoxyphthalic Acid, MMPP
(0.66 mole) of the compound of type II of WO 97/10203 is placed into a mixture of 2.50 L EtOH (industrial) and 0.50 L distilled H 2 O (v/v=5:1) in a receiver and slowly compounded under agitation and the continuous addition via a solid worm with 403 g (0.774 mole) magnesium monoperoxyphthalic acid hexahydrate (85%) at a temperature of 35-45° C. within 1.5 h. A transformation to the desired end product of 70% already is shown by GC analysis. A DC analysis shows the corresponding hydroxylamine as intermediate product and does not allow any more educt to be recognized. The suspension is agitated at not higher than 45° C. overnight. Iodine starch paper shows by rapid testing the presence or absence of available oxygen. After the reaction is completed, excess oxidizing agent is reduced by saturated Na 2 SO 3 solution and the reaction solution evaporated to dryness under vacuum. The residue is subsequently taken up in diethylether/5% NaOH, the phases separated and extracted two times more with diethylether. The combined organic phase is washed once with saturated NaHCO 3 solution and once with saturated NaCl solution, dried over MgSO 4 and concentrated by evaporation.
The NMR raw spectrum already shows a high purity of the raw product (GC %:98.7) in the case of the compound of general formula II with R 1 =Me, which product is isolated with 146 g (93%) in colorless, crystalline form. It can be recrystallized out of diethylether. Melting point: 125° C.
B) Oxidation to the Compound of Formula II Using hydrogen peroxide and a Catalytic Amount of methyltrioxyrhenium, MTO
(0.90 mmole) of the compound of type II of WO 97/10203 is placed in 20 mL EtOH (industrial) in a receiver and compounded under agitation with 0.35 g=0.31 mL 35% aq H 2 O 2 (3.60 mmoles) and 9 mg (0.036 mmole=4 molar %) methyltrioxyrhenium at RT. The mixture is agitated overnight at RT. After the reaction is completed, saturated Na 2 SO 3 solution is added for the reduction of excess oxidizing agent (starch iodine paper indicates completion). The MTO is absorptively removed by eluting over a silica-gel flash column. The mixture is rewashed twice with 15 mL EtOH each time. The eluate is evaporated to dryness under vacuum and taken up in diethylether/H 2 O. The aqueous phase is extracted twice with 15 mL diethylether, the combined organic phase washed with saturated NaCl solution, dried over NaSO 4 and evaporated to dryness under vacuum.
In the case of II with R 1 =Me a colorless, crystalline solid is obtained as raw product in 195 mg (92%).
C) Reaction of the Compound of Structural Type II to a Compound of Type IV Using the Example of the Preparation of (3S,5S,6S,9R)-3-tert-butyl-4-hydroxy-6-isopropyl-1,9-dimethyl-1,4-diazaspiro[4.5]decan-2-one
100 ml of a solution of 50.0 g (0.21 mole) II (R 1 =Me) in 100 ml toluene, 340.6 g (1.26 moles) potassium peroxodisulfate in 1000 ml water and 157 g (1.26 moles) tert-butylhydrazine hydrochloride in 1000 ml 10% sodium hydroxide solution are placed into a 4 l multi-neck flask and vigorously agitated. Subsequently, another 100 ml of the three solutions are added simultaneously every 30 min during which the initial production of nitrogen is observed in each instance as reaction control. 30 min after the last addition the organic phase is separated off and the aqueous phase washed twice with approximately 300 ml toluene. The combined organic phases are washed twice again with water and dried with sodium sulfate. After removal of the solvent under vacuum, 53.4 g raw product colored with a slightly yellowish color is obtained (yield=85.8%), which is present in pure form according to NMR spectra.
43.4 g (0.147 mole) colorless crystals are obtained by recrystallization from cyclohexane (yield=69.9%).
Total yield after postcrystallization: 48 g (77.2%)
______________________________________R.sup.2 yield (%) melting point (°C.)______________________________________CH.sub.2 CH.sub.3 41 (60 conversion) 176.7° C. C(CH.sub.3).sub.3 96 171.8 (decomposition) C.sub.6 H.sub.5 71 *______________________________________ *.sup.1 HNMR (400.1 MHz, CDCl.sub.3): δ = 7.25-7.50 (m, 5 H, aromat C--H); 4.84 (s, 1 H, NOH); 4.80 (s, 1 H, CH--C3); 2.85 (s, 3H NCH.sub.3); 0.85-2.1 (m, 18 H, menthyl CH.sub.x) including 1.06 (d, 3H, CH.sub.3 --C11/13/14, .sup.3 J = 6.6 Hz) 0.99 (d, 3H, CH.sub.3 C11/13/14, .sup.3 J = 6.6 Hz); 0.97 (d, 3H, CH.sub.3 --C11/13,14, .sup.3 = 6.6 Hz).
D) Electrochemical Radical Alkylation of the Compound of General Formula II
1.0 g compound of type II (R 1 =Me) (4.20 mmoles) is placed into 40 mL ethyl acetate (industrial) in a receiver and compounded with 500 mg tert-butylhydrazine hydrochloride (4.00 mmoles) as well as with 500 mg NaOH (12.50 mmoles) in 5 mL MeOH. The electrolysis is carried out in an undivided cell. A carbon rod anode (approximately 6 cm 2 ) and a carbon rod cathode (approximately 6 cm 2 ) are used as electrodes. A potential of min. 550 mV to a max. of 1000 mV vs. Ag/AgCl/KCl is put on the working electrode (anode). During the course of the electrolysis another 500 mg tert-butylhydrazine hydrochloride and 500 mg NaOH in 5 mL MeOH are added three times at 24 h intervals. After the reaction has been completed the precipitated NaCl is removed by suction. The organic phase is washed with H 2 O and the solvent removed under vacuum. The matter is eluted over a silica-gel column with a 2:1 mixture of cyclohexane:ethyl acetate. After evaporation to dryness under vacuum 1050 mg (87.5%) of a colorless, crystalline solid are obtained.
E) Preparation of (2S,5R,6S,9R)-3-tert-butyl-6-isporopyl-4,9-dimethyl-1,4-diazasprio[4.5]decan-3-One hydrochloride
43.4 g (0.147 mole) of the compound of general formula IV (R 1 =Me, R 2 =tBu, R 3 =OH) are dissolved in 200 ml ethanol and compounded with 200 ml 1.5 N HCl solution and 20 g Pd/C catalyst. The flask is briefly evacuated, gassed with hydrogen and the suspension agitated for 3 days. The catalyst is subsequently filtered off and washed intensively several times with 1 N HCl and ethanol. The collected filtrates are concentrated under vacuum and 49.4 g of a colorless, slightly moist raw product is obtained (yield=106%), which is present in pure form according to NMR spectra.
F) Release of L-tert-leucine methylamide hydrochloride
The 49.4 g of the product from (E) are suspended in 1200 ml 1 N HCl and 150 ml glacial acetic acid and heated up to 12 h under reflux. After removal of the solvent in a vacuum 25.6 g (0.142 mole) of a colorless solid is obtained (yield=96.5%) which is present in pure form according to NMR spectra. The ee value is 99.5%.
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The present invention is relative to a chemical method of producing compounds of the general formula (I) ##STR1## starting from compounds of the general formula (II) and (III) ##STR2## under radical conditions. Products I are used as intermediates in the synthesis of bioactive substances.
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